KAPP NILES
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  • Offer Profile
  • KAPP NILES is a global market leader in manufacturing machines and tools for finishing gears and profiles. Our expertise, that we have developed over the last 115 years, guarantees precision and efficiency for the machining of your sophisticated components.

    For gear grinding we differentiate between profile grinding and continuous generating grinding.

     

Product Portfolio
  • Innovative Solutions for Gears and Profiles

  • Continuous generating grinding

    For continuous generating grinding all tooth flanks of the workpiece are machined simultaneously during one stroke of the helical tool. This is realized with a synchronized constant rotation of the workpiece relative to the grinding tool. Due to the kinematics of this process indexing and positioning times are greatly reduced resulting in low cycle times. Therefore it is a highly productive and cost-effective process well suited for small and medium-sized gears. Both dressable ceramic tools and non-dressable CBN tools can be used (in cylindrical or globoid design).

    Discontinous profile grinding

    Profile grinding of gears describes a process for which the tooth flanks are machined gap after gap with single or multi-ribbed profiled tools. Regarding the possible work piece geometries this process offers highest flexibility while achieving highest quality.  Profile grinding is mostly utilized for small batch series and prototype manufacturing. Dressable ceramic wheels as well as non-dressable CBN-tools can be used for this grinding process.

      • Generating(Profile)-Grinding Machines

          • Gear Centres KX Series

          • max. tip diameter: 500 mm - prototype to large series production - external gears and shafts - custom automation - horizontal or vertical workpiece axis
              • KX 100 / 260 DYNAMIC

              • Machine concept
                The KX 100 DYNAMIC and the KX 260 DYNAMIC represent a systematic further development of the technology already applied in the KX 160 TWIN multiple spindle design. The patented machine concept makes it possible to minimise the auxiliary process times and to reduce set-up times. The integrated loading function and the optionally available automatic changeover of the workpiece fixture, make these machine concepts the perfect solution for medium and large batch production of external spur and helical gears.

                The KX 100 DYNAMIC includes two separate and pivoting columns, the KX 260 DYNAMIC includes one. A vertically moving pick-up-axis is mounted on the column(s); each pick-up-axis is equipped with a workpiece spindle. While one workpiece is ground, the second spindle transfers the completely processed workpiece to the handling conveyor and picks up an unprocessed part. The workpiece is aligned outside the working space. Subsequently, the workpiece spindle accelerates to the processing speed in order to minimise the auxiliary process times. The optional multi-function axis allows the sorting out of measuring and test pieces.

                Continuous generating grinding with a dressable threaded cylindrical tool is the grinding method. Dressing tools with integrated tip dresser as well as flexible tools with independent tip dressing can be used on the dressing device. Moreover, with the topological generating grinding option, it is possible to produce gears with or without targeted modifications.
              • KX 160 / 260 TWIN

              • Machine concept
                The KX 160 TWIN and the KX 260 TWIN are designed on a shared modular machine platform with features specifically for continuous generating grinding with dressable tools. The short set-up times are especially worth emphasising in this efficient machine concept.

                The machines of the KX TWIN type are particularly designed for medium and large batch production of gears and shafts where quality levels are especially demanding.

                The machine includes two identical workpiece spindles, arranged at opposing sides of an index table. While machining one part, the second workpiece spindle simultaneously unloads / loads and aligns another part. Thus, many of the auxiliary functions are carried out during the machining time, cutting the auxiliary processing time to a minimum.

                A total of ten NC-axes align the gear wheel with the tool and perform the necessary linear and rotary motions during grinding. Both the index table and tailstock are designed as NC-axes. The workpiece spindle and tool spindle are direct drives.

