P 800 S toP 3200 S

andP 800 ES to

P 1200/1600 ES

K E E P I N G T H E W O R L D I N M O T I O N TM

Gear Shaping Machines

2

New-generation Shaping Machines for large gears: fast, flexible, economical.

Faster, more economical production

of larger external and internal gears

requiring shaping rather than

hobbing is possible with the new-

generation Gear Shaping Machines

from Gleason-Pfauter.

m a c h i n e c o n c e p t

Gear Shaping Machines offer a useful

alternative to the soft machining of

involute gears where workpiece or tooling

geometry does not allow the use of

conventional processes such as hobbing

or form milling because of interference.

Gear Shaping Machine P 2000 S

with fully-enclosed work area

(outer safety railing removed for photo only).

more precise radial slide movements

across the complete speed range.

The extremely stiff table bearing

combined with a proven backlash-free

double-worm index drive allows for

a high torque range and high radial

and axial runout of the worktable.

● Modular design.A modular machine bed and table

design allows for a larger diameter

workpiece to be machined with

a smaller machine footprint to

optimize machine investment and

floor space utilization.

For example, the radial travel of the

P 800 S can be expanded to

accommodate a workpiece diameter

as large as 1200 mm (P 800/1200 S

model), enabling the user to increase

capacity without the investment

required for the larger machine.

All machine sizes and designs

available are summarized in the table

below.

● Versatile shaping heads.Mechanical and hydraulic shaping

heads are available for stroke lengths

up to 225, 380 and 650 mm.

This allows for an optimum, job-oriented

and cost-effective choice of shaping

heads to cover a broad range of different

workpieces.

● Advanced controls.The use of the latest Siemens CNC control

and Siemens digital drive technology

ensures maximum performance and the

complete compatibility of all drive and

control components.

c o m m o n p l a t f o r m

3

This line of machines is designed for

workpiece diameters of up to 3,200 mm

(higher diameters upon request).

The “Electronic Helical Guide” (ES)

design can be applied for workpiece

diameters of up to 1,600 mm.

The “Electronic Helical Guide” feature

is used to produce helical gears, thus

eliminating high procurement costs for

conventional mechanical helical guides

and retooling times.

This broad modular concept provides

a variety of benefits for the user:

● Proven platform.

The large-machine platform used

for Gleason-Pfauter gear shaping

machines is common to Gleason-

Pfauter hobbing and grinding machines,

operating with unsurpassed rigidity,

stability and reliability in hundreds of

production environments worldwide.

● Higher accuracies.The unique design of the machine

bed and worktable ensures that

cutting forces are absorbed and

transferred to the machine foundation.

The use of flat guideways and

narrow separate guides with

pre-loaded roller bearings ensures

Breakthrough technology.

Gleason-Pfauter offers “Electronic

helical guide” technology to

completely eliminate the expensive,

time-consuming procurement and

change over of mechanical guides for

the production of helical gears.

* with mechanical shaping head.

Machine sizes and designs with intermediate sizes.

Standard-machine

Intermediatesize

Standard machine with “ElectronicHelical Guide”

Intermediate sizewith “ElectronicHelical Guide”

P 800 S

P 1200 S

P 1600 S

P 2000 S

P 2400 S

P 2800 S

P 3200 S

P 800/1200 S

P 1200/1600 S

P 1600/2000 S

–

P 2400/2800 S

–

–

P 800 ES*

P 1200 ES*

P 800/1200 ES*

P 1200/1600 ES*

4

s h a p i n g h e a d s

The availability of a great choice of

shaping heads enables Gleason-

Pfauter Gear Shaping Machines to

be more easily customized to meet

the widest possible range of application

requirements.

The mechanical shaping head.For smaller to moderate requirements

with regard to shaping performance,

module and shaping stroke, the shaping

head with mechanically-driven cutter

spindle is ideal. The cutter spindle has

fully hydrostatic bearings and the

backlash-free, preloaded double-worm

index drive and the helical guides with

hydrostatic bearings are produced to the

highest precision specification.

The ideal conditions for top-quality and

pitch variation pattern result from the

rigid shaper cutter holding fixture of

a taper shank design. The drive of

the cam for cutter spindle back-off

movement is affected by a backlash-

free direct drive in the form of an NC

axis. The mechanical shaping head is

available with the unique “Electronic

Helical Guide” as an option.

Shaping heads with hydraulically-driven cutter spindle.To cover larger performance ranges

Gleason-Pfauter offers a shaping head

with hydraulically-driven cutter

spindles. This design with its fully

hydrostatic bearing and high-

performance hydraulic drive technology

provides considerable benefit in terms

of shaping force, cutting speed, module

and stroke length.

lnnovative, and extreme rigid backoff-

concept for hydraulic shaping heads.

