Gear Rack Milling Machines, Bandsaw Production Systems and Vices Kesel

German-engineered gear rack milling and grinding machines R-Series, continuous bandsaw production lines B240M and B127G, automotive steering mills S250M, and Bull precision clamping vices by Kesel. Engineering equipment selection.

R-Series M-Line High-Speed Gear Rack Milling Machines

R-Series M-Line machines are engineered for heavy-duty, high-speed milling of straight and helical gear racks up to module 32. The innovative X2T dual-table shuttle system allows simultaneous loading during machining, drastically reducing idle times and boosting overall output by up to 2.7 times.

R-Series M-Line modular rack milling systems
Milling straight and helical racks up to module 32
Shuttle X2T dual-table automation platform
Milling cutter heads, spindles, ball screws and guide rails

R-Series G-Line Precision Gear Rack Grinding Machines

The R-Series G-Line gear rack grinding machines deliver ultra-precise finishing on straight and helical gear racks requiring tight pitch tolerances. Built around the proven X2T dual-table platform, the machines allow setup during grinding cycles to maintain flawless tooth surface finish.

R-Series G-Line precision rack grinding machines
Ultra-precise finishing for fine pitch tooth profiles
X2T dual-table platform for continuous cycle time
Grinding wheel spindles, dressing units and hydrostatic bearings

B240M High-Throughput CNC Bandsaw Blade Milling Machines

The B240M high-throughput CNC bandsaw blade milling machine processes up to 425 m/h of saw coil stock in continuous production. Engineered for heavy industrial coil fabrication, the system integrates motorized coil winding systems with rigid clamping guides for uninterrupted output.

High-speed B240M bandsaw blade milling systems
Continuous coil milling throughput up to 425 m/h
Motorized vertical and horizontal coiler integration
Milling cutter arbors, feed drive rollers and band guides

FS-1500 Proven CNC Bandsaw Blade Milling Machines

The proven FS-1500 CNC bandsaw blade milling machine is purpose-built for precise tooth profiling on strip coil widths from 32 mm upwards. Featuring an enclosed cutting cabin, automated coiler interfaces, and chip extraction, the system delivers dependable geometry on bi-metal coils.

Proven FS-1500 CNC bandsaw blade milling machines
Precision tooth milling on strip widths from 32 mm
Compatible with vertical and horizontal coilers
Clamping shoes, band steady rests and feed guide rollers

B127G High-Power Bandsaw Blade Grinding Machines

The KESEL B127G bandsaw blade grinding machine features an 84 kW high-performance spindle and Siemens Sinumerik One CNC technology. Handling 400 mm grinding wheels, it provides precise tooth profiling on bimetal and carbide-tipped bandsaw coils while doubling workshop production rates.

High-power B127G grinding systems with 84 kW spindle
Siemens Sinumerik One CNC with 400 mm wheel support
Tooth grinding on bimetal and carbide-tipped bands
Grinding head assemblies, dresser units and band supports

S250M Steering Rack Gear CNC Milling Machines

The dedicated S250M Steering milling machine utilizes 45 kW motor power and an automated dual clamping setup for high-speed machining of steering rack gears. Designed for automotive Tier-1 manufacturing, the system ensures chatter-free cutting and dependable tooth pitch repeatability.

Dedicated S250M steering rack gear milling machines
Automated volume production for automotive Tier-1
45 kW heavy-duty drives and dual hydraulic clamping
Cutter spindle units, collet chucks, cylinders and steady rests

F200M Cross-Serrated Flange Milling Machines

The specialized F200M flange milling machine cuts precision cross-serrated end faces on driveshaft flanges in full compliance with ISO 8667 and ISO 12667 standards. A multi-stage clamping fixture secures the forged flange, guaranteeing high surface quality and minimal cycle times.

Specialized F200M cross-serrated flange milling machines
Precision milling of flange faces to ISO 8667 / 12667
Multi-stage clamping devices for forged component blanks
Face milling heads, rotary indexing tables and hydraulics

Bull, ARNO and NCA Precision Machine Vices and Clamping Systems

The Bull Pneumatik vice generates 40 kN clamping force at only 6 bar shop air using an engineered pull-down mechanism. Complementary ARNO high-pressure mechanical vices deliver up to 50 kN force, preventing workpiece lift during demanding milling runs on vertical and horizontal CNC machines.

Bull Pneumatik, ARNO and NCA high-pressure CNC vices
40 kN clamping force using 6 bar pneumatic shop line
Heavy-duty mechanical retention up to 50 kN clamping force
Interchangeable vice jaws, swivel plates, screws and seals

High-Speed Gear Rack Milling Technology on Kesel R-Series Machines

R-Series M-Line gear rack milling machines feature high-rigidity structural column design and heavy-duty spindle heads engineered for cutting coarse gear teeth up to module 32.

Maintaining high positioning accuracy and tooth flank surface finish requires steady spindle lubrication and thermal compensation under production load.

The machines integrate Siemens CNC technology and precision linear scales, ensuring repeatable indexing along the full length of straight and helical racks used in automation, machine tools, and heavy lifting drives.

Continuous Milling and Grinding Technology for Bandsaw Blade Coils

The B240M and FS-1500 machines set international benchmarks in continuous tooth profiling on carbon and bimetal bandsaw coil stock. Producing sharp tooth profiles at feed rates up to 425 m/h requires stable tension control and rigid guide roller positioning during strip travel.

Complementing the milling phase, the high-power B127G grinding machine utilizes 400 mm grinding wheels and Siemens Sinumerik One controls for precise tooth flank finishing, doubling overall tool workshop production capability.

Precision Milling of Steering Racks and Cross-Serrated Flange Shafts

Automotive tier-one suppliers utilize specialized Kesel S250M machines for rapid milling of variable and constant ratio teeth on steering gear shafts. A 45 kW heavy spindle motor combined with multi-stage hydraulic clamps guarantees rigid workpiece stability throughout the short production cycle.

For automotive driveline connections, the F200M flange milling machine cuts precision cross-serrated end faces in compliance with ISO 8667 and ISO 12667 standards, providing optimal torque transmission characteristics for commercial vehicle prop shafts.

Integrating Bull and ARNO High-Pressure Vices into Automated CNC Cells

The Bull Pneumatik vice series delivers reliable 40 kN clamping force operating from standard 6 bar factory compressed air lines. Its pull-down clamping geometry draws the workpiece securely against the ground base, preventing part lifting under heavy multi-axis milling cuts.

For conventional and CNC machining, ARNO mechanical vices provide retention forces up to 50 kN with fast-action mechanical spindle boosters. Swivel base plate accessories enable precise angular indexing for multi-face component setups.

Minimizing Non-Productive Cycle Time with the X2T Dual-Table Shuttle System

Machining long gear racks typically involves significant downtime during part loading, clamping, and alignment. The Kesel X2T dual-table innovation solves this bottleneck by establishing two independent shuttle tables moving seamlessly into the machining zone.

While the milling spindle works on one table, the operator or automation robot prepares and clamps raw stock on the exterior table, increasing productive spindle hours and elevating total shop floor throughput by up to 2.7 times.

Selecting Cutting Tool Geometry, Module Cutters, and Workpiece Clamps

Achieving DIN quality standards on gear racks requires careful selection of modular disc cutters, multi-tooth milling hobs, and vice clamping jaws. Using rigid toolholders with minimum overhang minimizes harmonic vibration and prolongs carbide insert life.

Kesel supplies specialized tool arbors, hydraulic clamping fixtures, and customized vise jaw inserts tailored to specific gear modules, steering shaft diameters, and alloy hardness levels across all machine models.

Kesel and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of Kesel and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.