                The design of these machines includes an integrated single spindle dresser for conventional grinding worms. Mounted staggered to the workpiece spindles, the dressing unit is assembled on the tailstock column, too. For the dressing process the profile dressing unit is aligned with the tool by turning the tailstock column.
              • KX 300 P

              • Machine concept
                Based on a modular system in combination with the application possibilities of different tool and process technologies, user-specific, optimal production solutions can be configured. The following methods are possible:
                • continuous generating grinding
                • discontinuous profile grinding
                • combination of both methods

                Thanks to the flexible system and loading options, the KX 300 P is equally suitable for all gear requirements and production volumes. In this series the following tool concepts are offered:
                • dressable ceramic tools for the flexible requirements of prototype machining as well as medium and high volume machining
                • non-dressable CBN tools for the highly productive manufacturing of medium and high-volume series

                Since the tool spindle (with counterbearing) can hold several tools, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, several gears can be machined in one set-up. In addition to the mainly used cylindrical grinding worms, single or multi-set CBN profile grinding wheels can be used for full-form machining as an alternative.
              • KX 500 FLEX

              • Machine concept
                The patented KX 500 FLEX is built on a shared modular machine platform. Application-specific production solutions can be configured on this versatile machine utilising flexible process technology such as:
                • continuous generating grinding
                • discontinuous profile grinding
                • combination of both methods

                The KX 500 FLEX is designed to perform diverse processing jobs efficiently and economically. Thus, it is suitable for the production of single pieces as well as for the serial production of high-quality gears. In this series the following tool concepts are offered:
                • dressable ceramic tools for prototype machining and grinding of medium to high-volume series
                • non-dressable tools for the manufacturing of medium to high-volume series, as well as the grinding of more challenging gear geometry

                The KX 500 FLEX concept features an index table which incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the index table. Besides the common axes the index table and tailstock are designed as NC-axes, too. The workpiece and tool are directly driven.
              • KX 1

              • Machine concept
                The KX 1 is an extremely stable, quick and easy to set-up gear centre, enabling continuous generating grinding as well as discontinuous profile grinding.

                The KX 1 is mainly designed for hard finishing of external spur and helical gears for medium to high-volume series manufacturing, predominately for the machining of shafts. Workpieces of modules up to 10 mm, of outside diameter up to 250 mm and a flank width up to 450 mm can be ground. Varying workpiece data is considered upon request.

                Depending on the definition of the specific task even application-specific solutions can be realised, e.g. the machining of two gears in one single set-up. The KX 1 uses only non-dressable precision hard finishing tools. They consist of a hardened steel base body with a ground base profile and a single-layer galvanic coating of CBN abrasives.

                Since the tool spindle can hold several CBN tools, grinding optimisation is possible by the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, gears can be machined in one set-up.
            • Gear Centres ZX Series

            • max. tip diameter: 1,000 mm - prototype to large series production - cylindrical and conical gears - custom automation
                  • Gear Centres ZX 630 - 1000

                  • Machine concept
                    The ZX series combines, both continuous generating grinding and discontinuous profile grinding in one machine. Thus a machine can be provided with high-end productivity even for bigger gears and larger modules. On the other hand the requirements for an outstanding flexibility can easily be achieved, too.

                    For the highly dynamic generating grinding technology, a very rigid basis was developed. All main components are made from vibration-absorbing ductile cast iron. The bed is a single unit offering extremely high stability. The machine needs no special foundation. The rotary table is largely dimensioned and accepts high table loads. It is driven by an electrical high-accuracy direct drive, providing the required positioning accuracy for profile grinding as well.

                    The one-piece machine bed is characterised by a compact design and a very good accessibility, especially for manual part loading. The compact design enables all operation and set-up from the shop floor. The changeover between the different grinding processes is very fast and reliable, allowing the use of the optimal process, no matter if it is prototype grinding, small batches or series production. The tool spindle has a counter support for better rigidity and surface finish.

                    A special machine type with cross slide can be offered for the series production of courser pitch gears. For loading and set-up the workpiece with rotary table has to be moved out of the working area.

                    Parallel the dressing unit will be positioned and the dressing process can be carried out at the same time, in order to save idle times. This version is particularly used for heavy and large module gears and automatic gantry loading, respectively.

