P 800 S to P 3200 S and Gear Shaping Machines P 800 ES to ... · The large-machine platform used...
Transcript of P 800 S to P 3200 S and Gear Shaping Machines P 800 ES to ... · The large-machine platform used...
P 800 S toP 3200 S
andP 800 ES to
P 1200/1600 ES
K E E P I N G T H E W O R L D I N M O T I O N TM
Gear Shaping Machines
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New-generation Shaping Machines for large gears: fast, flexible, economical.
Faster, more economical production
of larger external and internal gears
requiring shaping rather than
hobbing is possible with the new-
generation Gear Shaping Machines
from Gleason-Pfauter.
m a c h i n e c o n c e p t
Gear Shaping Machines offer a useful
alternative to the soft machining of
involute gears where workpiece or tooling
geometry does not allow the use of
conventional processes such as hobbing
or form milling because of interference.
Gear Shaping Machine P 2000 S
with fully-enclosed work area
(outer safety railing removed for photo only).
more precise radial slide movements
across the complete speed range.
The extremely stiff table bearing
combined with a proven backlash-free
double-worm index drive allows for
a high torque range and high radial
and axial runout of the worktable.
● Modular design.A modular machine bed and table
design allows for a larger diameter
workpiece to be machined with
a smaller machine footprint to
optimize machine investment and
floor space utilization.
For example, the radial travel of the
P 800 S can be expanded to
accommodate a workpiece diameter
as large as 1200 mm (P 800/1200 S
model), enabling the user to increase
capacity without the investment
required for the larger machine.
All machine sizes and designs
available are summarized in the table
below.
● Versatile shaping heads.Mechanical and hydraulic shaping
heads are available for stroke lengths
up to 225, 380 and 650 mm.
This allows for an optimum, job-oriented
and cost-effective choice of shaping
heads to cover a broad range of different
workpieces.
● Advanced controls.The use of the latest Siemens CNC control
and Siemens digital drive technology
ensures maximum performance and the
complete compatibility of all drive and
control components.
c o m m o n p l a t f o r m
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This line of machines is designed for
workpiece diameters of up to 3,200 mm
(higher diameters upon request).
The “Electronic Helical Guide” (ES)
design can be applied for workpiece
diameters of up to 1,600 mm.
The “Electronic Helical Guide” feature
is used to produce helical gears, thus
eliminating high procurement costs for
conventional mechanical helical guides
and retooling times.
This broad modular concept provides
a variety of benefits for the user:
● Proven platform.
The large-machine platform used
for Gleason-Pfauter gear shaping
machines is common to Gleason-
Pfauter hobbing and grinding machines,
operating with unsurpassed rigidity,
stability and reliability in hundreds of
production environments worldwide.
● Higher accuracies.The unique design of the machine
bed and worktable ensures that
cutting forces are absorbed and
transferred to the machine foundation.
The use of flat guideways and
narrow separate guides with
pre-loaded roller bearings ensures
Breakthrough technology.
Gleason-Pfauter offers “Electronic
helical guide” technology to
completely eliminate the expensive,
time-consuming procurement and
change over of mechanical guides for
the production of helical gears.
* with mechanical shaping head.
Machine sizes and designs with intermediate sizes.
Standard-machine
Intermediatesize
Standard machine with “ElectronicHelical Guide”
Intermediate sizewith “ElectronicHelical Guide”
P 800 S
P 1200 S
P 1600 S
P 2000 S
P 2400 S
P 2800 S
P 3200 S
P 800/1200 S
P 1200/1600 S
P 1600/2000 S
–
P 2400/2800 S
–
–
P 800 ES*
P 1200 ES*
P 800/1200 ES*
P 1200/1600 ES*
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s h a p i n g h e a d s
The availability of a great choice of
shaping heads enables Gleason-
Pfauter Gear Shaping Machines to
be more easily customized to meet
the widest possible range of application
requirements.
The mechanical shaping head.For smaller to moderate requirements
with regard to shaping performance,
module and shaping stroke, the shaping
head with mechanically-driven cutter
spindle is ideal. The cutter spindle has
fully hydrostatic bearings and the
backlash-free, preloaded double-worm
index drive and the helical guides with
hydrostatic bearings are produced to the
highest precision specification.
The ideal conditions for top-quality and
pitch variation pattern result from the
rigid shaper cutter holding fixture of
a taper shank design. The drive of
the cam for cutter spindle back-off
movement is affected by a backlash-
free direct drive in the form of an NC
axis. The mechanical shaping head is
available with the unique “Electronic
Helical Guide” as an option.
