KAPP NILES

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.

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.

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.

The profile grinding machine KNG 3P ready offers an inexpensive entry into precision machining. It has been designed as a solution for flexible production of small and medium lot sizes. The machine is characterised by a grinding spindle with high drive power for components up to module 10 mm. The directly driven rotary table is generously dimensioned for a table load of up to 350 kg. The dresser sits stationary against the tool axis and even allows 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. Thanks to the low height of the machine bed and the short distance to the machine elements all operations can be carried out without requiring means. The innovative, operator-friendly user interface KN grind allows a machine-oriented and an intuitive input of all relevant project data.

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 dressing and grinding spindles are equipped with state-of-the-art direct drives. The new functional and ergonomic machine design paired with an innovative user-friendly interface supports the user during set-up and optimisation of grinding projects. High-performance technology options and application-specific alignment and measuring devices mean that maximum quality can be achieved even with batch size 1.

The gear profile grinding machines in the ZE series are used for high-precision machining of external and internal gears. The machine concept stands for maximum quality, very straight forward handling and compact design. The machines are equipped with a dresser, counter support, integrated measuring device, balancing unit and comprehensive software for grinding and measuring of involute profiles, which enables machining of a wide range of applications. Easy accessibility provided by doors that open wide, and oper-ation from the hall floor allow 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 units.

The machine concept stands for maximum workpiece quality, flexibility and a long service life. The basic machines are equipped 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 technology, 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.

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 sequential 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 dressing and grinding programme is generated automatically based on the gear data. The combination of measuring system and profile dressing equipment also allows for automated machining according to the so-called GMG-strategy (grinding - measuring - grinding).

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 drive 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 efficient working process will be guaranteed.

The KNG 350 flex is based on a compact, set-up-optimised machine concept for use in the prototype sector up to large series production. Both externally and internally toothed workpieces can be machined. The performance-optimised grinding spindle with counter bearing is designed also for the use of large grind-ing worms with widths of up to 200 mm. This allows an efficient realisation, especially when machining of components with large modules and using 2-sector worms for fine grinding or polishing applications. From manual loading to a comprehensive automation solution, the concept offers full flexibility. The functional and ergonomic machine design paired with the innovative user-friendly interface KN grind supports the user during set-up and optimisation of grinding projects. Due to the use of auxiliary spindles small grinding wheels can be applied. Both involute internal gears and special profiles can be machined with the internal grinding device.

The KNG 350 flex HS is based on a compact, set-up-optimised machine concept and is intended for use in small, medium and large series production of externally toothed components up to 350 mm diameter. The machine is characterised in particular by the highest grinding quality and productivity, even when machining with small tools. Using a high-speed grinding spindle (HS) with a speed of 25,000 rpm, even gear teeth with interfering contours can be ground, requiring tool diameters of min. 55 mm (generating grinding) or 20 mm (profile grinding). The concept also offers full flexibility in the selection of loading and automation solutions. From manual loading to downsize automation to robotic loading. The optionally integrated ring loader ensures the shortest non-productive times and can handle both bore parts and shaft-shaped workpieces. The new functional and ergonomic machine design paired with the innovative user-friendly interface KN grind supports the user during set-up and optimisation of grinding projects.

Based on different tool and process technologies, user-specific, optimal production solutions can be configured. The tool spindle with counterbearing can hold dressable and non-dressable grinding worms or profile grinding wheels. Due to the use of auxiliary spindles small grinding wheels up to a minimum diameter of 25 mm can be used. Machines can be loaded either manually or automatically. The use of an integrated ring loader allows short loading times for both bore and shaft parts.

The patented KX 500 FLEX is designed for the flexible use of a wide range of tooling and machining technologies. Thus, application-specific production solutions can be configured to perform diverse processing jobs and a wide range of batch sizes efficiently 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 rotary indexing table which incorporates the tailstock and dresser offset against the workpiece spindle. The dressing unit can accommodate a single or twin spindle dresser. Due to the use of auxiliary spindles small grinding wheels can be applied. Both involute internal gears and special profiles can be machined with the internal grinding device.

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 drive 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 efficient working process will be guaranteed. With regard to pre-grinding, the patented rotor grinding machine RX 120 provides the option to use the advantages of continuous generating grinding instead of profile grinding in manufacturing 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 grinding time can be realised compared to conventional machines and processes.

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.

Intended to be used within the automotive industry, the DYNAMIC series convinces with minimal set-up and non-operational times. The concept is based on the integrated loading function and the optionally available automatic changeover of the workpiece fixtures. Parallel to grinding operation, the second pick-up axis can unload the finished workpiece and pick up an unmachined part. The workpiece is aligned outside the working area. To reduce non-productive times, the workpiece spindle can be swivelled into the working area in an already accelerated state. Continuous generating grinding with dressable grinding tools is used as machining process. For application-specific purposes, dressing tools with integrated tip dresser as well as multi-ribbed tools can be used on the dressing unit. The integrated automation reduces the space requirement to a minimum. Topological generating grinding is available as an option.

