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KAPP NILES

Products

precision for motion

HGS
HGS
High speed grinding machine
KAPP GmbH & Co. KG
High speed grinding machines
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.
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GAS
GAS
Grinding machine for other operation (grinding centre)
KAPP GmbH & Co. KG
Grinding machines for other operations (grinding centres)
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 and dressable ceramic grinding wheels

For specific applications, various tools can also be combined.
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GIS
GIS
Grinding machine for other operation (grinding centre)
KAPP GmbH & Co. KG
Grinding machines for other operations (grinding centres)
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.
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KNG 3P ready
KNG 3P ready
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
KNG 3P ready
Through the KNG ready series, KAPP NILES offers users an inexpen-sive entry into precision machining. The KNG 3P ready profile grinding machine and the KNG 320 ready generating grinding machine have been designed as solutions for flexible production of small and medi-um lot sizes. The KNG 3P ready features a grinding spindle with high drive power. The dresser is suitable for the use of small dressing wheels with a minimum diameter of 65 mm. The working area can be used without any restrictions at large helix angles. Alternatively, the swivel range of the machine allows the grinding of worms. The tool drive of the KNG 320 ready combines high speeds with high stability for a constant cutting speed - even with a smaller grin-ding worm. Due to the integrated automatic HSK interface for tool holding, the worm change can be carried out in the shortest possibletime. The smart aligning device rounds up the optimised set-up de-sign. Independently purchased automation systems such as robots can easily be connected to the machine.
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KNG 12P master
KNG 12P master
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
KNG 12P master
The machines in the master series are perfect for high-precision machining of external and internal gears as well as special profiles.
The machine concept stands for maximum workpiece quality. High thermal stability and rigidity are achieved through an optimised design and matching components. The inherently rigid machine base enables easy installation without anchoring in the hall floor.

The new functional and ergonomic machine design paired with a innovative user-friendly interface KN grind supports the user during set-up and optimisation of grinding projects. High-performance technology options and application-specific alignment and measuring devices mean that
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KX 300 P
KX 300 P
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
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 for generating gear grinding and profile gear grinding, 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.

A total of six NC-axes align the gear wheel and tool with each other. They swivel the tool to the axes cross angle and carry out the linear and rotary motions necessary for the machining process. Workpiece and tool are directly driven. In the machine configuration for the use of dressable tools, the profile dressing unit is integrated. From an easily accessible parking position this unit is automatically swivelled into the work area of the machine. By using the machine axes for dressing, the dressing of the cylindrical grinding worms as well as the profile grinding wheels can be performed very quickly and with a high degree of flexibility.
control and software

The control system Sinumerik 840D sl is equipped with an operator-friendly menu-driven user interface, developed by KAPP NILES to match the specific machining requirements.
measuring system

The optional measuring device allows to measure and to evaluate gear qualities against specifications. This functionality is mainly used to optimise the set-up processes in the machine, particularly in order to eliminate non-operational periods due to external measuring processes as far as possible. Alternatively, random samples can be tested during processing.