Gleason-Pfauter is once again setting

standards with its innovative, unique

concept of cutter spindle back-off

movement using hydrostatic drive and

guide elements. This solution renders

superfluous mechanical components

for the back-off movement.

The results are:● maximum precision of movement in

combination with optimum process

design,● no costs for special cams,● flexible change between external

and internal gears.

In this instance, the high-precision

shaping movement also guarantees a

backlash-free, preloaded double worm

index drive. There are two sizes of this

shaping head design available featuring

different performance data.

All available shaping heads can be used

on all machine sizes.

Generating cutter

loading/unloading system.

Mechanical shaping head.

Hydraulic shaping head.

“ e l e c t r o n i c h e l i c a l g u i d e ”

5

Shaping head design with “Electronic Helical Guide (ES)”.The mechanical helical guides of

conventional CNC-controlled gear

shaping machines present the user

with significant disadvantages.

A mechanical guide has serious

limitation such as:● High cost, long lead times,

complicated logistics for the initial

purchase and regrinding of

mechanical guides as well as long

change over time when required to

change a guide,● typically a mechanical guide is made

to cut a specific gear, i.e. is made to

the lead and hand of the cutter and it

is highly unlikely the guide can be

used to make another helical gear as

you would need to have the same

hand and lead of the cutter,● can not normally cut two or more

helical gears in a single part clamping

for previously stated lead and hand of

cutter issues,● can not normally shape a helical gear with

a shaper cutter’s lead less than 400 mm,● unable to have the flexibility to change

the lead of the gear shaped, i.e. change

lead results to compensate for helix

unwind in heat treat.

The mechanical shaping head has beencompletely redesigned with a backlash-free direct drive for the

cutter spindle in order to deliver higher

flexibility and operating ranges than

previously using conventional shaping

machines.

Gleason’s ES technology provides the user

with huge potential for savings:● No investment in mechanical helical

guides required.● Elimination of lead times needed to

purchase mechanical guides.● No time-consuming changeover.● Flexible setting of any helix angle,

including angles above 45°.● Simple helix angle corrections (e.g.

lead angle errors due to hardening).● Machining of different helix angles in

one setup (suitable tool arbor required).

Now available:

“Electronic Helical Guide

(ES)” technology for large

machines.

* Special shaping cycles available for oversize face widths.

Hydraulicshaping head 1

“S” series “ES” series “S” series “S” series

Generation of a helical gear’s lead mechanical electronic mechanical mechanical

Spindle stroke drive electro-mechanical electro-mechanical hydraulic hydraulic

Nominal module 12 mm 12 mm 16 mm 24 mm

Cutter spindle diameter 110 mm 110 mm 130 mm 160 mm

Max. cutter spindle rotary speed 27 rpm 235 rpm 8 rpm 8 rpm

Maximum stroke length 225 mm 225 mm 380 mm 650 mm

Maximum face width* 200 mm 200 mm 350 mm 600 mm

Cutter spindle stroke speed range 50 - 500 50 - 500 – –(strokes per minute)

Cutter spindle drive motor 22 kW 22 kW hydraulic hydraulic

Maximum cutting speed – – 50 m/min 30 m/min

Tooling arbor taper HSK - B 80 HSK - B 80 HSK - 80 HSK - 100

Minimum lead of guide 400 mm – 850 mm 850 mm

Mechanicalshaping head

Hydraulicshaping head 2

Technical data for shaping heads

p e r f o r m a n c e

6

Simplifying the operating interface

creates considerable advantages for users

of Gleason-Pfauter machines for the

different machining operations, i.e.

hobbing, shaping and profile grinding.

In addition, it offers a host of user benefits,

including:

● Dialogue-guided input enables

operators to rapidly change over

from one type of workpiece to the

next – even entering a new job while

the existing work is still being

completed.● Saving and archiving jobs allows fast

and accurate access to machining

data for repeat batches.● Exporting data to other machines is

simplified to help speed throughput

and increase operating flexibility.● Technical data and parts programming

information can be created or

reviewed off-line or even off-site

on a PC, via Ethernet networking.

lmagine the possibilities.

The new generation of machines, in

combination with the latest series of

control technology from Siemens and

the Gleason-Pfauter Dialog Program,

provides new features and capabilities

in gear shaping technology, including:

● Production of external/internal gears

by generating or index cutting.● Production of involute and

non-involute gears.● Up to six different gears per

workpiece/job.● A maximum of six cuts per cycle

with radial or rotational feed options.