Machines of the KX TWIN series have been designed for continuous 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 standardised, cost-effective combination of pallet conveyor and gantry loader. The profile grinding function is optionally available for the KX 260 TWIN. By using an optional high-speed grinding spindle (HS), it is even possible to grind gears with interfering edges which require a tool diameter of 55 mm (generating grinding) or 20 mm (profile grinding).

Based on the well-known ZP series, application-specific solutions have been developed. The machines of the ZP B model have been designed for complete hard finishing (gearing and reference surfaces) of external planetary and bull gears with a tip diameter of up to 3,000 mm. The combination of machining processes ensures a high potential for optimising workpiece quality while at the same time reducing set-up and machining times. The machines of the ZPI model are developed for profile grinding of highly precise internal gears with large modules. Especially the series production in the wind energy sector requires higher stiffness and stronger grinding power. A heavy internal grinding device was developed especially for this purpose, with the greatest emphasis on the rigidity of the grinding spindle bearing. The measuring device is permanently integrated in the grinding head which leads to a reduction of set-up times to a minimum. The machines of the ZP I/E model 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 device, a balancing unit and comprehensive software. The concept of the ZP E/I model is based on the use of two independent grinding columns. Thus, these machines will be used by job shops primarily. The use of a common rotary table and the peripheral units such as cooling lubricant system significantly reduces the investment cost and floor space compared with two individual machines. Different rotary tables and column bases of the ZP series are available.

KAPP NILES manufactures non-dressable, electroplated single-layer CBN tools for hard and soft finishing of gears and profiles. Our tools have been among the top products worldwide for decades. They are used when the highest demands are made on quality, performance and economy.
CBN profile grinding wheels are available in single or multi-ribbed roughing and finishing design and are used for grinding of:
- External and internal gears in automotive (passenger car, commercial vehicle) and aircraft industry
- Radial, screw, rotor and worm profile wheels
- High speed grinding of profiles and gears
- Plunge grinding, abrasive cutting and cylindrical grinding
 CBN grinding worms are available in roughing and finishing design.
They are used as cylindrical grinding worms for highly productive grinding of external gears and other profiles. Grinding worms and profile grinding wheels are often used in combination.
In addition to non-dressable CBN tools, dressable tools made by renowned manufacturers can be used with our machines. Vitrified corundum grinding tools have been dominant for this purpose. Due to its good stability and grinding performance, the use of sintered corundum is preferable for grinding steel. It is recommended to machine grey cast iron with fused aluminium oxide as grinding material.

KAPP NILES manufactures diamond profile rolls as well as diamond form rolls for generating grinding with ceramic-bonded worms. In large-scale production, the dressing of the worms can also be carried out with highly productive multi-ribbed diamond profile rolls. For profile grinding, diamond form rolls in sintered design are offered for profiling dressable profile grinding wheels. Diamond dressing gears for profiling dressable honing rings complete the portfolio.
Diamond form rolls are available in sintered design for profiling dressable profile grinding wheels. In addition to the economic version with natural diamond, these are also offered as a long-life tool with handset CVD diamond. It is possible to reground these tools several times and they are characterised by a long life time.
Our portfolio includes workpiece-specific dressing rolls for dressing of ceramic-bonded worms as well as dressing rolls for flexible or topological dressing. The dressing tools are used for generating grinding with natural entanglement and topological generating grinding with influenceable bias.
Multi-ribbed diamond profile rolls are also available for fast and efficient dressing. They are produced in galvanically negative design for a wide range of modules and rib numbers.
For serial production, an integrated tip dresser is used for defined grinding of the gear root area. Dressing rolls without tip dresser are also part of our portfolio.
The dressing tools for fine and polishing grinding - used in electromobility - are high-precision designed. The special feature of such a dressing roll is, in addition to the reference surface optimisation, the reworking of the diamond grains after the coating of the dressing roll base body.
Diamond dressing gears are offered for profiling dressable honing rings. This type of tool is also available as a tool set consisting of dressing gear and integrated tip dressing roll to move back the tip of the tooth at the honing ring.

The KNM 2X / 4X / 6X / 9X analytical measuring machines are designed for high-precision measurements of gears, gear tools and rotationally 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 operation properties ensure perfect and wear-free guides without short-term errors. Air spring elements underneath the base plates safely shield from jolts and vibrations. Separate 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 ranges ensure a tangential generating motion towards the base circle for any profile. Based on the requirements, different scanning touch probe systems can be used. The control cabinet can be arranged freely.

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.

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.

What does Closed Loop by KAPP NILES include? - Standardised transmission (GDE format) of correction values via network or USB - Automatic or manual execution of corrections - Correction values for profile angle deviation fh?, flank line angle deviation fh? and tooth width, sphere dimension, two-ball dimension Wk What are the advantages of Closed Loop by KAPP NILES? - Automatic correction of series parts during production according to defined rules, if necessary with spindle reference - Reduction of the rejection rate - Compatibility with machines from other manufacturers (both machining and measuring machine)