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Page 1: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

CylindricalGear

Solutions

Page 2: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

Horizontal Gear Hobbing Machines

H o b b i n g / S h a v i n g

Maximumaxial travel

mm

Nominal module

mm

P 60 80/100■ 2.5/3+,5 220/320●

P 90 100/125■ 2,3/5+,5 320/400●

P 90 EL 100/125■ 2,3/5+,5 800

P 210 L 180/210■ 2,3/4.5● 300/400●

Nominal workpiecediameter

mm

Maximumaxial travel

mm

Nominal module

mm

Genesis® 130SV(C) 150 4 40

Nominal workpiecediameter

mm

for horizontal workpiece mounting

for vertical workpiece mounting

P 90 WM 090 2,5/8,5 280

Worm milling machine

(C), (E) chamfering and deburring (T) plunge shaving () for plunge shaving

ZS(E) 150 (T) 200 5 (3.5) 100 (45)

ZS(E) 300 280 8 100

ZS 600 600 8 100

● option ■ manual loading + profile milling

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Vertical Gear Hobbing Machines

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Larger machines are available on request.

● option+ profile milling

❑ above 2400 mm only with reduced speed and feed rates.

Gear Shaving Machines

Genesis® 130H 130 3 350

Genesis® 210H 210 3/4● 350

Genesis® 260H 260 4/8● 400/600●

Genesis® 400H 400 8/4● 400/600●

P 400 400 16 400/600●/1000●

P 600 600/800● 16 400/600●/1000●

P 800 800/1200● 700/1000●/1300●/1600●

Titan® 1200H 1200 1000/1600●

Titan® 1600H 1600 1000/1600●

P 2000 2000

P 2400 2400/2800❑

P 2800 2800

P 3200 3200

P 4000 4000

P 5000 5000 30/40+

P 6000 6000 30/40+

P 8000/10000 8000/10000● 45 on request

20/30+ (30/40+)●

700/1000●/1300●/1600●/2200●

Page 3: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

G e a r S h a p i n g / D e b u r r i n g

Gear Shaping Machines with “Electronic Helical Guide”

P 200 ES 200 6 110

P 300 ES 300 6 110

P 400 ES 400 8/12● 110/225●/250●

P 600 ES 600/800● 8/12● 110/225●/250●

P 800 ES 800/1200● 12 225

P 1200 ES 1200/1600● 12 225

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

● option Larger machines are available on request.

Gear Shaping Machines

P 150 S 150 4 30

P 200 S 200 6 55/110●

P 300 S 300 6/12● 55/110●/225●

P 500 S 500 8/12● 110/225●

P 600 S 600/800● 8/12● 110/225●

P 800 S 800/1200●

P 1200 S 1200/1600●

P 1600 S 1600/2000●

P 2000 S 2000 12/16°/24° 225/380°/650°

P 2400 S 2400/2800●

P 2800 S 2800

P 3200 S 3200

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Larger machines are available on request.

● option

● option

° with hydraulic shaping head

Short Term Delivery Standard Gear Shaping Machine

AM 250 300 6 55/110●

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Chamfering and Deburring Machine

ZEA 4* 20/250 0.8 - 5 40

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

* also available with two deburring stations for twin gears.

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Page 4: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

Multi-functional Machine for Turning, Hobbing, Drilling, Chamfering andDeburring in one single set-up

180TH

Technical data

Workpiece data: – maximum diameter 180 mm– maximum length 500 mm– maximum weight 30 kg

Nominal module 3 mm

Maximum axial slide travel 500 / 600* mm

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C o m b i n e d P r o c e s s e s

✓ NC-controlled tailstock column with quill to hold tailstock centers.

✓ Tool turret to take up to 12 tools (VDI40).

✓ Designed for wet or dry machining.✓ Modular design.✓ Individual configuration of chip

transport/separation.

✓ Gleason chamfering and deburring station attached to turret.

✓ Workpiece-specific gripper jaws for loading/unloading via turret.

✓ Optional NC steady rest (Z3) axis withsurrounding three-point steady rest.

✓ Optional measurement on tool turret for tool wear compensation.

✓ In combination with other cells for additional turning operations.

✓ The combination of threaded wheel and profile grinding significantly reduces grinding times by up to 50%.

✓ Threaded wheel grinding up to module 14 for roughing.

✓ Profile grinding up to module 44. ✓ Advantage in profile grinding.

Unique and patented simultaneous doubleflank twist compensation or asymetrical lead modifications reducing finishing time by 50%.

✓ Automatic tool changer.– Fully-automatic tool change in less

than one minute.– Set-up occurs during gear grinding. – Optimum grit size for roughing and

finishing grinding wheel.– No interfering contours between

tool/workpiece in the entire diameterrange.

