State-of-the-art tool adjusting and measuring devices guarantee an optimum workflow, from servicing and repairing the tool to use in the machine tool. To enable efficient, trouble-free production of drive components for our customers, Klingelnberg offers a broad portfolio in a unique closed-loop process.
GRINDING MACHINE FOR STICK BLADES FROM ANY BEVEL GEAR TYPE
Maximum precision, economic production, multi-grinding methods, compact machine layout and automatic handling are the key features of the Oerlikon B 27 stick blade grinding machine, which has been designed for grinding the HSS and carbide blades that are used to cut spiral and hypoid gears in any system. The intelligent machine concept which is designed for robustness is the guarantee of maximum profile and repetition accuracy, while at the same time providing the shortest machining times.
FOR HIGH-PRECISION MEASUREMENT OF STICK BLADES
The quality control loop between the blade grinding machine and the ground blade can be closed efficiently and simply by measuring the stick blades. With the standard basic configuration, both the position and the shape of the main and secondary blades can be recorded using a scanning procedure. The KIMoS (Klingelnberg Integrated Manufacturing of Spiral Bevel Gears) calculation program supplies the necessary contour data, which eliminates the need for manual data entry and minimizes the preparation time.
OPTIMAL CUTTERHEAD SETTING FOR LONG SERVICE LIFE AND HIGH-QUALITY GEAR TEETH
The Oerlikon CS 200 cutter head setting and checking device makes it possible to set the individual blades quickly and easily, checks the position thereof and documents the measuring results. Through the combination of a semi-automated setting procedure, operator-guided setup actions and an automatic measuring procedure, cutter heads can be set easily, quickly and extremely accurately.
"Simplified with Passion" – true to this motto, Klingelnberg is driven to provide simple, unconventional solutions to high-tech challenges. A team of engineers and technical experts makes it possible – always with the goal of ensuring the highest technological standards in application-matched machine designs that are also easy to use. Case in point: The Oerlikon bevel gear cutting machines are based on established design concepts that are continually undergoing further development.
HIGHLY EFFICIENT, ENVIRONMENTALLY FRIENDLY DRY-CUTTING
Among other things, the C 15 concept is based on the modern production technology of dry-cutting without the use of cooling lubricant, with an application range that is suited to smaller gearbox sizes. This machine is equipped with direct drives for the workpiece spindle and the tool spindle.
HIGHLY EFFICIENT, ENVIRONMENTALLY FRIENDLY DRY-CUTTING
The application range of the C 27 bevel gear cutting machine is ideal for the gearbox sizes found in passenger car and small truck applications. This machine is equipped with direct drives and is designed for cutting workpiece diameters up to 270 mm. The C 27 makes it possible to achieve cutting speeds that allow highly cost-effective dry-cutting even for a large number of cutter head starts and small numbers of teeth.
HIGHLY EFFICIENT, ENVIRONMENTALLY FRIENDLY DRY-CUTTING Thanks to continuous
further development of the vertical concept, the Oerlikon C 30 bevel gear cutting machine sets new standards in dry processing. All of the bevel gear machines in this series are equipped with a thermostable, vibration-damping machine bed. The cutting machine utilizes an optimized axis arrangement, resulting in reduced traversing paths that significantly reduce the load on the drive components and stiffen the structure of the overall system at the same time. An integrated deburring tool also provides maximum productivity and maximum process safety using the PULSAR method. Use of the optional Power Skiving method makes it possible to achieve even greater machine flexibility and productivity.
The vertical design of the C 50 bevel gear cutting machine and the direct drives for the tool, workpiece and angle drive make it ideal for dry-cutting bevel gears with coated carbide cutters. The C 50 is designed exclusively for dry-cutting processes. When used in conjunction with the high-performance ARCON® and SPIRON® cutters, the bevel gear cutting machine can be used to produce all common spiral bevel gears in both continuous indexing and single indexing processes with maximum efficiency.
The C 60 bevel gear cutting machine covers the upper application range of the C series. It is used for cutting bevel gearboxes for heavy-duty trucks and tractors, and has the same well-tried design as every C machine. In the C 60, special emphasis was placed on high static and dynamic rigidity. A look at the large, extremely stiff machine components makes this apparent. And the proof is in the gear-cutting performance and quality.
