K E E P I N G T H E W O R L D I N M O T I O N TM

Profile Grinding Machines

P 800 Gto

P 5000 G

2

The ideal combination of productivity and accuracy – Profile Grinding Machines P 800 G to P 5000 G

If gearbox manufacturers in the wind

energy market, manufacturers of industrial

gear boxes, mining or marine industry,

job shops and many others:

Gleason-Pfauter Profile Grinding

Machines offer for high precise and high

loaded cylindrical gears for all kind of

applications the optimum solution.

Profile grinding – a proven technology for the most stringent demands.Profile grinding is a well established process

for hard finishing cylindrical gears. It is

difficult to imagine gear manufacturing and

its variety of applications without this

process. Gleason-Pfauter was a pioneer in

the development of this process and the

machines that provide it.

Gleason-Pfauter delivered its first profile

grinding machine 1984. Since then Gleason-

Pfauter has continuously developed

improvements and enhancements such as

integrated grinding wheel dressing and

on-machine gear measurement. Gleason-

Pfauter’s market leadership is exemplified

by its having installed over 400 machines

throughout the world. Groundbreaking

innovations and further developments will

ensure that the big success of Gleason-

Pfauter profile grinding machines will

continue in the future. Gleason-Pfauter

profile grinding machines with the recent

developments the zero-backlash swiveling

axis and unique software features achieve

productivity benefits beyond what

previously seemed possible.

The machine – utilizing advanced technology.The special expertise that comes with

decades of experience results in large

grinding machines that provide the

performance needed by demanding

customers. The sophisticated guideway

design provides high accuracy and

uniformity of motions. The X axis has a

standard hydrostatic guide. Large double-

worm index drives with a large number of

teeth combined with hydrostatic table

bearings allow slow rotational speeds while

maintaining the highest quality. This design

accommodates significant variations in

workpiece moments of inertia.

The automatic table relief ensures optimum

bearing conditions at all times independent

of the mass mounted to the work table. This

allows grinding of small helix angles of a

few arc minutes as well as minute flank

modifications to be generated with a high

degree of accuracy.

Utilization of the latest digital drive technology,

direct measuring systems on all linear axes as

well as precise thermal stabilization by means

of a special cooling system provide optimum

accuracy under varying conditions.

The combination of sophisticated technologies

ensures maximum productivity and accuracy.

An extensive selection of variants and options

allows flexible machine configuration at any

point to suit both application and customer.

m a c h i n e c o n c e p t

Profile grinding wheel engaged

with a workpiece space along the line of contact.

3

Profile Grinding Machine

P 2400 G installed below floor

level to allow optimum access

to the work area.

Profile Grinding Machine

P 2000 G installed on the floor,

grinding a double helical gear.

4

Tools – productivity and process reliability.

The NC dressing unit allows use of:● dressable grinding wheels made

of a variety of different materials

to achieve maximum flexibility,

productivity and surface quality or● high-precision plated CBN grinding

wheels for maximum stock removal

rate may also be applied.

CNC controls and software –productive intelligence.The latest generation Siemens

CNC controller meets the highest

demands of modern production.

The shop-oriented, user-friedly

Gleason-Pfauter dialog program

supports the entire machining process.

The machine operator calls up the

required workpiece, tooling and

technological data on a Windows-

based user interface.

The NC part programs are generated

automatically eliminating the need

for time-consuming programming.

There is not more required as the

workpiece drawing.

The software presents graphical

displays to provide visual information

to the operator. Graphics showing

lead and profile modifications are

presented. The software computes a

proposed grinding process utilizing

experience based data.

NC dressing unit accommodates

a wide range of grinding wheel

abrasives.

t o o l s / c o n t r o l

User-friendly data

entry in the dialog

program.

5

The unique concept with swivelling

grinding wheel allows a high helix

angle even in combination with large

face widths.

Grinding head for internal gears.For the increasing demand of internal gears

Gleason-Pfauter offers a new grinding head

for internal and external gears on P 1600 G

machines and larger, using dressable

grinding wheels. Changing from internal to

external is done by turning of the grinding

head.

The Gleason-Pfauter dialog program supports

all important functions well-known when

grinding external gears.