POWER GRIND Combined Threaded Wheel and Profile Grinding Machine

1200G

* turning

Vertical Gear Hobbing Machines with integrated chamfering and deburring unit

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Horizontal Gear Hobbing Machine with integrated chamfering and deburring unit

P 210 LiC 150 3/4.5● 300/400●

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Genesis® 210HiC 210 3/4● 350

Genesis® 260HiC 260 4/8● 400/600●

Genesis® 400HiC 400 8/4● 400/600●

Page 5: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

Profile Grinding Machinesfor external and internal gears

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Threaded Wheel Grinding Machines

P 90 G❑ 100/125■ 3 320/400●

Genesis® 160TWG 160 0.5 - 3 350

300TWG❑ 300 0.5 - 7 440

Maximumaxial travel

mm

Nominal module

mm

Nominal workpiecediameter

mm

Larger machines are available on request.

❑ Machine suitable for threaded wheel and profile grinding.

* for manufacturing of shaft-type workpiece up to 550 mm length.

● option■ manual loading

Gear Honing Machines

150SPH 150 4 45

150SPH-L* 150 4 45

ZH 250 250 6 100

Maximum face width

mm

Nominal module

mm

Nominal workpiecediameter

mm

H a r d P r o c e s s i n g

● option ❑ Machine suitable for threaded wheel and profile grinding.■ manual loading

Shaving Cutter Grinding Machine

Maximumface width

mm

Nominal module

mm

SRS 410 400 0.5 - 15 75

Nominal workpiecediameter

mm

5

P 90 G❑ 100/125■ 3 320/400●

300TWG❑ 300 8 440

P 400 G 400

P 600 G 600

P 600/800 G 800/1000●

P 800 G 800

P 1000 G 1000

Titan® 1200G 1200 1000/1600●

P 1600 G 1600

P 2000 G 2000

P 2400 G 2400

P 2800 G 2800

P 3200 G 3200

P 4000 G 4000

P 5000 G 5000

P 6000 G 6000

35/45●/55●/80●

80/120●

400/600●/1000●

700/1000●/1300●/1600●

700/1000●/1300●/1600●

Page 6: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

Workholding Solutions

Gleason designs and manufactures a complete line of workholding equipment for cylindrical gear machines. Designs areboth mechanical and hydraulic and include

quick change features for both Gleason and non-Gleason spindles.

Tapered and/or Ball Sleevedesigns ensure repeatability of both axial and radial runouttolerances.

Mechanical safety features are also designed into the equipment to preventover-travel.

Gleason developed workholding equipment includes UNI-SPAND®, ISO-SPAND®, Quik-Flex® gear arbors and LeCount® expanding mandrels.

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Analytical Gear Inspection Systems

175GMM 175 0.4 - 6.35 380 305

350GMS 350 0.4 - 18 650 450

475GMS 475 0.4 - 18 650 450

650GMS 650 0.4 - 22 1000 600

1000GMS 1000 0.4 - 22 1300 1000

1500GMS 1500 0.5 - 32 1300 1000

2000GMS 2000 0.5 - 32 2000 1200

3000GMS 3000 0.8 - 32 2000 1200

Centerdistance*

mm

Z-axistravel*

mm

Module range

mm

Nominal workpiecediameter

mm

* other dimensions on request.

M e t r o l o g y / W o r k h o l d i n g

X-Pandisk® for full range of solutions

Quik-Flex®

A standardized interface for workholdingchange without centering work in themicron-range. This selfcentering clampingsystem can be exchanged within a fewseconds with only one tool. This ensureslowest efforts for machine set up work.

The X-Pandisk® workholding equipmenthas resulted in workpiece changeover timebeing reduced by up to 70% compared toconventional manual workholding concepts. This is achieved by means ofautomatic clamping and centering of theworkpiece. The X-Pandisk® workholdingequipment is also designed for automaticloading to make production in medium tolarge-scale series even more economical.

The key component of the X-Pandisk®

is the centering disc which centers theworkpiece. The workpiece is not clampedin the axial plane by the pressure coveruntil the centering process is complete. It is this segregation of centering and clamping operations which allows suchhigh workpiece weights (up to 2 tons) to be centered accurately to < 30 µm.

Page 7: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

Hobs✓ Bore- or shank-type hobs, made of

high-speed steel and solid carbide. ✓ Coated with PVD-coatings based on

Titanium, Aluminium, Chromium andNitride or other coatings for extended toollife or dry cutting processes.

✓ Starting at module size 0.3 mm (DP 85) upto module 40 mm (DP 0.635).

✓ Maximum cutting rates using highly productive OPTI-CUT® tools equippedwith indexable carbide insert technology.OPTI-CUT® is also available for shapercutters.

Whether roughing with “EZ cutter” (roughing hob) or finishing with top quality finishing cutters – Gleason toolsalways have the right solution.

Gashing Cutters✓ Solid and carbide inserted tools for

highest accuracy and efficiency in internal and external gearing applications.

With the OPTI-CUT® tool system you get allthe performance benefits of the unique repla-ceable, indexable carbide insert technology.