This series was developed based on the C series machines, primarily for manufacturing spiral-cut bevel gears using Klingelnberg's Zyklo-Palloid® method. With this system, the main focus is on simple, on-target production of spiral bevel gears with an extremely small tool volume for the application area of ring gears with a diameter up to 450 mm.
Oerlikon bevel gear grinding machines were developed with real-world applications in mind to meet the varying demands of a whole range of different application industries. Used throughout the world, the "Simplified with Passion" system plays an important part in ensuring that machining tasks are made simple. Moreover, the Klingelnberg system contributes to standardization and quality assurance on a global scale.
Thanks to continuous further development of the vertical concept, the G 30 bevel gear cutting machine sets new standards in grinding. The grinding machine utilizes an optimized axis arrangement resulting in reduced approach paths that ensure a significantly reduced load on the drive components and at the same time a more rigid design of the complete system. The G 30 can be optionally equipped with a side loading door. This allows easy loading in automatic mode using a machine-integrated loading shuttle or handling robot. For series production, the machine also offers a range of process monitoring functions.
Thanks to its outstanding grinding performance and universal design, this CNC-controlled bevel gear grinding machine from the G model series is an extremely economical concept for high-precision final machining of the curved-toothed spiral bevel gears of any gearing system as well as face-type clutches. These machines operate up to a ring gear diameter of 600 mm, and have a vertical grinding spindle.
Thanks to its outstanding grinding performance and universal design, this CNC-controlled bevel gear grinding machine from the G model series is an extremely economical concept for high-precision final machining of the curved-toothed bevel gears of any gearing system as well as face-type clutches. These machines operate up to a ring gear diameter of 850 mm. The G machines are equipped with a side loading door for automation purposes, making loading using handling robots easy during automatic operation.
The Oerlikon bevel gear lapping machine is designed to allow all operational tasks, loading, unloading, and lapping compound replacement to be carried out from the front of the machine. A tried-and-tested horizontal spindle concept, with a clever arrangement of the axes and the use of an innovative compound slide, ensures optimal functionality – without compromising the space requirement, accessibility, or process.
The bevel gear lapping machine is designed to allow all operational tasks, loading, unloading, and lapping compound replacement to be carried out from the front of the machine. This opens up completely new ways of setting up the machine shop. In addition to the machine design itself, which primarily minimizes the active space requirements, special emphasis was placed on optimizing the passive footprint so that the individual machines can be arranged closer together, therefore reducing unproductive areas and distances for the operating personnel.
The Oerlikon bevel gear testing machine T 60 has an advanced machine design that features sophisticated technology and an ultra-modern CNC; is universal and user-friendly; and is designed for maximum reproducibility and test safety. The bevel gear test stands TS 30 make it possible to check bevel gear sets of different sizes for wear and fatigue strength.
The TS 30 bevel gear test stands are used to check bevel gear sets of different sizes for wear and fatigue strength. Electric drives initiate the rotary motion at the drive side (motor) and the brake torque at the output side (generator). This concept makes it possible to operate the test stand in an extremely energy-efficient way.
The T 60 bevel gear testing machine is a CNC testing machine with three linear axes for fully automatic hard and soft testing of spiral-bevel and hypoid gear sets with a 90° shaft angle. It offers a wide range of objective and subjective testing options, with speeds of up to 3,250 rpm and maximum brake torque of 95 Nm.
The Höfler cylindrical gear cutting machines of the HF range have become firmly established in the market due to their stable and solid construction. The machine series is completely suitable for environmentally friendly dry cutting and can be provided with wet cutter equipment if desired. All cutting machines in the HF range have ideal damping properties between the moving housings or slides and the machine bed.
Designed for workpiece diameters of up to 1,000 mm, the HF 1000 cylindrical gear hobbing machine combines leading technology with the perfect design: a machine table with torque motor drive, a heavy-duty gray cast iron machine bed, and integrated workpiece inspection are just some of its features. Through the use of HSS or indexable insert cutters and high-performance gashers in wet or dry cutting processes, this versatile cutting machine sets new standards in productivity and quality ideal for suppliers of durable, heavy-duty industrial gearboxes.