automation

There are several loading systems at your disposal which can be integrated in the machine arrangement.
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KX 500 FLEX
KX 500 FLEX
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
KX 500 FLEX
The patented KX 500 FLEX is designed for the flexible use of a wide range of tooling and machining technologies. Thus, appli-cation-specific production solutions can be configured to per-form diverse processing jobs and a wide range of batch sizes effi-ciently and economically. Dressable tools for versatile machining processes and non-dressable CBN tools can be used for highly productive manufacturing as well as grinding of gear geometry with interfering edges. The machine concept is based on a ro-tary indexing table which incorporates the tailstock and dresser offset against the workpiece spindle. The dressing unit can ac-commodate a single or twin spindle dresser.
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ZX
ZX
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
ZX
The ZX series provides high-end productivity, even for bigger gears and larger modules. The requirements for outstanding fle-xibility can easily be met, too. The inherently rigid machine base enables easy installation without anchoring in the hall floor. The rotary table is generously dimensioned and can bear heavy loads. It is driven by an electrical high-accuracy direct drive, providing a high level of positioning accuracy even for the profile grinding process. The compact design enables all operations from the hall floor and allows for easy set-up for machining individual parts, low and medium serial production volumes. The changeover bet-ween profile and generating grinding processes only lasts a few minutes. The tool spindle has a counter support for better rigidi-ty and optimal surface finish. A wide range of dressing processes are available, e.g. double flank dressing with simultaneous tip dres-sing, single flank dressing and topological dressing
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ZE
ZE
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
ZE
The gear profile grinding machines in the ZE series are used for high-precision machining of external and internal gears. The ma-chine concept stands for maximum quality, very straight forward handling and compact design. The basic machines are equipped with a dresser, counter support, integrated measuring device, ba-lancing unit and comprehensive software for grinding and mea-suring of involute profiles.Easy accessibility provided by doors that open wide, and ope-ration from the hall floor allow for easy set-up for machining individual parts and small-scale serial production. The machines feature generously dimensioned rotary tables with electrical direct drive and deep rotary table bores. All machines of the ZE series can be equipped with internal grinding attachments.
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ZP
ZP
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
ZP
The machine concept stands for maximum workpiece quality, flexibility and a long service life. The basic machines are equip-ped with a dresser, integrated measuring device, balancing unit and comprehensive software. The machines feature generously dimensioned rotary tables with electrical direct drive and large rotary table bores. Hydrostatic bearings and guides allow for pre-cise positioning, excellent load capacity and a virtually unlimited service life. Due to state-of-the-art drive and control technolo-gy, even the most challenging applications can still be machined using 5-axis interpolation. All machines of the ZP series can be equipped with internal grinding attachments. Different spindle variants are available for grinding external gears.
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VX
VX
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
VX
The profile grinding machines of the VX series are extremely suitable for meeting the highest requirements concerning the final quality of the produced gears. Both dressable tools and non-dressable CBN tools may be used in the process. As the grinding adapter can be fitted with two exchangeable grinding spindles, the cutting passes can be realised with the sequenti-al use of roughing and finishing tools in one workpiece set-up. As an alternative, multiple gears can be machined in one set-up. VX machines configured for the use of dressable tools feature integrated dressing equipment producing any type of grinding wheel profile. The combination of measuring system and profi-le dressing equipment also allows for automated machining ac-cording to the so-called GMG-strategy (grinding - measuring - grinding). The dressing and grinding programme is generated automatically based on the gear data.
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RX
RX
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
RX