                    Several dressing processes are available, e.g. double-flank dressing with simultaneous tip dressing for mass production, or single-flank dressing with separate tip dressing for economical costs on small lots and beyond that topological dressing for almost unlimited modifications and gear types for prototypes.
              • RX 120 rotor grinding machine

              • max. profile outer diameter: 120 mm - series production - screw compressors - optional: deburring parallel to grinding operation and optimised loading concept
                    • RX 120

                    • machine concept
                      The patented RX 120 rotor grinding machine utilizes the advantages of continuous generating grinding in manufacturing rotor profiles. Generating grinding is used for roughing of the rotor, or alternatively, discontinuous profile grinding. Then for finishing, profile grinding is used alone. Applying this combined process reduces grinding times up to 40% as compared to using conventional grinding and finishing methods.

                      The RX 120 rotor grinding machine is designed for highly efficient and economic series-production of small and midsize screw compressors. Directly-driven tool and workpiece axes minimises non-productive times during the grinding process.

                      The RX 120 uses only non-dressable CBN tools.

                      control and software
                      The control system of the rotor grinding machine is Siemens Sinumerik 840D, which is equipped with an operator-friendly menu-driven user interface, developed by KAPP NILES to match the specific machining requirements.

                      The following options are available, including
                      • alignment of pre-machined rotors using a non-contact sensor or measuring-probe in reference to one or all gaps
                      • runout inspection on bearing journal at tailstock side
                      • adaptive control of the feed axis depending on the power input of the grinding spindle motor, to prevent overloading the grinding process due to excessive stock amounts
                • Profile Grinding Machine

                    • gear centres KX series

                    • max. tip diameter: 500 mm - prototype to large series production - external gears and shafts - custom automation - horizontal or vertical workpiece axis
                        • KX 300 P

                        • Machine concept
                          Based on a modular system in combination with the application possibilities of different tool and process technologies, user-specific, optimal production solutions can be configured. The following methods are possible:
                          • continuous generating grinding
                          • discontinuous profile grinding
                          • combination of both methods

                          Thanks to the flexible system and loading options, the KX 300 P is equally suitable for all gear requirements and production volumes. In this series the following tool concepts are offered:
                          • dressable ceramic tools for the flexible requirements of prototype machining as well as medium and high volume machining
                          • non-dressable CBN tools for the highly productive manufacturing of medium and high-volume series

                          Since the tool spindle (with counterbearing) can hold several tools, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, several gears can be machined in one set-up. In addition to the mainly used cylindrical grinding worms, single or multi-set CBN profile grinding wheels can be used for full-form machining as an alternative.
                        • KX 500 FLEX

                        • Machine concept
                          The patented KX 500 FLEX is built on a shared modular machine platform. Application-specific production solutions can be configured on this versatile machine utilising flexible process technology such as:
                          • continuous generating grinding
                          • discontinuous profile grinding
                          • combination of both methods

                          The KX 500 FLEX is designed to perform diverse processing jobs efficiently and economically. Thus, it is suitable for the production of single pieces as well as for the serial production of high-quality gears. In this series the following tool concepts are offered:
                          • dressable ceramic tools for prototype machining and grinding of medium to high-volume series
                          • non-dressable tools for the manufacturing of medium to high-volume series, as well as the grinding of more challenging gear geometry

                          The KX 500 FLEX concept features an index table which incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the index table. Besides the common axes the index table and tailstock are designed as NC-axes, too. The workpiece and tool are directly driven.
                        • KX 1

                        • Machine concept
                          The KX 1 is an extremely stable, quick and easy to set-up gear centre, enabling continuous generating grinding as well as discontinuous profile grinding.

                          The KX 1 is mainly designed for hard finishing of external spur and helical gears for medium to high-volume series manufacturing, predominately for the machining of shafts. Workpieces of modules up to 10 mm, of outside diameter up to 250 mm and a flank width up to 450 mm can be ground. Varying workpiece data is considered upon request.

                          Depending on the definition of the specific task even application-specific solutions can be realised, e.g. the machining of two gears in one single set-up. The KX 1 uses only non-dressable precision hard finishing tools. They consist of a hardened steel base body with a ground base profile and a single-layer galvanic coating of CBN abrasives.