E-Z™ Cut Hobs E-Z Cut roughing hobs provide swiftremoval of metal to permit accurate andeconomical finishing of the gear toothprofile in a secondary operation.Conventional generating hobs use less thanone third of their tooth depth for about twothirds of the metal removal work. E-Z Cuthobs add extra cutting edges by adding specialized flutes. The additional flutes equa-lize cutting effort and eliminate the problemof “overworked tip.” Since there is a practicallimit to the chip load a tooth can carry, itstands to reason that a hob with more flutes(in a given diameter) can feed faster throughthe work

Shaper Cutters✓ High-speed steel shaper cutters in

disk-, bore- and shank-type designs.✓ Standard module range: 0.5 – 16 mm.✓ Special tooth forms.

Wafer® technology; hobs and shaper cuttersare designed to maximize productivity therefore saving costs. These tools are designed for quick change and eliminate the need for size adjustment.

Cutting ToolsChamfering and Deburring Tools✓ Chamfer shapes and sizes freely selectable.✓ For wet and dry machining.✓ Integrated burnishing feature.✓ Patented adjustable burnishing gear

to adapt helix angle to workpiece.✓ Module range 0.8 – 6 mm.✓ Extremely long tool life and high efficiency.

Shaving Tools✓ For external and internal gears.✓ For all shaving methods.✓ Module range 0.5 – 18 mm.✓ Cutter width up to 50.8 mm.✓ Shaving Cutter Serration with

Opti-Edge® for higher tool life.

Dressing, Honing and Grinding Tools✓ High-precision diamond dressers

and rolls.✓ Multiple replating of diamond dressing

tools. ✓ Externally and internally toothed fine

finishing, ceramic and honing wheels.✓ Honing rings in Opti-FormTM quality.✓ Adjusted outer contour for quick

honing wheel change.✓ Threaded wheel grinding worms.✓ Calculation/development and

manufacture from one source.✓ Single-layer, replatable CBN and diamond

grinding and dressing wheels in a wide range of configurations and sizes. Higher stock removal rates, lower costs per workpiece, long wheel life and more consistent quality.

Tool services ✓ Support in application engineering.✓ Resharpening and reconditioning services.

C u t t i n g To o l s

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Page 8: Cylindrical Gear Solutions - Produktechproduktech.com/wp-content/uploads/Gleason-katalog.pdf · for cylindrical gear machines. Designs are both mechanical and hydraulic and include

C o o p e r a t i o n

Printed in Germany.

www.gleason.com • [email protected] www.gleason.com for Worldwide Sales Locations and Additional Information.

1000 University Avenue P. O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348 [email protected]

1000 University Avenue P. O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348 [email protected]

1351 Windsor RoadLoves Park, IL, 61111, USATel. +1-815-877-8900Fax +1-815-877-0264 [email protected]

Maschinenfabrik GmbHDaimlerstrasse 14D-71636 Ludwigsburg, GermanyTel. +49-(0)7141-404-0Fax +49-(0)[email protected]

Maschinenfabrik GmbHSubsidiary StudenBüetigenstrasse 80CH-2557 Studen, SwitzerlandTel. +41-(0)32-366 61 71Fax +41-(0)32-365 30 [email protected]

300 Progress RoadDayton, OH 45449, USATel. +1-937-859-8273Fax [email protected]

W 212/8/2/812 e

Maschinen und Werkzeuge GmbHMoosacher Strasse 42-46D-80809 München, GermanyTel. +49-(0)89-35401-0Fax +49-(0)[email protected]

No. 85 Yangpu Road, Suzhou Industrial ParkJiangsu, 215024, ChinaTel. +86 (512)6732 5806Fax +86 (512)6810 [email protected]

Traverse angle:Axis 1 ± 165°

Axis 2 ± 110°

Axis 31) ± 133°

Axis 4 ± 190°

Axis 5 ± 120°

Axis 62) n/a

1) The travel range of axis 3 is dependent

on the position of axis 2.2) Axis 6 has no axis limitation.

Axis 1

Axis 4Axis 6

Axis 5

Axis 2

Axis 3

As standard the R500CHD with a table

load of 500 kg is available. For table

loads up to 6000 kg Gleason-Manutec

offers the models R1000CHD,

R2000CHD, R4000CHD and R6000CHD.

Higher table loads on request.

Chamfering/deburring with Gleason-Manutec: Strong, precise and agile in tight spaces.Gleason and Manutec have years of

experience in solving complex chamfering

and deburring tasks. The collective use of

know-how means that the end user is now

offered new, flexible and reproducible

solutions for the field of gear tooth systems.

The combination of gear cutting machine

and chamfering/deburring robots results

in an efficient and effective solution from

a single source.

The Gleason-Manutec solution is

distinguished by its high work speeds and

path accuracy.

Complex programming work can be

dispensed with and is replaced by a simple,

quick and automated duty cycle.

Chamfer shapes and angles can be freely

selected via data entry.

The information and specifications in thispublication are subject to change without notice.For requirements beyond specified valuesconsult Gleason Application Engineering.