Now available with improved

and increased capabilities:● torque (185 Nm)● face width (600/1000 mm)● grinding wheel width (65 mm)● profile depth (65 mm)● grinding wheel diameter (400 mm)● swivel axis with torque motor for fastest

and most precise swivel movement● direct measuring system for maximum

precision● automatic adjustment of cooling

oil nozzles.

i n t e r n a l a n d e x t e r n a l g e a r s

6

p r o c e s s

Profile grinding – for internal

and external gears.

The software automatically creates

the complete machining cycle and

associated parameters as a proposal.

Stock division as the basis for excellent grinding results.Before grinding starts, the angular position

of the workpiece must be accurately

defined in relation to the grinding wheel.

The workpiece must then be located to the

optimum angular position. The optimum

angular position is achieved on the basis

of measurements made by an on-machine

measuring probe. After appropriate

calculations are made by the software the

workpiece is automatically turned into the

proper rotary position relative to the

grinding wheel. This results in balanced

stock removal from both flanks during

grinding. This protects and improves the life

of the tool and prevents thermal damage to

the workpiece which could otherwise be

caused by inappropriate removal of large

amounts of stock.

The software calculation also provides

further information about corrections needed

to accommodate gear blank distortion which

could affect clean up of the flanks during

grinding. Contacting and non-contacting

probes are available where applicable.

Optimized grinding process.In the profile grinding process, the

workpiece spaces are completed in a

single indexing process in one or

several rotations. Depending on the

task definition, a number of different

strategies such as single flank or dual

flank grinding can be used.

The software automatically generates

the complete grinding process

sequence.

Among other things it sets: ● number of rotations● number of strokes per tooth space● amount of infeed per stroke● axial feed speeds of the grinding

strokes.

These parameters are set based on the

maximum stock allowance per flank

calculated during the stock division

procedure. The user can either accept the

processing proposal which has been

generated by the software or make

individual changes by means of manual

entries. The advantages of using the

software selected parameters is the time

saved in defining optimal workpiece

processing. The user can also alter the

master data forming the basis for the

automatic technology generation if

desired.

The benefits to you:

The software, being an open system,

can easily be adapted by the user to

suit future technological developments

and strategies.

7

Dressing.The NC dressing unit accurately imparts

the required profile onto the grinding

wheel. The software supports many types

of modifications to basic involute

profiles. The grinding wheels can be also

dressed for both surface grinding and

internal grinding.

p r o c e s s

Optimal arrangement of dressing units

for shortest dressing times for internal and external gears.

lnternal stock dividing and measuring

with contacting probe.

The time required for stock division

and measuring has been reduced

drastically using modern, integrated

programming technology.

On-machine gear inspection. After the grinding is complete, all the

customary gear evaluation characteristics

can be measured and displayed in both

graphical and numerical form. DIN 3961,

DIN 3962, ISO 1328, AGMA 2000-A88

and/or AGMA 2015 form the basis for

the evaluation.

Practical experience has shown that in

most cases, it is possible to dispense with

time-consuming, cost-intensive external

measuring of the gears. For documentation

purposes, the results can be printed out

using a printer as is done on a gear

inspection machine. Providing data in a

PDF format is also available.

8

The dynamic zero-backlash swiveling

axis increases productivity.

Five machine axes interpolate

simultaneously (1) providing ● twist compensations (2), ● specific defined twists (3) and ● asymmetric tooth modifications (4).

Complex geometries incorporating

these features can be ground

simultaneously on both flanks

reducing finishing time by fifty

percent!

Adaptive process control (optimizing axial feed and dressing interval).Adaptive process control detects

sections where there is no contact

between the grinding wheel and the

workpiece during the roughing

revolution. The axial feed and dressing

interval are subsequently adapted

accordingly. Feed rates are increased

where there is no stock to be removed.

The structure-borne noise sensor system

ensures that the actions required take

place in real time such that imparting

undesirable thermal effects into the

workpiece is avoided.

Adaptive axial feed control.Axial feed is controlled dynamically as

a function of actual contact conditions

between grinding wheel and workpiece

flanks.

Adaptive determination of dressing interval.The same geometric measurement is

used for adaptive calculation of dressing

interval.

Benefits● reduced grinding and dressing time,● reduced tool wear and costs.