The machines of the RX series are used for pre-finish and finish grinding of pre-profiled steel and cast iron screw rotors. Due to the innovative drive concept on the tool side, a maximum dri-ve power of 46 kW is reached. Especially for roughing, this high performance results in extremely high stock removal rates and shortens machining times considerably. In combination with an optimally adapted tool technology, a highly productive and ef-ficient working process will be guaranteed.With regard to pre-grinding, the patented rotor grinding ma-chine RX 120 provides the option to use the advantages of con-tinuous generating grinding instead of profile grinding in manu-facturing rotor profiles. For the finishing operation, only profile grinding is used. By applying the generating grinding process as the pre-grinding process, a reduction of up to 40 % in grin-ding times can be realised compared to conventional machines and processes.
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VG
VG
Profile grinding machine
KAPP GmbH & Co. KG
Profile grinding machines
VG
The universal gear grinding machine VG was developed for 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.
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KNG 350 expert
KNG 350 expert
Gear cutting centre
KAPP GmbH & Co. KG
Gear cutting centres
KNG 350 expert
The KNG 350 expert is based on a compact, set-up-optimised and modularized machine concept for use in medium and large-scale series production of externally geared components with a diameter of up to 350 mm. The integrated loading ensures shortest non-productive periods and can accommodate both bore parts and shaft workpieces. The new ergonomic machine design paired with the innovative user interface KN grind supports during set-up and optimisation of grinding projects. The machine is equipped with high-performance technology options and application-specific alignment and measuring devices.
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KNG 320 ready
KNG 320 ready
Gear cutting centre
KAPP GmbH & Co. KG
Gear cutting centres
KNG 320 ready
hrough the KNG ready series, KAPP NILES offers users an inexpen-sive entry into precision machining. The KNG 3P ready profile grinding machine and the KNG 320 ready generating grinding machine have been designed as solutions for flexible production of small and medi-um lot sizes. The KNG 3P ready features a grinding spindle with high drive power. The dresser is suitable for the use of small dressing wheels with a minimum diameter of 65 mm. The working area can be used without any restrictions at large helix angles. Alternatively, the swivel range of the machine allows the grinding of worms. The tool drive of the KNG 320 ready combines high speeds with high stability for a constant cutting speed - even with a smaller grin-ding worm. Due to the integrated automatic HSK interface for tool holding, the worm change can be carried out in the shortest possibletime. The smart aligning device rounds up the optimised set-up de-sign. Independently purchased automation systems such as robots can easily be connected to the machine.
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KX 260 DYNAMIC
KX 260 DYNAMIC
Other grinding machine
KAPP NILES
Gear cutting centres
KX 260 DYNAMIC
The gear centre KX 260 DYNAMIC minimises the auxiliary process times while reducing set-up times. Both axes of the machine are mounted on one pivoted workpiece column and its twin spindle pick-up concept is outstanding in gear grinding manufacturing.
While machining one part, the other pick-up-axis unloads the fully machined and de-oiled workpiece, if applicable, and loads an unmachined one. After clamping the workpiece, the column rotates to the alignment device NC-controlled. As soon as the alignment process is finished, the workpiece spindle is able to accelerate to the grinding speed reducing the non-productive process times to a minimum.
Due to the integrated loading function as well as the option of change of clamping fixtures automatically, the KX 260 DYNAMIC is particularly well-suited for medium and large batch production of external spur and helical gear manufacturing for parts up to 260 mm in diameter. Clear labelling of clamping device, dressing- and grinding-tool using RFID chips is the main requirement for a zero-defect strategy during the set-up process as well as an intelligent monitoring of the production materials according to Industry 4.0.
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KX TWIN
KX TWIN
Gear cutting centre
KAPP GmbH & Co. KG
Gear cutting centres
KX TWIN
Machines of the KX TWIN series have been designed for continu-ous generating grinding with dressable and non-dressable tools. They are particularly suitable for the high production volumes in the medium and large batch production of gears and shafts. The concept includes two identical workpiece spindles arranged at opposing sides of an rotary indexing table. While machining one part, the second workpiece spindle simultaneously loads /unloads and aligns another part. The machines are optimised for automatic loading with a stan-dardised, cost-effective combination of pallet conveyor and gan-try loader. By using an optional high-speed grinding spindle (HS), it is even possible to grind gears with interfering edges which re-quire a tool diameter of 55 mm (generating grinding) or 20 mm (profile grinding).
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ZP Sondermaschinen
ZP Sondermaschinen
Gear cutting centre
KAPP GmbH & Co. KG
Gear cutting centres
ZP Sondermaschinen
Based on the well-known ZP series, application-specific soluti-ons have been developed.

