EMAG Samputensili gear machines: grinding, shaving and shaping

G 160 and SG 160: generating gear grinding

Generating gear grinding machine with two workpiece spindles on linear drives: a spindle change takes under 2 seconds, including wheel repositioning.

• Module 0.5–4.0 mm; workpiece diameter up to 160 mm, length up to 300 mm.
• Face width up to 180 mm; helix angle from −45° to +95°.
• Wheel 210–275 mm, speed up to 80 m/s, Siemens 840 D sl control.
• The SG 160 variant grinds dry, without coolant.

G 250 and G 250 HS: generating and profile grinding

A cast-iron bed and two workpiece spindles almost remove idle time. The G 250 HS with a high-speed head is built for parts with interfering contours.

• G 250: module 0.5–7.0 mm, diameter up to 250 mm, length up to 550 mm.
• G 250: face width up to 380 mm; wheel 170 or 250 mm, up to 80 m/s.
• G 250 HS: generating grinding module 0.5–5, profile grinding 0.5–7; up to 20000 rpm.
• Profile wheels: electroplated CBN, dressable CBN or ceramic.

G 400: grinding gears and shafts up to 400 mm

Universal machine for medium and large series of gears and shafts, and single parts in profile grinding; direct-drive workpiece table.

• Generating grinding: module 0.5–8; profile grinding: module 0.7–12.
• Workpiece diameter up to 400 mm, length up to 750 mm, toothed length up to 380 mm.
• Wheel 220 or 300 mm, spindle speed up to 80 m/s.
• Swivel ±45°, Siemens Sinumerik ONE control.

G 375 H, G 500 H and GP 500 H: profile grinding

Horizontal machines for gears, worms, screws and rotors. The GP 500 H has two spindles: roughing and finishing in one setup without a tool change.

• G 375 H: module 0.5–15, diameter up to 375 mm, length up to 870 mm, up to 18000 rpm.
• G 500 H: module 0.5–22, diameter up to 500 mm, length up to 1250 mm, up to 32500 rpm.
• The G 375 H grinds asymmetric profiles and cycloid gears.
• GP 500 H: module 0.5–15, length up to 1250 mm, two tool spindles.

GR 250, GR 500 H, GT 500 HL and GW 3600 H: worms, screws and rotors

Profile grinding machines for screw-type profiles: worms, ball screws, hydraulic pump screws, rotors and extruder screws, including very large ones.

• GR 250: worms up to 250 mm in diameter and 550 mm long, double table.
• GR 500 H: module up to 35, diameter up to 400 mm, length up to 1250 mm.
• GT 500 HL: module 0.5–35, diameter up to 380 mm, tool spindle 50 kW.
• GW 3600 H: length up to 3800 mm, diameter up to 500 mm, module 1–10.

GS 400: sharpening shaving cutters and master gears

Fourth-generation machine for resharpening shaving cutters and grinding master gears by generation; software calculates the profile, no indexing blocks needed.

• Module 0.5–15; tool diameter from 60 to 400 mm.
• Workpiece length up to 90 mm, face width up to 70 mm.
• Grinding wheel diameter 640 or 762 mm.
• Number of teeth is not limited.

Wheel dressing and topological grinding

Dressing affects gear quality: a diamond dressing wheel restores the grinding wheel profile. Operators view and edit topological corrections on the machine.

• All common dressing methods are possible, including high-speed worms.
• The left and right tooth flanks can be corrected differently.
• The finishing stroke uses a wheel zone that the tangential axis brings into work.
• The second workpiece spindle is loaded while the first part is being ground.

Profile grinding: when it is the better choice

Profile grinding works tooth gap by tooth gap. It is universal and often the best choice for interfering contours, internal gears and special profiles.

• Wheels: electroplated CBN, dressable CBN or ceramic; dressed on the machine.
• Any profile that can be described with XY coordinates.
• Internal and external teeth can be ground, even with very small wheels.
• Long parts: extruder shafts, ball screws, trapezoidal screws.

RASO 200 and RASO 400 gear shaving machines

Gear shaving is done before hardening: it gives quiet surfaces and costs less than grinding. The machines are modular, with three, four or five CNC axes.

• RASO 200: module 0.5–5, diameter up to 200 mm, length up to 100 mm.
• RASO 400: module 1–8, diameter up to 400 mm, length up to 160 mm.
• Methods: plunge, parallel, diagonal, underpass and combined cycles.
• A table rocker sets crowning and taper; options: deburring, marking.

Gear shaving: how the process works

The workpiece and cutter form a gear pair with crossed axes. Flank sliding and small grooves on the cutter teeth remove a thin layer.

• Productivity is higher than in grinding, with good quality and low noise.
• The method is widely used in the automotive industry and by suppliers.
• The process needs precise machines, cutters, fixtures and automation.
• Cutters are resharpened on the GS 400 from the same family.

CLC SZ gear shaping machines

Vertical machines for spur and helical, internal and external gears and shafts. An electronic helical guide allows machining with a helix angle.

• Module up to 10, workpiece diameter up to 500 mm, axial travel up to 500 mm.
• The shaft steady retracts when internal teeth are cut.
• Tool changer: carbide roughing and HSS finishing cutters.
• Crowning and taper are set from the CNC.

Gear shaping: where the method is irreplaceable

For parts with interfering contours and a small run-out, shaping is often the only option. It also cuts keyways.

• Two processes: linear infeed and helical infeed.
• The head sits on a moving Z slide, and the spindle stroke is set by an NC axis.
• The tool defines the profile shape, NC axes control flank line modifications.
• The tool lifts off on the return stroke, so wear on the cutting edges is lower.

VSC 400 PS: skiving and turning in one clamping

A turning center with power skiving for internal and external gears: up to four skiving tools on two spindles and up to six turning tools.

• Workpiece diameter up to 340 mm, height up to 420 mm, chuck 315 or 400 mm.
• Power skiving is an alternative to broaching and shaping of internal gears.
• Roughing, finishing and turning in one clamping.
• EMAG also offers skiving as an add-on module for turning centers.

Power skiving: continuous gear cutting

Power skiving combines hobbing and shaping: continuous machining with axial feed and crossed axes of tool and workpiece.

• The method suits one-off and medium-volume production.
• Especially attractive for internal teeth previously broached or shaped.
• Pre-turning and tooth cutting happen in one clamping.
• Machine and tool must be matched precisely.

EMAG hobbing machines: HLC 150 H, CLC 200 HC, CLC 260 H, CLC 500 H

Gear hobbing is the main process for gears, shafts, worms and rotors: any number of teeth, helix angle and face width.

• HLC 150 H: module 0.3–3.0, diameter up to 150 mm, length up to 500 mm.
• CLC 200 HC: module up to 3 (up to 5), diameter up to 250 mm, length up to 300 mm.
• CLC 260 H and CLC 500 H: module up to 6 and up to 30, workpiece length up to 3200 and 3000 mm.
• CNC, direct-drive table and milling head; dry and wet machining.

KOEPFER K 160 and K 300 from the same range are covered on the KOEPFER page.

CLC 260 H-FR and CLC 500 H-FR: profile milling

Profile milling of worms, lobes and rotors demands accuracy, surface finish and cost-effectiveness; the machine combines a stable design, precise tool guidance and reliable control.

• CLC 260 H-FR: module up to 12, profile height up to 28 mm, cutting depth 28 mm.
• CLC 500 H-FR: profile height up to 75 mm, workpiece diameter up to 500 mm.
• A side cutter follows the tooth-gap shape, then the pitch is indexed and the cycle repeats.
• Suits rough milling of large tooth gaps.