● The ability to shape gears with face

width larger than the machine maximum

stroke length capacity.● Wide range of lead modifications.● Tool indexing to improve tool life

and tool utilization.● Reduced machining times through

accelerated return stroke.● Use of direct-drive servo spindle motor

for the cutter spindle allowing for

a nearly constant cutting speed, thus

improving tool life vs. the non-constant

velocity of conventional eccentric drives.

Display with input screens

A

C

D

B

E

FG

w o r k a r e a d i m e n s i o n s

7

Work area dimensions.

● Values for intermediate sizes, e.g. on P 800 S for P 800/1200 S or on P 1200 ES for P 1200/1600 ES.◆ Shaping head for “S” and “ES” series. ■ Shaping head for “S” series only.* middle stroke position. ** upper stroke position.

Machine NC axes.

Standard NC axes

X = Radial axis

Y = Column lateral offset

Z = Axial slide position range

Z2 = Stroke length setting

A = Cutter spindle drive

A2 = Tool backoff

C2 = Cutter rotation

C' = Workpiece rotation

+Z

+Z2

C 2

+C’

A

+X +Y

+A2

Work area dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 SP 800 ES P 1200 ES

Nominal workpiece diameterinternal and external gear A mm 800/1200● 1200/1600● 1600/2000● 2000 2400/2800● 2800 3200

Maximum workpiece swingwithout tailstock(internal gear) 200/1600● 1600/2000● 2000/2400● 2400 2800/3200● 3200 3600

Min./max. center distance B– mechanical shaping head ◆ mm 0/520/720● 200/720/920● 260/920/1120● 460/1120 460/1320/1520● – –– hydraulic shaping head H1 ■ mm 0/550/750● 0/750/950● 0/950/1150● 0/1150 0/1350/1550● 520/1550 520/1750– hydraulic shaping head H2 ■ mm 0/570/770● 0/770/970● 0/970/1170● 0/1170 0/1370/1570● 475/1570 475/1770

Axial slide position range C– mechanical shaping head ◆ mm 250/400 250/400 250/400 250/400 250/400 – –– hydraulic shaping head ■ mm 1100 1100 1100 1100 1100 1100 1100

Lowest cutter spindle position above table D– mechanical shaping head ◆ mm* 280 280 280 280 280 – –– hydraulic shaping head H1 ■ mm** 560 560 560 560 560 560 560– hydraulic shaping head H2 ■ mm** 660 660 660 660 660 660 660

Table diameter E mm 800 1200 1460 1870 1870 2500 2500

Table bore diameter F mm 245 300 500 600 600 800 800

Depth of table bore G mm 875 875 875 875 875 875 875

d i m e n s i o n s / t e c h n i c a l d a t a

W 192/2/3/707 e Printed in Germany.

1000 University AvenueP.O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348e-mail: sales@gleason.com

1000 University AvenueP.O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348e-mail: sales@gleason.com

www.gleason.com • sales@gleason.com For Worldwide Locations and Additional Information.

Machine dimensions of gear shaping machines with mechanical shaping head.

C

A

B

▼

▼

▼ ▼

▼

▼

Machine dimensions of gear shaping machines with hydraulic shaping head on request. The information and specifications in this publication ◆ Shaping head for “S” and “ES” series. are subject to change without notice.■ Shaping head for “S” series only.

Maschinenfabrik GmbHDaimlerstrasse 14D-71636 Ludwigsburg, GermanyTel. +49-(0)7141-404-0Fax+49-(0)7141-404-500e-mail: pfauter@gleason.com

Machine dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 SP 800 ES P 1200 ES

Technical data

Column lateral offset, mechanical ◆ mm ± 25 ± 25 ± 25 ± 25 ± 25 – –

Column lateral offset, hydraulic ■ mm ± 50 ± 50 ± 50 ± 50 ± 50 ± 50 ± 50

Maximum table speed rpm 15 10 8 6 6 4 4

Maximum table load kg 10,000 15,000 20,000 30,000 40,000 40,000 40,000

Total power rating of machine – mechanical shaping head ◆ (approx.) kVA 80 80 80 80 80 – –– hydraulic shaping head ■ (approx.) kVA 150 150 150 150 150 150 150

Machine weight (approx.) kg 22,000 24,000 35,000 40,000 44,000 60,000 61,000

A mm 6,550 6,550 7,800 8,000 8,000 8,200 8,200B mm 6,000 7,100 10,500 10,800 11,000 11,400 11,600C mm 4,250 4,850 5,200 5,200 5,200 5,250 5,250