Equipped with flexible stock-handling system and integrated automation, a universal production gear hobbing machine cuts gear and gear-shaft type components up to module 4

The EMAG-Koepfer 300 series Gear Hobbing Machine offers a universal concept with highly flexible stock material handling magazines and integrated automation designed to cater for a wide range of gear and gear-shaft type components up to module 4. The outstanding technical attributes of the 300 series, said EMAG to manufacturingtalk.com at EMO 2007, are underpinned by uncomplicated user interface, quick set-up, consistent reliability and high precision, as well as the flexibility to adapt and cater for the smallest and largest production batch sizes.
Gear hobbing gear- and shaft-type components - the gear profiling specialist Jos Koepfer and Soehne, in Furtwangen, Germany, said manufacturing companies are under enormous time and cost pressures.

It makes it absolutely crucial that their production machine concepts should be adaptable to suit their machining requirements.

The K 300 has been specially designed for the machining of a variety of components and batch sizes.

Its application range includes gear-type as well as shaft-type components.

To ensure that these can be produced in small or larger quantities, and to cover just about every conceivable gear cutting task, the Gear Hobbing Machine 300 has a selection of automation systems.
* Nine CNC axes for optimal gear profiles - the Gear Hobbing Machine 300 features nine active CNC axes that accommodate a fully automated machining process.

The company said that only a polymer granite machine base can produce optimum results, which is why Koepfer uses the Mineralit material for its vibration damping properties, said to be eight times better than those of grey cast iron.

Mineralit forms a static, dynamic and thermo-stable foundation for the machine and guarantees an excellent tool life and a superb surface finish.

Other features of the K 300 type include the following.

* The machine is of a closed-loop framework design that offers maximum stability for tailstock and main spindle, even when great clamping pressure and heavy cutting forces are applied.

* Maintenance-free direct drives in all tool and workpiece axes ensure that the gear cutting quality achieved is the best and that it remains so throughout the life of the machine.

* The milling head has been aligned diagonally to the machine base to guarantee easy chip flow during wet and dry machining.

This design allows the chips to fall unhindered into the chip conveyor below.

Two further important points in the development of the machine were easy access and an ergonomically designed machining area.

The latter offers the possibility to mount NC pilot tools such as wheels or turning tools for deburring, vibration dampers, sensors for automatic component orientation, or special applications such as live deburring tools.

* Compact loader with flexible workpiece magazines - the principle of highly flexible magazines and automation equipment that was applied to other Koepfer gear hobbing machines has also been applied and adapted to the K 300.

Close attention has been paid to the different machine and workpiece requirements.

The main feature of the automation is the fast acting Koepfer loading device with V-profile gripper, suitable for workpieces of up to 5kg.

Also available are a variety of magazines for the raw-parts and finish-machined components of different ranges of workpieces.

The capacity of the magazines - and thus the autonomy of the machine - can be increased very easily, and without taking up additional space, by employing various parallel running workpiece feeders.

This ensures the machine can handle small component batches as easily as large quantities of workpieces.

* The control system of the Gear Hobbing Machine K 300 - the control system of the K 300 is equipped with a touch panel and a user interface that closely resembles Windows.

The specially developed, extensive Koepfer dialogue software ensures that complex programs can be generated with ease.