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KAPP NILES Products

precision for motion

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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