Designed for workpiece diameters of up to 1,250 mm, the HF 1250 cylindrical gear hobbing machine combines leading technology with the perfect design: a machine table with torque motor drive, a heavy-duty gray cast iron machine bed, and integrated workpiece inspection are just some of its features. Through the use of HSS or indexable insert cutters and high-performance gashers in wet or dry cutting processes, this versatile cutting machine sets new standards in productivity and quality ideal for suppliers of durable, heavy-duty industrial gearboxes.
Designed for workpiece diameters of up to 1,600 mm, the HF 1600 cylindrical gear hobbing machine combines leading technology with the perfect design: a machine table with torque motor drive, a heavy-duty gray cast iron machine bed, and integrated workpiece inspection are just some of its features. Through the use of HSS or indexable insert cutters and high-performance gashers in wet or dry cutting processes, this versatile cutting machine sets new standards in productivity and quality ideal for suppliers of durable, heavy-duty industrial gearboxes.
Designed for workpiece diameters of up to 2,000 mm, the HF 2000 cylindrical gear hobbing machine combines leading technology with the perfect design: a machine table with torque motor drive, a heavy-duty gray cast iron machine bed, and integrated workpiece inspection are just some of its features. Through the use of HSS or indexable insert cutters and high-performance gashers in wet or dry cutting processes, this versatile cutting machine sets new standards in productivity and quality ideal for suppliers of durable, heavy-duty industrial gearboxes.
Designed for workpiece diameters of up to 2,500 mm, the HF 2500 cylindrical gear hobbing machine is known for its solid, sturdy design and high precision. Modern high-performance tools can make use of their full machining potential due to having appropriately powerful machines. With its high degree of functionality, the HF model series is not only capable of meeting this requirement, but also the requirements of the future.
Designed for workpiece diameters of up to 3,000 mm, the HF 3000 cylindrical gear hobbing machine is known for its solid, sturdy design and high precision. Modern high-performance tools can make use of their full machining potential due to having appropriately powerful machines. With its high degree of functionality, the HF model series is not only capable of meeting this requirement, but also the requirements of the future.
Designed for workpiece diameters of up to 4,000 mm, the HF 4000 cylindrical gear hobbing machine is known for its solid, sturdy design and high precision. Modern high-performance tools can make use of their full machining potential due to having appropriately powerful machines. With its high degree of functionality, the HF model series is not only capable of meeting this requirement, but also the requirements of the future.
Designed for workpiece diameters of up to 6,000 mm, the HF 6000 cylindrical gear hobbing machine is known for its solid, sturdy design and high precision. Modern high-performance tools can make use of their full machining potential due to having appropriately powerful machines. With its high degree of functionality, the HF model series is not only capable of meeting this requirement, but also the requirements of the future.
Designed for workpiece diameters of up to 8,000 mm, the HF 8000 cylindrical gear hobbing machine is known for its solid, sturdy design and high precision. Modern high-performance tools can make use of their full machining potential due to having appropriately powerful machines. With its high degree of functionality, the HF model series is not only capable of meeting this requirement, but also the requirements of the future.
Klingelnberg is regarded as the leading specialist for high-precision cylindrical gear grinding machines, a position it maintains through significant investments in research and development. Extreme reliability and high efficiency are hallmarks of the Höfler cylindrical gear grinding machines in the HELIX/PROMAT, RAPID, VIPER 500 and SPEED VIPER ranges.
The Höfler cylindrical gear grinding machine Speed Viper – which focuses on high-productivity generating grinding in large-series manufacturing – draws on the successful concept of the Viper 500 series. It is available in four different configurations based on individual requirements. The Speed Viper 300 is designed for maximum workpiece diameters of 300 mm. In addition to toothed gears, it can also grind extra-long shafts. This is possible thanks to a distance between centers over table of up to 1,100 mm.
The Höfler cylindrical gear grinding machine Speed Viper – which focuses on high-productivity generating grinding in large-series manufacturing – draws on the successful concept of the Viper 500 series. It is available in four different configurations based on individual requirements. The Speed Viper 180 is designed for maximum workpiece diameters of 180 mm. In addition to toothed gears, it can also grind extra-long shafts. This is possible thanks to a distance between centers over table of up to 1,100 mm.
