The KAPP Group has introduced the KX 500 FLEX Gear Center. Like other KX models, the KX 500 FLEX offers continuous generating grinding, discontinuous profile grinding, or a combination of both methods.
But the KX 500 FLEX features a rotating circular table that incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the circular table and is flexible enough to use either conventional dressable worms or profile grinding wheels. The unit also accommodates a single or twin spindle dresser. Depending on the applied dresser, different technologies can be used for the dressing process.
The KX 500 FLEX Gear Center grinds external spur and helical gears of modules up to
10 mm (0.4 in) with an outside diameter of maximum 500 mm (19.7 in) and a gear width of up to 520 mm (20.5 in).
The machine offers the diverse tooling concepts of dressable ceramic tools for prototype machining and grinding of medium- to high-volume series, and non-dressable tools for manufacturing medium- and highvolume series. It also grinds more challenging gear geometry by using smaller tools.
The position of the workpiece spindle on the rotary table makes it possible for the KX 500 FLEX to be
conveniently loaded by hand or by an automatic unit. For hand loading, the table swivels the part to the operator’s door. For automatic loading, it is shifted laterally 90 degrees. A detailed configuration is created for each specific application. Automation options include a standardized combination of pallet conveyer and gantry loader, or a robot system.
The KX 500 FLEX uses a Siemens Sinumerik 840 D control system. A total of eight NC-axes perform the linear and rotary motions necessary for the machining process. The circuit table and tailstock are used as NC-axes, too. The part and tool are directly driven.
There is an optional measuring unit for measuring gear profile plus gear or tooth size over span. Additionally, a sample inspection of the gear quality can be sequenced to occur periodically during normal production runs.