Gear grinding is currently attracting a lot of attention, especially in the production of components for electric drives. Production planners are demanding new solutions for a perfect surface that assures their smooth running at high speeds and heavy torque loads. To see how a niche machine tool builder implements these requirements, look no further than Emag SU and its tooth-flank grinding machines.

The gear grinding machine specialist’s G 160 model, for example, features a special ‘virtual’ axis concept for microscopically near-perfect surfaces. Simultaneously, the integrated material handling technology reduces cycle times to a minimum.

Emag SU says that its G 160 is the fastest machine on the market for components up to module 3 with a maximum outside diameter of 160 mm. The G 160’s speed is made possible by a special slide axis concept with two parallel workpiece tables that take turns moving at high speed (with the help of durable, high performance linear motors) towards the grinding wheel.

During the time that one component takes to machine, the loading robot inserts a blank into the other spindle, after first unloading the completed part, as needed. Self-centring alignment, or ‘meshing’, of the grinding wheel to the rough-cut gear component takes place directly on the workpiece spindle, at load position, in parallel with the main machining operation. This results in a chip-to-chip time between the grinding processes of only 1.6 seconds (a small value compared to grinding machines with turntables).

Here, it is important to note that the actual grinding time needed for a typical component such as a planetary gear wheel, is only about 10 seconds. The difference between the chip-to-chip times between grinding is therefore a real game changer.
For further information www.emag.com

Gearboxes used in electric vehicles are not only designed for high speeds and high torques, they are also very compact. This fact is not only true for the automotive sector, but also innovative applications such as e-bikes. These small but high power and electrically driven gearboxes inspire design engineers to come up with more creative solutions. With gear manufacturing technology manufactured by Kapp Niles, the Engineering Technology Group (ETG) says it offers UK manufacturers an innovative solution for producing electric vehicle and e-bike gearboxes.

Through ETG, Kapp Niles offers two machine types for meeting customer requirements. Both series are equipped with high-efficiency drives for the tools (25,000 rpm) and the workpieces (5000rpm). The KNG350 flex HS has a conventional design featuring a single workpiece drive. This machine is available in two versions, one for small lot sizes with manual loading. For higher volumes, an automated version is available with an integrated ring loader. It is possible to process workpieces up to 350 mm in diameter using this machine.The machine offers short set-up times thanks to the use of intelligent components and innovative ergonomics.

For large-scale production, it is worth taking a closer look at the productivity times of machines pre-set by design. The KX TWIN series with two workpiece drives and a loading and unloading process performed in parallel to actual grinding offers further potential for the reduction of non-productive times. The in-line centrifugation of components directly in the machine enables compliance with the ‘clean factory’ approach across all known automation concepts.
For further information www.engtechgroup.com

The 5th edition of DeburringEXPO will present innovations and trends for deburring and surface finishing at the Karlsruhe Exhibition Centre on 10-12 October 2023. With its bilingual expert forum, this leading trade fair also hosts one of Europe’s most coveted sources of knowledge.

Outlining the potential of the event, Iris Münz, commercial director of Ultratec Anlagentechnik Münz GmbH, an exhibitor at the last event in 2021, says: “We were pleasantly surprised, not only by the number of leads, but by their quality as well. Visitors came to us with very precise requirements for specific components.”

Hartmut Herdin, managing director of promoter fairXperts GmbH & Co KG, adds: “Companies are being confronted with ever-stricter or modified and new requirements, where previously used processes and technologies are reaching their limits. For example, these include more demanding specifications for surface quality, more complex component geometries and a changing component spectrum, as well as new and modified materials and manufacturing processes.”

Based on existing bookings and enquiries, fairXperts is expecting around 150-180 exhibitors, which is a significant increase compared with the last event in 2021 and almost matches pre-Covid levels.

DeburringEXPO will also feature theme parks covering topics such ascomponent cleaning, quality control and automation, while an integrated three-day expert forum will see presentations delivered in both German and English. The forum is one of the most sought-after sources of knowledge anywhere in Europe. It enables visitors to enhance their know-how in the fields of deburring, rounding and component cleaning, as well as in the production of precision surface finishes, by presenting new solutions, research results and benchmark applications.
Further for information www.deburring-expo.de

At the Apex Tool Group GmbH (ATG) in Westhausen, a new S31 cylindrical grinding machine from Studer is proving truly universal. From individual components to medium series, the machinecost-effectively and flexiblygrinds gear and control shafts for the company’sCleco brand ofelectric and pneumatic assembly tools.

ATG produces almost all the essential screwdriver components in-house, which applies in particular to motor and gear shafts, levers, valves, cams and housings.

“We need to grind our motor and gear shafts to an accuracy of just a few microns,” revealsNiko Schindelarz, supervisor -machining. “This is essential to ensure the extremely quiet running and long service life of our screwdrivers.”

But this was still a very complex process until just a few months ago. Only one proven grinding machine, purchased in the early 1980s, was available for cylindrical grinding. In order to grind the large number of 30 to 650 mm long shafts with diameters between 3 and 65 mm, it was necessary to reset the machine manually, over and over again. The search therefore began for a new cylindrical grinder.

Schindelarz explains it was firstly necessary to prepare the requirement analysis, in order to obtain approval for the necessary budget from the commercial manager in the US group.

“However, we were able to demonstrate on the basis of operational benefits that the higher initial investment – in comparison with competitor products – would quickly prove profitable,”he says.

Production engineers atATG are now able to grind the entire range of shafts on just one machine. Furthermore, the S31 cylindrical grinding machine is easily accessible for workpiece and grinding wheel set-up, despite the complete enclosure.
For further information www.studer.com