Shaping heads with hydraulically-driven cutter spindle.To cover larger performance ranges
Gleason-Pfauter offers a shaping head
with hydraulically-driven cutter
spindles. This design with its fully
hydrostatic bearing and high-
performance hydraulic drive technology
provides considerable benefit in terms
of shaping force, cutting speed, module
and stroke length.
lnnovative, and extreme rigid backoff-
concept for hydraulic shaping heads.
Gleason-Pfauter is once again setting
standards with its innovative, unique
concept of cutter spindle back-off
movement using hydrostatic drive and
guide elements. This solution renders
superfluous mechanical components
for the back-off movement.
The results are:● maximum precision of movement in
combination with optimum process
design,● no costs for special cams,● flexible change between external
and internal gears.
In this instance, the high-precision
shaping movement also guarantees a
backlash-free, preloaded double worm
index drive. There are two sizes of this
shaping head design available featuring
different performance data.
All available shaping heads can be used
on all machine sizes.
Generating cutter
loading/unloading system.
Mechanical shaping head.
Hydraulic shaping head.
“ e l e c t r o n i c h e l i c a l g u i d e ”
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Shaping head design with “Electronic Helical Guide (ES)”.The mechanical helical guides of
conventional CNC-controlled gear
shaping machines present the user
with significant disadvantages.
A mechanical guide has serious
limitation such as:● High cost, long lead times,
complicated logistics for the initial
purchase and regrinding of
mechanical guides as well as long
change over time when required to
change a guide,● typically a mechanical guide is made
to cut a specific gear, i.e. is made to
the lead and hand of the cutter and it
is highly unlikely the guide can be
used to make another helical gear as
you would need to have the same
hand and lead of the cutter,● can not normally cut two or more
helical gears in a single part clamping
for previously stated lead and hand of
cutter issues,● can not normally shape a helical gear with
a shaper cutter’s lead less than 400 mm,● unable to have the flexibility to change
the lead of the gear shaped, i.e. change
lead results to compensate for helix
unwind in heat treat.
The mechanical shaping head has beencompletely redesigned with a backlash-free direct drive for the
cutter spindle in order to deliver higher
flexibility and operating ranges than
previously using conventional shaping
machines.
Gleason’s ES technology provides the user
with huge potential for savings:● No investment in mechanical helical
guides required.● Elimination of lead times needed to
purchase mechanical guides.● No time-consuming changeover.● Flexible setting of any helix angle,
including angles above 45°.● Simple helix angle corrections (e.g.
lead angle errors due to hardening).● Machining of different helix angles in
one setup (suitable tool arbor required).
Now available:
“Electronic Helical Guide
(ES)” technology for large
machines.
* Special shaping cycles available for oversize face widths.
Hydraulicshaping head 1
“S” series “ES” series “S” series “S” series
Generation of a helical gear’s lead mechanical electronic mechanical mechanical
Spindle stroke drive electro-mechanical electro-mechanical hydraulic hydraulic
Nominal module 12 mm 12 mm 16 mm 24 mm
Cutter spindle diameter 110 mm 110 mm 130 mm 160 mm
Max. cutter spindle rotary speed 27 rpm 235 rpm 8 rpm 8 rpm
Maximum stroke length 225 mm 225 mm 380 mm 650 mm
Maximum face width* 200 mm 200 mm 350 mm 600 mm
Cutter spindle stroke speed range 50 - 500 50 - 500 – –(strokes per minute)
Cutter spindle drive motor 22 kW 22 kW hydraulic hydraulic
Maximum cutting speed – – 50 m/min 30 m/min
Tooling arbor taper HSK - B 80 HSK - B 80 HSK - 80 HSK - 100
Minimum lead of guide 400 mm – 850 mm 850 mm
Mechanicalshaping head
Hydraulicshaping head 2
Technical data for shaping heads
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Simplifying the operating interface
creates considerable advantages for users
of Gleason-Pfauter machines for the
different machining operations, i.e.
hobbing, shaping and profile grinding.
In addition, it offers a host of user benefits,
including:
● Dialogue-guided input enables
operators to rapidly change over
from one type of workpiece to the
next – even entering a new job while
the existing work is still being
completed.● Saving and archiving jobs allows fast
and accurate access to machining
data for repeat batches.● Exporting data to other machines is
simplified to help speed throughput
and increase operating flexibility.● Technical data and parts programming
information can be created or
reviewed off-line or even off-site
on a PC, via Ethernet networking.
lmagine the possibilities.
The new generation of machines, in
combination with the latest series of
control technology from Siemens and
the Gleason-Pfauter Dialog Program,
provides new features and capabilities
in gear shaping technology, including:
● Production of external/internal gears
by generating or index cutting.● Production of involute and
non-involute gears.● Up to six different gears per
workpiece/job.● A maximum of six cuts per cycle
with radial or rotational feed options.