                          Since the tool spindle can hold several CBN tools, grinding optimisation is possible by the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, gears can be machined in one set-up.
                      • Universal Gear Grinding Machines VX Series

                      • max. tip diameter: 630 mm - prototype to small series production - designed for internal and external gears and special profiles - machining parts of complex geometry
                            • Universal Gear Grinding Machines VX 55 / 59

                            • Machine concept
                              All machine types of the gear profile grinding machines VX are based on a modular system which is designed for the use of various tool technologies. All versions are exclusively configured for profile grinding.

                              The machines of the VX series are extremely suitable for meeting the highest requirements concerning the final quality of the produced gears. Based on exchangeable grinding units, machines of this series can work both external and internal gears as well as spur and helical gears and other profiles.

                              The following tool concepts are offered:
                              • dressable ceramic tools for prototype machining
                              • non-dressable CBN tools for the high-productive batch production

                              Since the grinding adapter can hold two exchangeable grinding spindles, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, two or more gears can be machined in one set-up.

                              The CNC dresser is integrated in the working area of the VX machines and allows any grinding wheel profiles to be generated.

                              The combination of measuring system and profile dressing unit allows the automatic machining according to the so-called GMG strategy (grinding – measuring – grinding). The dressing and grinding programme is automatically generated based on the entered gear data..
                        • Gear Profile Grinding Machines ZE Series

                        • max. profile outer diameter: 800 mm - prototype to large series production - external / internal gears and special profiles - highest flexibility
                              • Gear Profile Grinding Machines ZE 400 - 800

                              • Machine concept
                                The gear profile grinding machines of the ZE series are designed for precise grinding of external and internal gears. The ZE machine concept represents accuracy, long lifetime and ergonomics.

                                Even the basic machines are equipped with coolant filtration unit, dresser, tailstock, in process measuring system, balancing unit, acoustic emission sensor and comprehensive software for grinding and measuring of involute profiles. The compact design enables all operation and set-up from the shop floor. No anchoring or fixing of the machine is necessary. Further outstanding features of the ZE machines are, amongst others, a well dimensioned rotary table with electrical direct drive, hydrostatic bearing and large table bores and an ergonomic machine design. The machine perfectly fits to customer-specific requirements, no matter if it is prototype grinding, small batches or series production.

                                All machines of the ZE series can be equipped with internal gear grinding attachment. From standard applications to customer-specific grinding tasks either with dressable wheels or CBN grinding wheels; KAPP NILES will provide the right solution for your requirements.

                                Multiple spindle configurations are available. The machines can be equipped with a stronger motor and grinding spindle and optimised axes with increased stroking speed for productive grinding of large module workpieces.

                                Gears with short run-out or workpieces with interfering shoulders can be ground with a spindle and wheel adaptor for smallest grinding wheels.
                          • Gear Profile Grinding Machines ZP Series

                          • max. tip diameter: 8,000 mm - external / internal gears and special profiles - stability, high drive power - electrical direct drive
                                • Gear Profile Grinding Machines ZP 10 - 80

                                • Machine concept
                                  The ZP series is well known worldwide for profile grinding of external and internal gears. The ZP machine concept represents great quality, durabi- lity and outstanding flexibility.

                                  Even the basic machines are equipped with coolant filtration unit, dresser, in process measuring system, balancing unit, acoustic emission sensor, and comprehensive software for grinding and measuring of involute profiles. Further outstanding features are, amongst others, a well dimensioned rotary table with electrical direct drive and large table bores; optional hydrostatic bearing and guideways for highly accurate positioning, excellent load capacity and almost unlimited lifetime. The latest drive and control technology enables grinding of even very complex gear geometries using a 5 machine axes interpolation. The machine perfectly fits to customer-specific requirements, no matter if it is prototype grinding, small batches or series production.

                                  All machines of the ZP series can be equipped with internal gear grinding attachment. From standard applications to customer-specific grinding tasks either with dressable wheels or CBN grinding wheels; KAPP NILES will provide the right solution for your requirements.

                                  Multiple spindle configurations are available. The machine can be equipped with stronger motor and grinding spindle and optimised axes with increased stroking speed for productive grinding of large module workpieces.