Increased productivity due to leading-edge software functions

Increased productivity from adaptive technology

2

4

3

1

t e c h n o l o g y

Feed

Rapidtraverse

Grinding wheel

without contact

Infeed direction

Tooth flank

Engaged

grinding wheel

Face

wid

th

▲

▲

Ove

rtu

rn p

ath

▲

▲ Infeed/set-in

Grinding wheel

▲

▲

Dynamic adaptation of axial feed rate

to actual contact conditions.

p o w e r d r e s s i n g

9

With the modular machine and

software concept a wide range

of additions and modifications

are available:

Comparison of productivity basic dressing (with two dressing rollers).

During conventional dressing, the

dressing roller generates the desired

profile on the grinding wheel by

performing a high number of dressing

cycles. This leads to a high number of

non-productive machine movements,

resulting in the user losing precious time.

● fixed or retractable tailstock column, ● grinding of spline shafts with

dressable wheels,● definition and evaluation

with “K” profiles,● double helical gears (also with apex

point determination),● wheel profile calculation,● integrated grinding time calculation,● high-performance

grinding head (50 kW),

● spot evaluation of measuring for

corrected profile/tooth trace, ● grinding from the solid,● grinding/measuring tooth segments, ● dressable grinding/measuring of

non-involute profiles, ● tip and root circle measurement, ● envelope line modification,● graphical representation of anticipated

gear deviations, ● central data archiving.

Power Dressing reduces dressingtime and extends the service life of dressing rollers.Grinding wheel dressing can be a

significant portion of the total cycle

time. The new Power Dressing

software function makes this process

more efficient.

Power Dressing has several positive

effects on basic dressing.

The most significant effects are the

dramatic reduction in dressing time and

extended dressing roller service life.

t e c h n o l o g y

Module 032 14 08

Number of teeth 016 15 34

Wheel width 100 50 30

Wheel type

Conventional (h:mm:ss) 1:58:06 4:26:25 0:26:17 1:12:00 0:13:20 0:44:15

Power Dressing 200 mm/min 0:12:30 0:17:18 0:05:25 0:07:00 0:03:41 0:05:02

Factor in favor of Power Dressing 9.4 15.4 4.8 10.3 3.6 8.8

Dressing cycles

Target profile Target profile

Dressing volume

infeed

path n + 1path n

path 1path 3

path 2path 4

Conventional basic dressing.

Power Dressing.

Target profile Target profile

path

1pa

th 2

path

n

path

2n

path

n +

2

path

n +

1

Dressingcycles

Processed volume

infeed

Power Dressing is used to reduce these

non-productive machine movements to

an absolute minimum. A more efficient

use of the dressing roller also leads to

a considerably longer service life of the

dressing tool.

The benefits to you:● considerably shorter basic dressing

times,● longer service life of the dressing roller

(see adjacent table).

Definableoffset

Power Dressing allows basic

dressing of new or to be

reprofiled grinding wheels in

highest productivity.

10

m a c h i n e d i m e n s i o n s

▼

▼

C

▼

▼

A

▼ ▼B

Machine dimensions P 800 G P 1000 G P 1200 G P 1600 G P 2000 G P 2400 G P 2800 G P 3200 G P 4000 G P 5000 G

mm A■ 7100 7100 7100 7400 8200 8200 8200 0.9700 0.9700 10,200

mm B■ 8000 8000 8000 8000 9300 ●8800● ●9300● ●11,000● ●11,400● ●11,800●

mm C■ 4650 4650 4650 4650 4650 4650 4650 0.5150 0.5150 0.5150

mm C▲ 5150 5150 5150 5150 5150 5150 5150 0.5650 0.5650 0.5650

Technical data

Maximum grinding depth/profile(external gear) mm 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100)

Grinding spindle drive rating– Standard kW 24 24 24 24 24 24 24 24 24 24– Option kW 50 50 50 50 50 50 50 50 50 50

Grinding wheel spindle rpm range – 24 kW rpm 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300 1200 - 6300– 50 kW rpm 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000 0400 - 4000

Grinding wheel dimensions(external grinding head)– Diameter mm 400 400 400 400 400 400 400 400 400 400– Width– – 24 kW mm 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100) 80 (100)– – 50 kW mm 160 160 160 160 160 160 160 160 160 160

Rapid traverse speeds– axial mm/min 0.6000 0.6000 0.6000 0.6000 0.6000 0.6000 0.6000 0.6000 0.6000 0.6000