The Höfler cylindrical gear grinding machine Speed Viper – which focuses on high-productivity generating grinding in large-series manufacturing – draws on the successful concept of the Viper 500 series. It is available in four different configurations based on individual requirements. The Speed Viper2 180 is designed for maximum workpiece diameters of 180 mm. In addition to toothed gears, it can also grind extra-long shafts. This is possible thanks to a distance between centers over table of up to 895 mm. The Speed Viper² dual-spindle concept achieves minimal auxiliary times, fulfilling the productivity requirements of the automotive industry.
The Höfler cylindrical gear grinding machine Speed Viper – which focuses on high-productivity generating grinding in large-series manufacturing – draws on the successful concept of the Viper 500 series. It is available in four different configurations based on individual requirements. The Speed Viper2 80 is designed for maximum workpiece diameters of 80 mm. In addition to gears, it can also grind extra-long shafts. This is possible thanks to a distance between centers over table of up to 895 mm. The Speed Viper² dual-spindle concept achieves minimal auxiliary times, fulfilling the productivity requirements of the automotive industry.
The HELIX 400 cylindrical gear grinding machine is a compact, flexible profile grinding machine for workpiece diameters of up to 400 mm. Its well-engineered mechanical system makes it a reliable partner for precision manufacturing. The innovative control and software functions are also ideal for manufacturing special profile and tooth trace modifications for special series.
The VIPER 500 cylindrical gear grinding machine is designed for component diameters of up to 500 mm and is optimally suited for small to medium-sized batches. To suit individual requirements, the machine is available in three different configurations: profile grinding, small grinding wheels for custom jobs and multiple-wheel technology (K) and generation grinding (W) . The special machine axis arrangement is a contributing factor to the machine's tried-and-tested precision, consistent quality and tremendous flexibility. The highly dynamic axes allow optimized 5-axis machining of wide variety of modifications in the shortest possible grinding time.
Cylindrical gear manufacturers all around the world appreciate the advantages and productivity of the RAPID 650 for workpiece diameters of up to 650 mm. With standard features that include a cast polymer machine bed, a torque motor-driven machine table, an integrated inspection system, a sturdy grinding spindle, and a dressing system for frequent profile modifications, it is the perfect solution for cylindrical gear manufacturers. Technologies such as high-speed grinding [HsG] and best-fit grinding [BfG] also reduce grinding times by up to 30 % ensuring a clear leading edge in production efficiency for the entire manufacturing process.
Cylindrical gear manufacturers all around the world appreciate the advantages and productivity of the RAPID 800 for workpiece diameters of up to 800 mm. With standard features that include a cast polymer machine bed, a torque motor-driven machine table, an integrated inspection system, a sturdy grinding spindle, and a dressing system for frequent profile modifications, it is the perfect solution for cylindrical gear manufacturers. Technologies such as high-speed grinding [HsG] and best-fit grinding [BfG] also reduce grinding times by up to 30 % ensuring a clear leading edge in production efficiency for the entire manufacturing process.
Cylindrical gear manufacturers all around the world appreciate the advantages and productivity of the RAPID 1000 for workpiece diameters of up to 1,000 mm. With standard features that include a cast polymer machine bed, a torque motor-driven machine table, an integrated inspection system, a sturdy grinding spindle, and a dressing system for frequent profile modifications, it is the perfect solution for cylindrical gear manufacturers. Technologies such as high-speed grinding [HsG] and best-fit grinding [BfG] also reduce grinding times by up to 30 % ensuring a clear leading edge in production efficiency for the entire manufacturing process.
Cylindrical gear manufacturers all around the world appreciate the advantages and productivity of the RAPID 1250 for workpiece diameters of up to 1,250 mm. With standard features that include a cast polymer machine bed, a torque motor-driven machine table, an integrated inspection system, a sturdy grinding spindle, and a dressing system for frequent profile modifications, it is the perfect solution for cylindrical gear manufacturers. Technologies such as high-speed grinding [HsG] and best-fit grinding [BfG] also reduce grinding times by up to 30 % ensuring a clear leading edge in production efficiency for the entire manufacturing process.