                                  Gears with short run-out or workpieces with interfering shoulders can be ground with a spindle and wheel adaptor for smallest grinding wheels. Some machines even allow the use of two grinding spindles for even more flexibility.
                            • Rotor Grinding Machines RX Series

                            • max. profile outer diameter: 320 mm - series production - screw compressors - high stock removal capability for efficient manufacturing - roughing and finishing in one set-up
                                • Rotor Grinding Machines RX 55 / 59

                                • Machine concept
                                  The RX series machines are designed exclusively for discontinuous profile grinding. A special highlight is the extremely high stock removal capability, which is required for efficient grinding of rotor profiles, and which is made possible by the drive power.

                                  The machines of the RX series are employed for pre-finish and finish grinding of pre-profiled steel and cast-iron profiles. The part spectrum covers screw-type compressors rotors, rotary pistons, screw-type pump spindles etc.

                                  The RX series uses only non-dressable CBN tools. The directly driven grinding spindle of the RX machine can hold two grinding wheels whereas the tools are sequentially moved into the grinding position. This allows the pre-finish and finish grinding in one set-up.

                                  Due to the innovative drive concept on the tool side, the machines of the RX series reach up to 46 kW in the speed range of 2,000 to 8,000 min-1. Especially for roughing this high performance is resulting in highest stock removal rates and is shortening machining times considerably. In combination with an optimally adapted tool technology, a highly productive and efficient working process will be guaranteed.
                                • Rotor Grinding Machine RX 120

                                • Machine concept
                                  The patented rotor grinding machine RX 120 offers using the advantages of continuous generating grinding in manufacturing rotor profiles. Generating grinding is used for roughing of the rotor, or alternatively, discontinuous profile grinding. For the finishing operation profile grinding is used only. Applying this process combination up to 40 % reduction of grinding times can be realised compared to conventional grinding times on established machine concepts.

                                  The rotor grinding machine RX 120 is designed for high productive and economic series production of small and midsize screw compressors. The machine is equipped with direct driven tool and workpiece axes for minimised main and non-productive times during the grinding process.

                                  The RX 120 uses only non-dressable CBN tools.
                              • Special Solutions

                                  • WEISSER-KAPP MultiCELL

                                  • Machine concept
                                    The WEISSER-KAPP MultiCELL is an innovative gear grinding centre for high productive finishing of gears. This integrated system merges the WEISSER hard turning/grinding process for finishing of the reference surfaces and KAPP gear grinding. Especially for medium and large batch production this process integration causing significant effects.

                                    Reference surfaces are machined by the UNIVERTOR AC-1 within the cell. The WEISSER rotational turning, usable for OD-, ID-turning and facing, considerably shortening processing times compared to conventional procedures as well as gaining excellent surfaces free of lead. The rotational turning allows using considerably higher infeed and cutting speed.

                                    Finally the tooth flanks are being ground in the gear centre KX 100 DYNAMIC using generating grinding. The machine includes two vertically moving pick-up axis; both are mounted on separate pivoting workpiece columns. Each pick-up axis is equipped with a workpiece spindle. While one workpiece is ground, the second spindle transfers the completely processed workpiece to the handling conveyor and picks up an unprocessed part. By means of the optional multifunction axis, measuring and test pieces can be sorted out by the machine.
                                  • GAS / GIS / HGS

                                  • GAS
                                    Machines from the GAS model range are used for processing external threads and similar profiles. Typical components for these machines are external ball screws for automotive steering systems, as well as drive worms and small pumps and metering components. In line with the shaft-type geometry of the components, these machines are designed with a horizontal workpiece axis and have correspondingly long travelling paths. Parts are machined by discontinuous profile grinding only; the tool concept is adapted to the corresponding component requirements:
                                    • non-dressable CBN profile grinding wheels
                                    • dressable ceramic grinding wheels

                                    For specific applications, various tools can also be combined.

                                    GIS
                                    Machines of this type are used for the hard and soft finishing of internal threads in ball screw tracks or similar profiles. Typical applications besides vehicle steering are recirculating ball screws in the field of automotive.