(10,000) (10,000) (10,000) (10,000) (10,000) (10,000) (10,000) (10,000) (10,000) (10,000)– radial mm/min 0.3000 0.3000 0.3000 0.3000 0.3000 0.3000 0.3000 0.3000 0.3000 0.3000

Maximum table load kg 10,000 10,000 10,000 15,000 20,000 30,000 40,000 40,000 40,000 40,000(70,000) (70,000) (70,000) (70,000)

● Without tailstock column ■ for axial slide travels 700/1000/1300 mm ▲ for axial slide travel 1600 mm ( ) Special order

11

w o r k a r e a d i m e n s i o n s

▼ ▼B

▼ ▼Ø A

▼ ▼Ø H

▼ ▼

▼

▼

C

▼

▼

G

▼

▼

D

▼

▼

I

▼

▼

F

Ø E

Work area dimensions P 800 G P 1000 G P 1200 G P 1600 G P 2000 G* P 2400 G* P 2800 G* P 3200 G* P 4000 G* P 5000 G*

Nominal workpiece diameter(external gear) mm A 0800 1000 1200 (1480) 1600 2000 2400 2800 3200 4000 5000

Min./max. center distance mm B 100/700 100/800 100/900 100/1100 100/1200 300/1500 600/1700 600/1900 600/2300 600/2800

Maximum axial slide travel:– Standard mm C 0700 0700 0700 0700 0700 0700 0700 0700 0700 0700– Optional mm C 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000– Optional mm C 1300 1300 1300 1300 1300 1300 1300 1300 1300 1300– Optional mm C 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600

Lowest grinding wheel position over table mm D 0450 0450 0450 0450 0450 0450 0450 0450 0450 0450

Table bore diameter mm E 0245 0245 0245 0300 0500 0610 0880 0880 0880 0880

Depth of table bore mm F 0870 0870 0870 0870 0870 0870 0980 0980 0980 0980

Min./max tailstock armposition over table mm G 780/1680 780/1680 780/1680 780/1680 925/1825 925/1825 925/2335 925/2335 925/2335 925/2335

Table diameter mm H 0800 0800 0800 1200 1460 1870 2500 2500 2500 2500

Table height mm I 0970 0970 0970 0970 0970 0970 1000 1000 1000 1000

* Available as special design with special grinding head. ( ) Special order

The information and specifications in this publication are subject to change without notice.

Tooling and Workholding.Gleason is the world’s leading source for

advanced new tooling and Quick Change

workholding systems to meet the latest

requirements for accuracy, speed, and tool

life. Only Gleason provides the complete

range of gear cutting and finishing tools

for cylindrical and bevel gears, including

hobs, milling cutters, shaper cutters,

deburring tools, shaving cutters, honing

tools, bevel gear blades and cutter heads,

plated diamond and CBN grinding wheels,

diamond dressing gears and diamond

dressing rolls.

The Complete System. At every stage of the gear production

process, Gleason offers advanced new

technology to significantly reduce

production time and cost.

Gleason offers a full range of vertical

and horizontal hobbing machines, gear

shapers (electronic and mechanical helical

guides), shaving and honing machines,

and advanced profile and threaded wheel

grinding machines for the manufacture of

spur and helical gears.

A complete range of bevel gear cutting,

grinding, lapping and testing machines is

available from Gleason.

The cutting tools, grinding wheels,

workholding and support services are

offered for all gear manufacturing

processes and machines.

Gleason’s ability to manufacture and

completely inspect all types of gears is

unmatched.

w o r l d w i d e

Global Service and Support. With a manufacturing presence worldwide

and fast-growing sales and service

representations in over 30 countries,

Gleason is truly a global company.

Our broad-based infrastructure and strong

worldwide presence place us in a unique

position to respond to customer

requirements anywhere, anytime.

W 238/3/3/308e Printed in Germany.

1000 University AvenueP.O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348e-mail: sales@gleason.com

1000 University AvenueP.O. Box 22970Rochester, NY 14692-2970, USATel. +1-585-473-1000Fax +1-585-461-4348e-mail: sales@gleason.com

www.gleason.com • sales@gleason.com For Worldwide Locations and Additional Information.

Maschinenfabrik GmbHDaimlerstrasse 14D-71636 Ludwigsburg, GermanyTel. +49-(0)7141-404-0Fax +49-(0)7141-404-500e-mail: pfauter@gleason.com