Cylindrical gear manufacturers all around the world appreciate the advantages and productivity of the RAPID 1600 for workpiece diameters of up to 1,600 mm. With standard features that include a cast polymer machine bed, a torque motor-driven machine table, an integrated inspection system, a sturdy grinding spindle, and a dressing system for frequent profile modifications, it is the perfect solution for cylindrical gear manufacturers. Technologies such as high-speed grinding [HsG] and best-fit grinding [BfG] also reduce grinding times by up to 30 % ensuring a clear leading edge in production efficiency for the entire manufacturing process.
Cylindrical gear manufacturers all around the world appreciate the advantages and productivity of the RAPID 2000 for workpiece diameters of up to 2,000 mm. With standard features that include a cast polymer machine bed, a torque motor-driven machine table, an integrated inspection system, a sturdy grinding spindle, and a dressing system for frequent profile modifications, it is the perfect solution for cylindrical gear manufacturers. Technologies such as high-speed grinding [HsG] and best-fit grinding [BfG] also reduce grinding times by up to 30 % ensuring a clear leading edge in production efficiency for the entire manufacturing process.
The RAPID 2500 cylindrical gear grinding machine is the specialist for large, heavy workpieces up to 2,500 mm in diameter and weighing up to 25 tons. These giants combine maximum dimensions with absolute precision, speed, and flexibility: Topologically correct results with reduced grinding times and an optional internal grinding device form the basis for economical, reliable cylindrical gear production on this scale. In combination with the cutting machines, RAPID machines in the cylindrical gear technology division provide an ideal system for the cylindrical gear production process.
The RAPID 3000 cylindrical gear grinding machine is the specialist for large, heavy workpieces up to 3,000 mm in diameter and weighing up to 30 tons. These giants combine maximum dimensions with absolute precision, speed, and flexibility: Topologically correct results with reduced grinding times and an optional internal grinding device form the basis for economical, reliable cylindrical gear production on this scale. In combination with the cutting machines, RAPID machines in the cylindrical gear technology division provide an ideal system for the cylindrical gear production process.
The RAPID 4000 cylindrical gear grinding machine is the specialist for large, heavy workpieces up to 4,000 mm in diameter and weighing up to 40 tons. These giants combine maximum dimensions with absolute precision, speed, and flexibility: Topologically correct results with reduced grinding times and an optional internal grinding device form the basis for economical, reliable cylindrical gear production on this scale. In combination with the cutting machines, RAPID machines in the cylindrical gear technology division provide an ideal system for the cylindrical gear production process.
The RAPID 6000 cylindrical gear grinding machine is the specialist for large, heavy workpieces up to 6,000 mm in diameter and weighing up to 50 tons. These giants combine maximum dimensions with absolute precision, speed, and flexibility: Topologically correct results with reduced grinding times and an optional internal grinding device form the basis for an economical, reliable cylindrical gear production on this scale. In combination with the cutting machines, RAPID machines in the cylindrical gear technology division provide an ideal system for the cylindrical gear production process.
The RAPID 8000 cylindrical gear grinding machine is the specialist for large, heavy workpieces up to 8,000 mm in diameter and weighing up to 100 tons. These giants combine maximum dimensions with absolute precision, speed, and flexibility: Topologically correct results with reduced grinding times and an optional internal grinding device form the basis for an economical, reliable cylindrical gear production on this scale. In combination with the cutting machines, RAPID machines in the cylindrical gear technology division provide an ideal system for the cylindrical gear production process.
Gear manufacturing today is not just limited to gear cutting machines. These days, machining centers are equally capable of manufacturing gears. With the TM 65, Klingelnberg is taking a fresh approach to complete machining of toothed gears using a method that relies on Klingelnberg’s Closed Loop system. Bevel gears designed with KIMoS (Klingelnberg Integrated Manufacturing of Spiral Bevel Gears) are manufactured true to design on the basis of a virtual twin, making technological knowhow for the automotive industry available for small-batch production.
With the HÖFLER complete machining center TM 65, Klingelnberg has designed a machine that can produce gear bodies and gearing systems of any complexity up to 65 mm in diameter, in a complete machining process starting with rod material – whether bevel gears, cylindrical gears or internal gearing with an involute or non-involute tooth profile. The presence of a main spindle and subspindle allows complete machining of even complex components on a single machine.