                                    Parts are machined by discontinuous profile grinding.

                                    Non-dressable CBN profile grinding wheels are exclusively used, typically in a combination of roughing and finishing tools.

                                    HGS
                                    The high-speed grinding machine HGS is mainly used for grinding slots in pump rotors into the solid, through-hardened material. Slot widths of 0.5 to 2.0 mm can be produced with high efficiency due to package clamping and automatic unloading and loading. The in process measuring control ensures maintaining slot width tolerances.

                                    The HGS uses non-dressable CBN profile grinding wheels only.
                                  • Gear Grinding Centres ZP B

                                  • Machine concept
                                    The machines of the ZP B type are designed for the complete hard finishing of external spur and helical gears. Special feature of this series – tooth spaces, bores and faces of the gears may be machined in one set-up using two independent machine columns. Since the implementation of the electrical direct drive the combination of gear and bore grinding became possible. This hybrid process allows maximum positioning accuracy in gear grinding in connection with a fast rotation for the bore grinding.

                                    The machines of the ZP B type were designed and built to comply with the highest demands in large gear grinding. Thanks to the combination of two machining processes, they offer further advantages
                                    • savings in set-up, aligning and idle times
                                    • realisation of smaller stock allowances
                                    • no machining of auxiliary surfaces
                                    • reduction of cycle times
                                    • reduction of scrap and reworking percentage
                                    • smaller space required

                                    Like all machines of the well known ZP series, the ZP B machines may be applied for large module gear grinding because of their comprehensive equipment. Due to the combination of internal cylindrical grinding and face grinding, these machines are mainly used for the grinding of gears where quality and economic benefits can be derived from performing all tasks in a single clamping. The bore can be either cylindrical or conical.
                                  • Gear Profile Grinding Machines ZP I/E

                                  • Machine concept
                                    The internal grinding attachment is mounted directly on a large machine column and carries the complete grinding arm including a dressing and measuring unit. The grinding wheel will be dressed by a patented method using the tangential axis of the grinding head and a dressing axis. The CNC dressing device is located directly above the grinding wheel, which allows the wheel to be dressed in its grinding position. This eliminates long dressing paths and at the end, reduces the process times significantly. The grinding spindle is driven by a timing belt. This concept increases the torque on the grinding wheel, allows the grinding spindle to be thermally separated from the motor, and provides a compact design. The strong drive delivers enough power for high material removal even when using large and wide grinding wheels.

                                    Even the basic machines are equipped with coolant filtration unit, dresser, in process measuring system, balancing unit, acoustic emission sensor and comprehensive software for grinding and measuring of involute profiles.
                                    The use of high-strength, vibration-absorbing and durable spheroidal cast iron is one of the key features for the machine accuracy. Further outstanding features are, amongst others, a well dimensioned rotary table with electrical direct drive and hydrostatic bearing for highly accurate positioning, excellent load capacity and almost unlimited lifetime.
                                  • Gear Profile Grinding Machines ZP E/I

                                  • Machine concept
                                    The machine concept is based on the use of two independent grinding columns similar as used in the ZP B type. Beside the regular ZP grinding co- lumn for external gear grinding the machine is equipped with an additional ZPI grinding column for internal gear grinding. Both grinding columns allow optimum machining without limitation. The biggest advantage is the ease of changing the machine set-up. Especially on large machines it takes a lot of time to replace the whole grinding head. The switch between external and internal gear grinding on a ZP E/I machine doesn’t require a set-up time at all.

                                    Thus machines will be used by job shops primarily. The use of a common rotary table and peripheral units as the coolant filtration unit, for example, significantly reduces the investment cost and floor space compared with two single machines. Nevertheless full functionality for external and internal gear grinding is still available.

