Gear grinding machine

Gear grinding machines for industrial production

How a gear grinding machine works

A gear grinding machine is a specialised machine tool for the high-precision machining of gear manufacturing on gears, shafts and similar workpieces. It is used in particular for the production of spur gears, worm gears or bevel gears. The machining process is based on the principle of generating grinding, a combination of grinding and generating motion in which a grinding wheel cuts the tooth flanks in a continuous relative motion.

In generating grinding, the workpiece to be machined is turned in synchronisation with the grinding wheel. The grinding wheel is usually a profiled grinding wheel made of CBN or corundum, which corresponds to the tooth profile. During machining, the workpiece rolls along the grinding wheel - similar to a pair of meshing gears. This rolling motion grinds each tooth flank evenly, resulting in high dimensional and shape accuracy.

The process can be carried out using either dry grinding or wet grinding with cooling lubricant. Modern gear grinding machines are CNC-controlled and enable both roughing and fine grinding in a single pass. A distinction can be made between discontinuous generating grinding (single-tooth process) and continuous generating grinding of gear manufacturing (generating process). The latter is significantly more productive and is often used for large series.

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Structure of a gear grinding machine

A gear grinding machine consists of several central assemblies: the machine bed as a stable base, the grinding spindle with grinding wheel, a workpiece table with clamping device and a CNC-controlled axis system. In addition, there is the dressing unit for profile correction of the grinding wheel, the cooling lubricant system for temperature control and chip removal, as well as a control system for process monitoring. Modern machines have integrated measuring probes for in-process control and automatic loading systems for cycle time optimisation.

Thanks to their precision and process reliability, gear grinding machines offer optimum conditions for the production of gear parts with tight tolerances, high surface quality and low noise levels in later use.

Other types of gear cutting machines

Depending on the production technology used to manufacture gears, we differentiate between the following gear cutting machines:

Applications for gear grinding machines in industrial production

Gear grinding machines are used primarily in the automotive, mechanical engineering, aerospace, wind energy and drive technology industries. This process is indispensable wherever precise gears and gear parts are required. Medical technology also uses smaller variants for the production of miniature gears.

Examples of typical workpieces are

Spur gears
worm gears
bevel gears
toothed shafts
Internal gears
Synchroniser rings
Pinion shafts
Clutch gears
Planetary gears
Pump gears

These components require maximum dimensional accuracy and surface quality - properties that can be guaranteed by generating grinding in series.

Tools of a gear grinding machine

The following tools are used in gear grinding machines:

CBN grinding wheels
Aluminium oxide grinding wheels
Grinding wheels with longitudinal or transverse profile
Dressing rolls
Diamond dressing tools
Balancing systems
Chucks
Centre points
Workpiece stops
Coolant nozzles

The choice of tool depends on the workpiece material, machining objective and production volume. Tool manufacturers are often searched for using the following terms: skiving horn, Reishauser grinding wheels

Accessories and operating materials for a gear grinding machine

Accessories primarily include workpiece clamping devices, automatic loading systems, measuring probes, dressing devices and balancing units. Operating materials such as cooling lubricants, filter systems and extraction systems are essential for smooth operation. Control software, wear parts such as grinding wheels and dressing tools as well as workpiece inspection gauges are also required. Temperature control systems and oil mist separators are also useful for automated continuous operation.

Leading manufacturers of gear grinding machines

In our manufacturers directory you will find companies that manufacture gear grinding machines for metalworking.

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Selecting the right gear grinding machine

If you want to buy a gear grinding machine, precisely coordinated specifications are crucial for the quality and efficiency of production.

Firstly, the maximum workpiece diameter that can be machined and the module are decisive, as are the number of axes and the travel distances on the individual axes.
The rigidity of the machine, thermal stability and vibration damping are decisive for the achievable precision.
The grinding spindle power and the available torque determine the machining efficiency.
The type of control (e.g. Siemens or Fanuc) and its operability also play a major role.
CNC automation, measurement and correction functions as well as interfaces for loading units and ERP systems offer advantages for series production.
Finally, service, spare parts availability and manufacturer experience should also be taken into account when making a decision.

Find the gear grinding machine that suits your production requirements now at maschinenauswahl.de.

All machines from the category Gear grinding machine