P 90 G Grinding and Machine

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

P 90 G Ð three grinding methods + hobbing combined in one machine.

The P 90 G is a new development Standard features Special features/options based on the proven P 90 Hobbing ¥ Grinding head with infinitely ¥ Electronic handwheel. Machine platform. variable high-speed direct drive and ¥ Remote diagnostics system via modem. The P 90 G is a universal machine maintenance-free bearings. Spindle with ¥ Loading systems available: providing three grinding methods. hob arbor taper or with straight bore and Ð H grippers In addition to hobbing it will meet collet chuck for shank-type hobs. Ð rotational grippers requirements for prototype, small and ¥ Work spindle with maintenance-free Ð NC gantry loader for workpieces large volume production. direct drive. up to 7 kg. ¥ Work area guarding made of stainless ¥ Power clamping equipment. The P 90 G machine is capable of hobbing steel with steep angles for optimum ¥ Deburring unit. and grinding spur and helical and chip disposal. ¥ Motorized safety withdrawal for effective pinions up to module 3 mm*, and single ¥ Integrated hydraulic unit for hob and protection of machine and tool. and multi-thread worms up to module workpiece clamping. ¥ Meshing/stock division. 5 mm* in a range of diameters up to ¥ Siemens numerical control of the latest ¥ Magnetic/scraper conveyor or coalescing 100 mm*. Various designs of grinding generation with 12" flat color monitor filter with chip box. tools made of non-dressable CBN are used. integrated in a 19" control panel. ¥ Coolant system. A variety of processes and software ¥ Gleason-Pfauter operator interface, ¥ Oil mist separator. options is available, depending on the menu-assisted and shop-oriented ¥ Workholding equipment for workpieces. users’ individual requirements. programming with operator-friendly ¥ Other accessories available on request. help functions and service support. ¥ Digital drive technology on all axes with integrated interpolation functions. ¥ Absolute measuring systems. ¥ Machine meets all the relevant standards and is CE certified.

* Standard values Ð deviations or restrictions may result from machine features, workpiece clamping or methods and require technical clarification.

2 technology

Threaded wheel grinding. Grinding using single or multi-thread options are available for lead CBN grinding worms. modifications, such as crowning or taper. If required, several grinding worms can be mounted on one arbor for roughing and finishing, thus machining the workpiece in one setting. The option of using small-diameter grinding wheels allows workpieces to be ground with limited approach and overrun distances.

The machine is programmed by means of a user-friendly dialog system. In the basic version, several

Profile grinding. Single Ð index form grinding. The process is divided into a roughing CBN profile grinding wheels are and a finishing operation. A specific shaped to suit the desired tooth form. software package provides a variety Profile modifications (e.g. tooth tip of standard options for selection chamfer or profile crowning) are (e.g. multiple-flank roughing, dual-flank incorporated directly into the grinding finishing) and cycles (e.g. random indexing wheel. Lead modifications such as cycle). The precise positioning of the crowning or taper, can be programmed grinding wheel is supported by a special directly via the CNC dialog. function in the software and this The possibility of using small-diameter considerably reduces set-up time. grinding wheels allows workpieces to be ground with limited approach and overrun distances.

Indexing generation grinding. Single Ð index generation grinding Involutes are generated by applying the Desired modifications to both using a module-independent CBN tangent (edge of the grinding wheel) profile and tooth trace can be wheel. The grinding wheel is based on across the reference circle. The spacing of the profile of the rack (standard basic individual points and “feed direction” are conveniently defined by means rack tooth profile); the form angle of both freely selectable in this process. of the dialog. the grinding wheel does not have to be identical to the pressure angle of the gear to be ground. This fact makes the method of particular interest for grinding prototypes and small volumes. Arranging one roughing wheel and one finishing wheel on one arbor allows workpieces to be ground from the solid blank in one set-up.

3 automation

The combination of indexing chain belt and V-magazine for supplying blanks and the unloading belt for discharging finished parts provides another interesting option for rapidly changing over long shafts, pinions and gears.