                                    The machine concept can be tailored according to the customer requirements. Therefore it can be choosen from multiple rotary table groups and grinding column bases out of the ZP machine series larger 3 m. The machine layout can be straight – both column against each other – or as an L-shape.
                                  • Machine VIG

                                  • The internal gear grinding machine VIG was developed for the grinding of internal spur gears and profiles with highest quality demands. In this series the tool concept, non-dressable CBN tools, is used. It is possible as appropriate after testing to enlarge the working area.
                                  • Universal Profile Grinding Machine VGG

                                  • Profile grinding up to 250 mm tip diameter

                                    The universal gear grinding machine VG was developed for the grinding of external and internal profiles with highest quality demands. In this series the tool concept, non-dressable CBN tools, is used. It is possible as appropriate after testing to enlarge the working area.
                                • Tools

                                • As a manufacturer of gear and profile grinding machines KAPP NILES offers sophisticated/highly developed technologies with different, the particular task customised tooling concepts.
                                    • Dressing tools

                                    • for profile dressing of vitrified bonded grinding tools. In addition to CBN and diamond tools for hard and soft finishing of gears and profiles there are dressing tools for profiling of vitrified bonded grinding tools in the product line.
                                        • Dressing rolls

                                        • Continuous generating grinding is one of the most productive technologies to grind high precision gear tooth flanks. KAPP manufactures dressing tools in positive and negative electroplated version. Highest flexibility can be achieved with form rolls for topological dressing. For the so called “flexible dressing” the tools are designed to dress worms for different workpieces with one tool, while the tip of the worm is dressed separately.

                                          For serial production there are profile rolls with integrated tip dresser in a workpiece specific manner also for grinding of well defined gear root area. Most productive for high volume are multi-ribbed diamond profile rolls made in a negative electroplating process.
                                        • sintered dressing rolls

                                        • Discontinuous profile grinding is usually used for smaller lot size production and also for bigger gears. Therefore KAPP delivers sintered diamond form rolls which can be in an economic version with natural diamond or in a long life version with handset CVD diamond sticks.

                                          These rolls can be reground several times and exhibit a high tool life.
                                        • dressing gears

                                        • Continuous gear honing is mainly used in the automotive industry as an alternative to generating grinding. This type of tool is also available as a set with DDG and integrated tip dressing roll. Diamond dressing gears produce the expected geometry precisely and fast and guarantee the demanded quality on the workpiece.
                                      • Grinding tools

                                          • Non-dressable grinding tools

                                          • CBN profile grinding wheels
                                            single or multi-ribbed roughing and finishing wheels suitable for
                                            • grinding of external and internal gears for automotive and aircraft industry
                                            • radial, screw, rotor and worm profile wheels
                                            • high speed grinding of profiles and gears
                                            • lunge grinding, abrasive cutting, cylindrical grinding

                                            CBN grinding worms
                                            roughing and finishing worms in form of cylindrical worms and globoidal worms for highly efficient grinding of external gears and profiles.

                                            diamond Coroning rings and -gears
                                            to process
                                            • automotive gears for passenger and commercial vehicles
                                            • advanced, low noise gears
                                            • workpieces with interfering geometry
                                          • Dressable grinding tools

                                          • dressable aluminium oxide tools
                                            Beside the non-dressable CBN grinding tools, dressable grinding tools of leading manufacturers can be used on our machines, too. Vitrified bond aluminium oxide tools are dominant. Sintered aluminium oxide is preferred as the grinding tool for grinding of steel due to its resilience and grinding capability. Gray cast-iron can also be processed with normal aluminium oxide. The profiling of the grinding tools takes place via a machine-integrated CNC dressing unit. A diamond-plated, rotating dressing tool profiles the wheel in accordance with the respective gear parameters. The grinding tool is conditioned specifically for rough or finish grinding by selecting respective technological dressing parameters. Form consistency and cutting capacity of the grinding wheel is assured by repeated dressings, dependent on pre-defined stock removal rates. The automatic balancing produces smoother turning for larger grinding tools, and consequently, high gear quality.

                                            dressable CBN tools

                                            Single-layered electroplated CBN wheels slowly change their grinding characteristics caused to the wear of grids. Tools with dressable CBN however modify their surface during the grinding process permanently. These tools come in different designs; as a profile grinding wheel or as a cylindrical grinding worm.