● The ability to shape gears with face
width larger than the machine maximum
stroke length capacity.● Wide range of lead modifications.● Tool indexing to improve tool life
and tool utilization.● Reduced machining times through
accelerated return stroke.● Use of direct-drive servo spindle motor
for the cutter spindle allowing for
a nearly constant cutting speed, thus
improving tool life vs. the non-constant
velocity of conventional eccentric drives.
Display with input screens
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C
D
B
E
FG
w o r k a r e a d i m e n s i o n s
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Work area dimensions.
● Values for intermediate sizes, e.g. on P 800 S for P 800/1200 S or on P 1200 ES for P 1200/1600 ES.◆ Shaping head for “S” and “ES” series. ■ Shaping head for “S” series only.* middle stroke position. ** upper stroke position.
Machine NC axes.
Standard NC axes
X = Radial axis
Y = Column lateral offset
Z = Axial slide position range
Z2 = Stroke length setting
A = Cutter spindle drive
A2 = Tool backoff
C2 = Cutter rotation
C' = Workpiece rotation
+Z
+Z2
C 2
+C’
A
+X +Y
+A2
Work area dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 SP 800 ES P 1200 ES
Nominal workpiece diameterinternal and external gear A mm 800/1200● 1200/1600● 1600/2000● 2000 2400/2800● 2800 3200
Maximum workpiece swingwithout tailstock(internal gear) 200/1600● 1600/2000● 2000/2400● 2400 2800/3200● 3200 3600
Min./max. center distance B– mechanical shaping head ◆ mm 0/520/720● 200/720/920● 260/920/1120● 460/1120 460/1320/1520● – –– hydraulic shaping head H1 ■ mm 0/550/750● 0/750/950● 0/950/1150● 0/1150 0/1350/1550● 520/1550 520/1750– hydraulic shaping head H2 ■ mm 0/570/770● 0/770/970● 0/970/1170● 0/1170 0/1370/1570● 475/1570 475/1770
Axial slide position range C– mechanical shaping head ◆ mm 250/400 250/400 250/400 250/400 250/400 – –– hydraulic shaping head ■ mm 1100 1100 1100 1100 1100 1100 1100
Lowest cutter spindle position above table D– mechanical shaping head ◆ mm* 280 280 280 280 280 – –– hydraulic shaping head H1 ■ mm** 560 560 560 560 560 560 560– hydraulic shaping head H2 ■ mm** 660 660 660 660 660 660 660
Table diameter E mm 800 1200 1460 1870 1870 2500 2500
Table bore diameter F mm 245 300 500 600 600 800 800
Depth of table bore G mm 875 875 875 875 875 875 875
d i m e n s i o n s / t e c h n i c a l d a t a
W 192/2/3/707 e Printed in Germany.
1000 University AvenueP.O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348e-mail: [email protected]
1000 University AvenueP.O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348e-mail: [email protected]
www.gleason.com • [email protected] For Worldwide Locations and Additional Information.
Machine dimensions of gear shaping machines with mechanical shaping head.
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A
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Machine dimensions of gear shaping machines with hydraulic shaping head on request. The information and specifications in this publication ◆ Shaping head for “S” and “ES” series. are subject to change without notice.■ Shaping head for “S” series only.
Maschinenfabrik GmbHDaimlerstrasse 14D-71636 Ludwigsburg, GermanyTel. +49-(0)7141-404-0Fax+49-(0)7141-404-500e-mail: [email protected]
Machine dimensions P 800 S P 1200 S P 1600 S P 2000 S P 2400 S P 2800 S P 3200 SP 800 ES P 1200 ES
Technical data
Column lateral offset, mechanical ◆ mm ± 25 ± 25 ± 25 ± 25 ± 25 – –
Column lateral offset, hydraulic ■ mm ± 50 ± 50 ± 50 ± 50 ± 50 ± 50 ± 50
Maximum table speed rpm 15 10 8 6 6 4 4
Maximum table load kg 10,000 15,000 20,000 30,000 40,000 40,000 40,000
Total power rating of machine – mechanical shaping head ◆ (approx.) kVA 80 80 80 80 80 – –– hydraulic shaping head ■ (approx.) kVA 150 150 150 150 150 150 150
Machine weight (approx.) kg 22,000 24,000 35,000 40,000 44,000 60,000 61,000
A mm 6,550 6,550 7,800 8,000 8,000 8,200 8,200B mm 6,000 7,100 10,500 10,800 11,000 11,400 11,600C mm 4,250 4,850 5,200 5,200 5,200 5,250 5,250