Innovation and

Technology

TOPOLOGICAL GENERATING GRINDING

In generating grinding, part of the required modifications are applied to the wheel and another part to the grinding cycle. By interpolating several axes between the dressing tool and the grinding wheel during dual-flank dressing, the desired wheel profile is generated point by point, so that any type of profile desired can be created with no need for a dedicated roller.

The “disadvantage” to this type of cycle is that production setup times and dressing cycle are longer than in standard dressing.

The benefits become evident when comparing this type of machining with profile machining. While it requires longer dressing times, the process is faster than profile machining, and reduces both the risk of burns and production times.

Below is an example of the products that can be obtained with this technology with an excellent ratio of quality to machining time:

GRINDING WITH SHIFTING CHAIN OR STRUCTURE SHIFTING FEATURE

The market, especially in the automotive industry, has been posing increasing demands in terms of low rolling noise. To meet such demand, we equipped our plants with latest generation technologies to reduce gear noise.

The “structure shifting” technology developed by KAPP causes the grinding wheel to perform micro-oscillations in a direction perpendicular to tooth width during machining, so as to “break” the longitudinal ridges created as the grinding wheel rotates with respect to the tooth.

Shown below are the two types of noise-reducing processes we have to offer.

SUPERFINISHING

Current research findings show that gearbox efficiency can be improved without adversely affecting durability by reducing the roughness of the tooth flanks and using low-viscosity oils in the gearboxes. Such findings are mainly due to research work carried out by KAPP with gears machined using polishing wheels in the finishing cycle.

Surface grades of Rz – 1 m can be achieved by incorporating a superfinishing process in gear grinding machines.

Current KAPP grinding machines now offer the possibility of using the superfinishing technology in both profile and worm grinding.

PROFILE GRINDING

In profile grinding, superfinishing wheels are used in addition to conventional (dressable or electroplated) grinding wheels. Both wheels are mounted simultaneously on a wheelhead spindle. At the end of the conventional grinding process, an additional cycle is carried out using the superfinishing wheel with the same workpiece setup to achieve the desired roughness grade.

WORM GRINDING

Presently, worm grinding is used for the series production of gearwheels thanks to its excellent productivity. Combined grinding wheels make it possible to achieve roughness grades in the Rz 0.5 – 1 µm range in a single workpiece setup. The additional cycle required usually takes less than 50% of the time required for conventional grinding.