The machines of the ZP B model have been designed for complete hard finishing (gearing and referencesurfaces) of external planetary and bull gears with a tip diameterof up to 3,000 mm. The combination of the machining processes achieves a high potential of cost-saving opportunities based on the following effects:
-Reduction of set-up, alignment and idle times
-Reduction of cycle times
-Realisation of smaller dimensions
-Reduction of scrap and reworking percentage
-No machining of auxiliary surfaces
-Reduction of space requirements

The machines of the ZP I/Emodel are used for high precision profile grinding of internal gears with large modules with a root diameter of up to 2,900 mm. The grinding arm is designed to allow it to rotate by 180°, thus the machine can be refitted for grinding external gears and special profiles within 30 minutes. The basic machines are equipped with a dresser, integrated measuring de-vice, a balancing unit and comprehensive software.

The concept of the ZP E/Imodel is based on the use of twoindependent grinding columns. Thus, these machines will be used by job shops primarily. The use of a common rotary tab-le and the peripheral units such as cooling lubricant system sig-nificantly reduces the investment cost and floor space compa-red with two individual machines. Different rotary tables and column bases from the ZP series, the machines that are larger than 3 m, are available.
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Dressing Tools
Dressing Tools
Dressing Tools
KAPP NILES
Dressing tools
Dressing Tools
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 manufactured in a negative electroplating process, whereby the dressing times can be reduced up to 60 %.
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KNM 2X | 5X | 9X
KNM 2X
Measuring machine, general
KAPP GmbH & Co. KG
Measuring machines, general
KNM 2X | 5X | 9X
The KNM 2X / 5X / 9X analytical measuring machines are desig-ned for high-precision measurements of gears, gear tools and rota-tionally symmetric workpieces. All guides and base plates made of granite are extremely stable in the long-term and have identically low expansion coefficients. Air bearings with emergency operati-on properties ensure perfect and wear-free guides without short-term errors. Air spring elements underneath the base plates safe-ly shield from jolts and vibrations. Special bases are not required. Non-ferrous linear and torque motors of the rotary tables ensure ultimate position precisions and path accuracy. Despite the compact design, spacious travel ran-ges ensure a tangential generating motion towards the base circ-le for any profile. Based on the requirements, different scanning touch probe systems can be used. The control cabinet can be ar-ranged freely.
  • KNM 2X
  • KNM 9X
  • KNM 2X measuring
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KNM X
KNM X
Measuring machine, general
KAPP GmbH & Co. KG
Measuring machines, general
KNM X
According to customer-specific requirements, the KNM X se-ries can be either designed as a stationary machine for medium and larger sized gears, or as a docking station. For this purpo-se, any size of the machine base can be combined with a ro-tary table and a transportable 3-axes measuring device. The KNM X machines boast high-precision mechanics with opti-mal accessibility, laser-based safety equipment, large bearing clearances and generously dimensioned guiding cross-sections. Linear motors are used in all linear axes. High-precision rota-ry tables with air or hydrostatic bearing (diameter of 500 to 1,800 mm) feature direct drives / through-holes. Controlled air spring elements underneath the base plates safely shield from jolts and vibrations. No special foundations are required. The use of drives close to the centre of gravity ensures a low level of dynamic distortions.
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KNM P
KNM P
Measuring machine, general
KAPP GmbH & Co. KG
Measuring machines, general
KNM P
The equipment of the KNM P series has been optimally adap-ted directly to the production machine according to the specific customer requirements regarding the autonomous measurement of gears, ring-shaped workpieces such as bearing rings, housings etc. The combination of base plate and rotary table in a customi-sed design (docking station) forms a full-featured 4-axis measu-ring device. Measurements can even be carried out without rota-ry table directly in the workshop area. In the KNM P machines, specially designed high-precision mechanics add to optimal ac-cessibility with state-of-the-art drive technology (linear motors). The CNC-controlled 3-axis structure allows for checking all gear parameters or general workpiece profiles. Arbitrary workpiece diameters and easy transport are especially worth emphasising. The measuring equipment is placed on a sturdy base connected directly to the production machine or foundation.
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KNM 7C
KNM 7C
Measuring machine, general
KAPP NILES
Measuring machines, general
KNM 7C
The machine has been optimally adapted for the determination of geometrical errors at bearing rings, slewing rings and cylinder-sha-ped workpieces. The CNC-controlled 4-axis structure allows for the expansion to a significantly larger component range, such as gears or 3D-measurement tasks on prismatic workpieces. All machines of the KNM C series are equipped with state-of-the-art drive techno-logy (linear motors), and feature generously dimensioned guiding cross-sections and large bearing clearances.The base plate, vertical columns and axes are made of granite. This ensures stable thermal behaviour. Air spring elements un-derneath the base plate safely shield from jolts and vibrations. The raised Y-guide and a drive close to the centre of gravity reducethe dynamic distortions to a minimum. Measurement uncertain-ties are at MPEE? 0.6 ?m + L/400 | MPETHP? 0.8 ?m. Reliablesoftware is available for fully automated measurement cycles.
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Digital solutions
Digital solutions
Other services for production
KAPP GmbH & Co. KG
Other services for production
Digital solutions
RFID Technology,
Tool data management in KN assist | the digital workbench KN extender,
Condition monitoring,
Maintenance manager,
Remote service
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