Stringent accuracy requirements for gear measurements and increasingly
complex drive components demand the best measuring technology available and
a machine and software concept optimized for these applications. That's why
leading manufacturers put their trust in Klingelnberg precision measuring
centers, which represent the most widely used standard in the industry,
while also serving as the reference for metrology institutes. Klingelnberg
precision measuring centers (P-series) today are ideally suited to handle
most measurement tasks in a wide range of sectors: Users in the automotive
and commercial-vehicle industries, the aerospace and aeronautical
engineering industries rely on this technology, which replaces up to four
conventional measuring devices. This allows the following measurement tasks
to be fully automated in a single setting: gear measurement, general
coordinate measurement, form and position measurement, and roughness
measurement.
All Klingelnberg Precision Measuring Centers are equipped with heavy-duty, stable beds and guide bodies made of cast iron. At the same time, all bearings and guides are backlash-free at the measuring axes. These form the basis for the measuring centers' high basic mechanical accuracy. The integrated 3D tracer head enables both discrete-point probing and scanning, continuous measured value logging.
The fully automatic CNC-controlled P 16 precision measuring center is designed as a compact unit for the workpiece diameter range up to 160 mm. The machine is used to inspect cylindrical gears, pinion type cutters, worms and worm wheels, hobs, bevel gears, general dimension, shape, and positional deviations of axially symmetrical workpieces, cam and camshaft measurement and rotor measurement.
Whether turning blanks, ground workpieces, circular blades, spacers for circular blades, or ball bearings – the new P 16 G precision measuring center is purpose-designed – not to measure gear teeth, but rather specifically for use in manufacturing round components. The P 16 G is the only machine in the P series to be equipped with software for dimension, form, and position measurement as standard. The software records diameter and cylindrical form/conicity, measures axial runout, evenness, and angularity, and delivers a wealth of information for quality management as required. Hence with this precision measuring center, there’s no need for gages.
The fully automatic CNC-controlled P 26 precision measuring center is designed as a compact unit for the workpiece diameter range up to 260 mm. The machine is used to inspect cylindrical gears, pinion type cutters and shaving cutters, worms and worm wheels, hobs, bevel gears, general dimension, shape, and positional deviations of axially symmetrical workpieces, cam and camshaft measurement and rotor measurement.
The fully automatic CNC-controlled P 40 precision measuring center is designed as a compact unit for the workpiece diameter range up to 400 mm. The machine is used to inspect cylindrical gears, pinion type cutters and shaving cutters, worms and worm wheels, hobs, bevel gears, general dimension, shape, and positional deviations of axially symmetrical workpieces, cam and camshaft measurement and rotor measurement.
The fully automatic CNC-controlled P 65 precision measuring center is designed as a compact unit for the workpiece diameter range up to 650 mm. The machine is used to inspect cylindrical gears, pinion type cutters and shaving cutters, worms and worm wheels, hobs, bevel gears, general dimension, shape, and positional deviations of axially symmetrical workpieces, cam and camshaft measurement and rotor measurement.
The fully automatic CNC-controlled P 100 / P 100 L precision measuring centers are designed as compact units for the workpiece diameter range up to 1000 mm and 1250 mm respectively. The machines are used to inspect cylindrical gears, pinion type cutters and shaving cutters, worms and worm wheels hobs, bevel gears, general dimension, shape, and positional deviations of axially symmetrical workpieces., cam and camshaft measurement and rotor measurement.
The fully automatic CNC-controlled P 150 precision measuring center is designed for the workpiece diameter range up to 1800 mm. The machine is used to inspect a wide range of cylindrical gear designs, as well as large bevel gearings and worm gears.
The fully automatic CNC-controlled P 250 precision measuring center is designed for the workpiece diameter range up to 2800 mm. The machine is used to inspect a broad range of cylindrical gear designs, as well as large bevel gearings and worm gears.
The fully automatic CNC-controlled P 350 precision measuring center is designed for the workpiece diameter range up to 3800 mm. The machine is used to inspect a wide range of cylindrical gear designs, as well as large bevel gearings and worm gears.