Cylindrical shafts placed in and Fast and flexible workpiece loading/ Customer-specific material unloading systems are available for removed from stacks by lifting loader. flow system with pallet the P 90 G. This automated solution provides The machine can easily be incorporated circulating system. a high level of autonomy for little into customer-specific conveyor systems. The workpiece pallets can be space. changed over in minimum time, The gantry loader, which is integrated in the machine, can also be optimized with no tools required for the in terms of length and function to suit process. unique workpiece loading requirements.

Machine with NC gantry loader, lifting capacity per gripper of 7 kg. Continuous indexing chain belt with central lifting station for supplying blanks and discharging finished parts.

4 technical data / machine dimensions

Technical data Nominal workpiece diameter: Ð automatic loading 100 mm Ð manual loading 125 mm Nominal module of machine: Ð threaded wheel grinding approx. 3.0 mm Ð profile grinding approx. 3.0 mm Ð indexing generation grinding approx. 3.0 mm Maximum axial slide travel 300/400* mm Maximum grinding head swivel angle: Ð left 45¡ Ð right 115¡ Maximum grinding wheel dimensions: Ð form wheel diameter 115 mm Ð grinding worm diameter 100 mm Ð grinding worm length 180 mm Maximum grinding wheel travel (shifting) 160 mm Maximum work spindle speed 3000 rpm Minimum/maximum center distance 10/100 mm Grinding wheel drive rating 14 kW Grinding wheel speed range 50 Ð 12000/20000* rpm Rapid traverse speeds: Ð axial 10000 mm/min Ð radial 7500 mm/min Ð tangential 5000 mm/min Machine weight (without filtration unit) approx. 5500 kg

* Special design.

▲ ▲ 625 ▼ ▲ 2645 ▲ ▲ 2020 ▲ 120 1 120 1 750 ▼ ▼ ▼ ▼ ▼ 270 ▲ ▼ ▲ 440 ▼ ▲ ▲ ▲ ▼ ▼ ▼ ▲ 1250 ▼ 700 1900 1000 ▲ 4850 ▼

Machine dimensions ▲ ▲ ▲ ▲ ▲

of P 90 G in mm. 580 520 ▼ ▼ ▼ ▼ 450 ▲ ▲ 135 ▼ 460 545 ▲ ▼ 2900 3468

▲

▼ 440 ▲ ▲ 145 ▼ ▲

310 ▼ ▼ ▲ 800 ▼ 1000

▼ ▼

5 Information and specifications in this publication are subject to change without notice. w orldwide

Tooling and Workholding. The Complete System. Global Service and Support. Gleason is the world’s leading source for At every stage of the gear production With a manufacturing presence world- advanced new tooling and Quick Change process, Gleason offers advanced wide, as well as service support in over workholding systems to meet the latest new technology that takes significant 30 countries, Gleason is truly a global requirements for accuracy, speed, and tool production time and cost out of the company. life. Only Gleason provides the complete operation. Our broad-based infrastructure and range of gear cutting and finishing tools For the production of spur and helical strong worldwide presence place us for cylindrical and bevel gears, including gears, for example, Gleason offers a full in a unique position to respond to hobs, cutters, shaving and honing range of vertical and horizontal hobbing customer requirements anywhere, tooling, bevel blades and heads, replatable machines, gear (electronic and anytime. CBN and diamond grinding and dressing mechanical helical guides), shaving and wheels and plated diamond rolls. honing machines, and advanced threaded wheel and profile grinding machines.

Gleason’s ability to manufacture and completely inspect all types of gears and gear cutting tools is unmatched.

1000 University Avenue Maschinenfabrik GmbH Maschinenfabrik GmbH P.O. Box 22970 Daimlerstrasse 14 Subsidiary Studen Rochester, NY 14692-2970, USA D-71636 Ludwigsburg, Germany Büetigenstrasse 80 Tel. +1-585-473-1000 Tel. +49-(0)7141-404-0 CH-2557 Studen, Switzerland Fax +1-585-461-4348 Fax +49-(0)7141-404-500 Tel. +41-(0)32-366 61 71 e-mail: [email protected] Fax +41-(0)32-365 30 03 e-mail: [email protected] e-mail: [email protected]

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W 219/1/3/1006e Printed in Germany.