Fast and Flexible Automated Gear Grinding

In Booth N-7040, Reishauer AG (Wallisellen, Switzerland), the inventor of continuous generating gear grinding, will demonstrate their RZ260, the machine that sets the standard for gear grinding machines in this size range. The RZ260 has not only been increased in size, all relevant components have been adapted to handle higher loads and forces that occur when grinding larger gears. Gears with an outside diameter of 260 mm and modules up to 5 mm can be ground with highest reliability. An important focus of this machine is its adaptability to different production requirements of numerous customers. The machine can be fitted with one or two work spindles. The version with two work spindles is used to minimize the loading times. When investment and tooling costs must be minimized and/or the workpiece handling times are not critical, the RZ260 with a single work spindle might be a more suitable choice.

When grinding gears with space limitations or small lot sizes, it might be advantageous to use the changeable Profile Grinding Spindle that enables the use of a small plated or dressable wheel to grind gears using the discontinuous profile method. Both versions of the RZ260 can be equipped with a fixed or CNC-controlled axis for swiveling the dressing tool. With this option, the flexibility of the dressing tools can be increased since the same tool can be used for a range of gears as compared to the fixed dresser where the tools are normally workpiece specific. The RZ260 has been developed exclusively without compromises for the high demands of the continuous generating gear grinding process: its Generating Module ensures the highest gear quality, LNS™ Low Noise Shifting technology guarantees very low gear noise emissions, Polish & Fine Grinding handles surface roughness reduction, Twist Control™ Grinding technology creates defined values for flank twist and the HMI makes for fast change over and set-up times.

The RZ260 machine will be tended by an FRC600 compact loading system from Felsomat USA, Inc. (Schaumburg, IL), the newest member of the Reishauer Group that is re-defining gear production technology with complete process chains that use standardized machine platforms to create extremely flexible and highly efficient manufacturing systems for high precision transmissions, transmission gears and engine components used in automotive markets.

Felsomat will also unveil the latest version of their innovative FSC 600 Flexible Stacking Cell, which will be displayed together with a Reishauer gear-grinding machine. This new cell is completely built on a fabricated base for easy transportation and quick installation. The base is also designed to contain any cutting fluids that may be required in the machining process and prevent those fluids from migrating to the factory floor. The cell also features active basket hanger locks that ensure an accurate and uninterrupted loading sequence and allow for a higher tolerance in the baskets. This type of automation is available with a gantry loader or with a Fanuc robot.

Also on display for the first time will be the enhanced FHC 80 hobbing machine with integrated conveyor that is loaded/unloaded directly from/to dunnage with skewers. This solution minimizes floor space requirement and is controlled directly by the machine in one compact hobbing cell. Additional modules can be added to unload into heat treatment alloys or baskets.

Reishauer Corporation, 1525 Holmes Road, Elgin, IL 60123, 847-888-3828, Fax: 847-888-0343, www.RZ260.com.

Felsomat USA, Inc., 1700 North Penny Lane, Schaumburg, IL 60173, 847-995-1086, Fax: 847-885-2691, www.felsomat.com.