KOEPFER / EMAG KOEPFER Gear Hobbing Machines: K 160, K 300, HLC 150 H

Horizontal gear hobbing and worm milling machines KOEPFER / EMAG KOEPFER for precision gears, shafts and worms. Engineering selection by part drawing.

KOEPFER K 160 horizontal gear hobbing center

The high-precision horizontal gear hobbing center KOEPFER K 160 is designed for production of spur and helical small-module gears. A rigid slant-bed polymer mineral concrete structure attenuates vibration and ensures thermal stability during high-speed cutting cycles.

Machining module range from 0.3 to 2.5 mm with workpiece blank diameter up to 100 mm
Maximum overall workpiece length up to 1000 mm with productive hobbing travel of 200 mm
Direct-drive tool spindle delivers rotational speeds up to 5000 revolutions per minute
Selection of linear guideway blocks, ballscrews, and protective metal bellows by serial ID

K 160 Longbed XL machine for long motor shafts

The specialized KOEPFER K 160 Longbed XL version with extended base bed is engineered for long electric motor and gearbox shafts. The machine layout accommodates up to 15 programmable motion axes and rapid changeover of clamping fixtures between manufacturing batches.

Gear tooth generation on extended shafts up to 1000 mm length and workpiece weight of 25 kg
Operational module envelope from 0.2 to 2.5 mm with maximum workpiece blank diameter of 100 mm
Tooling changeover duration reduced to 15–20 minutes when switching workpiece profiles
Ordering of steady rests, tailstock center sleeves, and automated loading gantry grippers

KOEPFER K 300 universal gear hobbing machine

The universal 9-axis horizontal hobbing machine KOEPFER K 300 is tailored for production of pinions and gear shafts up to 200 mm diameter. A closed-frame machine design and roller guideways ensure geometric repeatability during wet and dry gear cutting operations.

Workpiece capacity up to 200 mm diameter and 800 mm length with gear modules up to 4.0 mm
Hobbing travel up to 300 mm with swivel head angle adjustable within plus or minus 45 degrees
Tool spindle speed range between 200 and 2500 rpm with high-speed option reaching 4000 rpm
Selection of hydraulic tailstock clamping components generating clamping force up to 15 kN

EMAG KOEPFER HLC 150 H hobbing and worm milling center

The horizontal machining center HLC 150 H unites hobbing, single-index worm milling, and integrated chamfering. An interpolated virtual Y-axis broadens the tool shifting envelope and extends cutting tool wear life during continuous automotive transmission production.

Tooth milling from module 0.3 to 3.0 mm on blanks up to 150 mm diameter and 500 mm length
Swivel head articulation from minus 45 to plus 135 degrees with shift travel up to 220 mm
Tool head motor power of 28 kW delivering 140 Nm torque with speeds up to 4000 rpm
Supply of integrated chamfering attachments, precision spindle bearings, and rotary seals

Hob arbors and hydraulic expanding chucks

Precision tooling assemblies from KOEPFER comprise hob clamping arbors and hydraulic expanding chucks with HSK-C50 interfaces. Tight radial runout control prevents uneven tooth wear on hob cutters and preserves profile pitch accuracy across gear batches.

Hob mounting arbor diameters from 8 to 32 mm and inch sizes with HSK-C50 spindle taper
Hydraulic chucks with runout within 3 microns for rigid shank-type cutter clamping
Clamping width accommodation for hob packs up to 195 mm on K 300 and 220 mm on K 160 machines
Selection of precision spacing rings, locknuts, arbor spacers, and SK30 counter support bushings

Collet fixtures, rotating centers, and workholding mandrels

Workpiece clamping equipment for KOEPFER machine tools includes DIN 6341 collet chucks, expanding mandrels, and rotating tailstock live centers. Fixtures deliver rigid positioning repeatability for thin-walled harmonic flexspline gears and long transmission drive shafts.

Collet chuck systems matching DIN 6341, Hardinge 3C/5C, and Schaublin W20/W25 clamping profiles
Precision rotating live centers featuring carbide-tipped conical inserts in Morse taper MK 2
Spring-loaded clamping cylinders and actuation drawbars for automated production cells
Selection of gantry loader transfer jaws, chain magazine nests, and gripper jaws from 10 to 40 mm

Slant-bed kinematics and dynamic stability of K 160 hobbing centers

Horizontal gear hobbing centers KOEPFER K 160 utilize an inherently rigid polymer mineral concrete machine base that dampens high-frequency cutting harmonics during high-speed hobbing operations.

The inclined slant-bed geometry directs cutting chips and emulsion coolant downward away from the machining zone, eliminating chip recutting between hob teeth and gear blanks.

Direct-drive electro-spindles on the workpiece axis and tool head eliminate gear backlash, preserving lead accuracy when generating steering pinion teeth and electric drive shafts.

Extended bed layout of K 160 Longbed XL for long transmission shafts

The KOEPFER K 160 Longbed XL configuration is engineered to produce precision gearing profiles across long rotor shafts and transmission drive shafts reaching 1000 mm length.

Longitudinal roller guideway assemblies coupled with an auxiliary tailstock support structure eliminate workpiece deflection under radial cutting tool pressure. Up to 15 programmable CNC motion axes synchronize cutter approach, feed velocity, and steady-rest tracking.

Modular quick-clamping tooling fixtures enable fast changeovers within 15 to 20 minutes between production batches.

Multi-axis interpolation and closed-frame rigidity of K 300 series

Universal horizontal gear hobbing machines KOEPFER K 300 feature a closed-loop portal frame that symmetrically balances thermal and static machining loads.

9 programmable CNC motion axes accommodate conventional climb and conventional hobbing, radial-tangential worm gear generation, and hard power skiving on heat-treated blanks.

Zero-clearance roller guideways and a heavy-duty hydraulic tailstock quill delivering 15 kN clamping force uphold pitch precision for gears up to 200 mm diameter during high-speed dry machining.

Combined worm milling and hobbing technology on HLC 150 H centers

The EMAG KOEPFER HLC 150 H horizontal center combines conventional spur gear hobbing with high-velocity single-index milling of multi-start worms using profile disc cutters.

Interpolated virtual Y-axis kinematics expand tool swivel articulation from minus 45 to plus 135 degrees with 220 mm axial shift capability.

An integrated autonomous chamfering attachment removes burrs simultaneously during the gear-cutting sequence, reducing overall cycle durations for power steering worms and planetary gear assemblies.

Hob arbor architecture and high-pressure hydraulic expanding chucks

Rigid tooling setups for KOEPFER hobbers employ ground cutter arbors with HSK-C50 tapers and high-pressure hydraulic expanding chuck systems.

Uniform radial hydraulic clamping around the tool shank limits radial runout to less than 3 microns, preventing micro-displacement under interrupted cutting impacts. Ground spacing collars and SK30 tapered counter support fixtures maximize stiffness across tool packs up to 220 mm wide.

Routine precision inspection of mounting faces prevents chatter and uneven hob tooth wear.

Precision workholding fixtures for thin-walled harmonic flexspline gears

Generating gear teeth on thin-walled flexible cups for robotic harmonic reducers on KOEPFER machines requires specialized workholding to prevent blank distortion.

Precision expanding mandrels and DIN 6341, Hardinge 3C/5C, or Schaublin W20/W25 collet chucks distribute clamping forces uniformly around thin rims.

Live tailstock centers with Morse taper MK 2 and carbide tips ensure axial alignment within 5 microns, enabling class 4 tooth quality per DIN 3960 standards in volume robotic production.

KOEPFER / EMAG KOEPFER 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 KOEPFER / EMAG KOEPFER and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.