CylindricalGear
Solutions
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
2
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●
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.
3
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
4
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●
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●
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.
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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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.
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