SService Department:
(303) 630 1790
PParts Department:
(303) 630 1791
TTools Department:
(303) 630 1792 



Mon-Fri 7:30AM - 5:00PM MST

Main Phone: (303) 447 1130




machining of gears and special profiles
• suitable for prototyping to large batch production

• considerably shortening idle times
• integrated index table
• dressable and non-dressable CBN tools
• manual or automated loading


machine concept

The patented KAPP KX 500 FLEX is built on a shared modular machine platform. Application-specific production solutions can be configured on this versatile machine utilizing flexible process technology such as:
• continuous generating grinding
• discontinuous profile grinding
• combination of both methods

The KX 500 FLEX is designed to perform diverse processing jobs efficiently and economically. Thus, it is suitable for the production of single pieces as well as for serial production of high-quality gears. In this series the following tool concepts are offered:
• dressable ceramic tools for prototype machining and grinding of medium to high-volume series
• non-dressable tools for the manufacturing of medium to high-volume series, as well as the grinding of more challenging gear geometry

The KX 500 FLEX concept features an index table which incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the index table. In addition to the common axes, the
index table and tailstock are designed as NC axes, too. The workpiece and tool are directly driven.

The profile dressing unit can accommodate a single or twin spindle dresser. Depending on the solution applied, different technologies can be used for the dressing; as example, topological dressing of grinding worms with a radius tool.

control and software
The Siemens Sinumerik 840D control system is equipped with an operator-friendly menu-driven user interface, developed by KAPP NILES to match the specific machining requirements.

measuring system
An optional measuring device measures and evaluates gear qualities against specifications. This function optimizes the set-up process in the machine, drastically reducing lengthy machine down-time caused by external measuring. Alternatively, random samples can be tested during processing.

The workpiece spindle is conveniently positioned on the index table to make it possible for the KX 500 FLEX to be loaded both manually and automatically. Automation options include a standardized combination of pallet conveyor and gantry loader, or a robot system. For manual loading, the index table swivels the part 90° in front of the machine operator. For automatic loading it is turned 180° to the left side. A detailed configuration is created for each specific application.


type max. tip diameter [mm] module range - generating[mm] module range - profile[mm] max. face width [mm] max. helix angle [deg]
KX 500 FLEX 500 0.5 – 8 0.5 – 10 520 ± 45