G 400 generating and profile grinding machine

economy

Our aim is simple: to bring an economic surplus to your daily manufacturing life.

precision

2 G 400

Simply efcient. G 400 generating and prole grinding machines.

The G 400 has been designed for the efcient mass production of gears and shafts with straight and helical gearings. This simple-to-operate and reliable machine is equipped with latest drive and tool technology for the efciency you demand in today's production and the exibility you might need tomorrow.

+ Small footprint, space saving and compact + Modular design for cost savings and spare parts availability + Thermally stabile and vibraton damped machine structure + Optimised direct drives for tool and work spindle + Easy service and maintenance with quick access and online support + Extended workarea for wider workpiece range + Generating grinding with electroplated CBN and dressable tools + Dressing with profile dressing rolls or diamond-plated dressing gear + Modular dressing unit for tool packages on one spindle + Profile grinding with electroplated CBN wheels + High speed loading system + Quick-change tool clamping for fast tool change + Universal workholding + Siemens 840 D control + Windows-based Samputensili Operator interface for easy operation + System solution machine, tool and process out of one hand

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G 400 ingeniously simple

Your advantages
+ Modular platform for lean and cost-efcient manufacturing + Cast iron, ribbed structure for superior vibration damping + Circulation coolant system for thermal stability of structure + Inclined chute planes and additional residue ushing for optimum swarf removal

Basics rst. With innovative concepts and attention for the necessary details.
The common modular platform is the base for a very compact but stabile machine with an optimum costbenet ratio. Nevertheless no compromises are made when it comes to thermal stability and vibration damping: advanced cast iron compositions allow tighter tolerances while maintaining the optimum characteristics of rigid and thermal stabile cast iron bases. The coolant ooded machine structure supports the rigidity and keeps temperature deviations to a minimum.
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The chute is designed with inclined planes to avoid the buildup of swarf nests in the workarea. Swarf is evacuated immediately by the integrated ushing system and directly transfered to the ltration unit. With no heat transfered to the machine structure thermal stability is maintained even in the harshest production environments.

anti-vibration

stability

A B C W X X1 Y Z Z1

Swivel grinding head Rotation grinding spindle Rotation workpiece spindle Swivel coolant nozzle Radial movement grinding column Radial movement centring unit Tangential movement grinding head Vertical movement grinding head slide Vertical movement tailstock

U1 Rotation dressing spindle A U2 Rotation dressing spindle B

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power

exibility

Electroplated CBN Grinding wheel

Dressable corundum

Grinding worm

6 G 400

Highly productive results with a future-safe investment

The grinding spindle with its specifically large tool capacity allows the use of long grinding worms to raise the tool life of single worms or combinations of roughing and finishing tools employing electroplated CBN or ceramic bound grinding worms and wheels. So you can always rely on the most efficient technology or the most beneficial combination to complete your grinding task. Due to the extremely high rotational and linear accelerations with their appropriate absolute speeds the machine guarantees excellent cycle times and is perfectly suited to benefit from future developments on the grinding tool sector.

efciency

Optimised direct drives for tool and work spindle with indipendent refrigerating circuits. Large tool capacity New enlarged workarea capacity Electroplated CBN and dressable corundum tools Universal quick change clamping systems for mass production environments allow rapid tool change so valuable grinding time is never compromised. Grinding worms and wheels on one spindle Standard tool clamping systems and workpiece xtures Tool usage determination by power input control

Your advantages
+ Tailored solutions for each application + Grinding of smaller workpieces and complex geometries + Power and speed reserves for future tool developments + Simple, stabile and exible workholding solutions + Choice of tool suppliers + Reduction of overall cost

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Automatic centering of workpieces

Centering of workpieces is one of the key issues when it comes to errorfree and fast production. The G 400 allows you to center your workpieces automatically and reliably. The centering unit is mounted on a stabile arm which is swivelled into the workarea when required. During grinding it is stored safely out of the way so centering results are not influenced by swarf and heat.

Your advantages
+ Completely automatic centering + Stabile and reliable solution + Protected from swarf and heat + Optional time-paralllel precentering of workpieces

Time-parallel centering of workpieces

The automation via portal loader allows the time parallel pre-centering of workpieces on a separate station outside the work-area reducing the actual centering process on the workspindle.

speed

Portal loader waiting for a wokpiece to be pre-centered while another workpiece is being ground. Up front the dressing master standing by. 8 G 400

reliability

control

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Dressing for exible efciency via standard prole dressing rolls

The profile dressing unit consists of a standard profile dressing roll and an OD dressing stick mounted on a stabile arm which can be swivelled into the workarea. If the tooth rot diameter must be ground as well a tip radius dressing roll is applied to create the required tip radius on the grinding tool. When required the dressing unit is automatically brought into working position. The dressing movements are actuated by interpolation of the axes B and Y. The application of generic profile dressing rolls saves you costs and grants fast supply of dressing tools. You may deploy single or double flank dressing rolls without inclination. Optionally you can mount a double dressing unit which allows you to dress two grinding worm packages on one spindle without dressing tool change. If not required the second dressing unit is stored orderly away, protected from swarf within the workarea.

Your advantages
+ Flexible dressing, no special dressing tools required, no sourcing problems, less costly supply + Very precise, high quality dressing results + Automatic applicaton, completely integrated intow CNC

Additional dressing spindle stored away readily available

exibility

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efciency

Option
+ Dressing unit for the dressing of tool packages on one spindle + No tool or format changes for the grinding of 2 gearings on one workpiece + Cutting down of nonproductive auxiliary times

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Fast and simple profile dressing via dressing gear

Non-productive dressing times can be reduced considerably by dressing via a diamond-plated dressing gear. With its total length in contact and its ten times larger diamond-plated surface, the dressing gear dresses a lot faster and with less wear, thus much more productively than a single dressing roll. Additionally dressing tool changes are reduced as well. For further cost reductions positive plated dressing masters are up to three times replatable. Doublereversed plated dressing masters will raise your productivity even more. For the dressing cycle, the dressing master is transferred like a workpiece from an external station into the workarea. Consequently it always stays clean and is not affected by swarf and heat.

Your advantages
+ Faster dressing and less tool wear with larger contact surface between dressing and grinding tool + Simple error-free process with all necessary data already included in the master geometry + Dressing process controlled by the generating grinding software. No additional software, programming or special dressing cycle setup necessary + Clean and protected storage of the dressing master outside the workarea

productivity

Diamond plated dressing master gear

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Your advantages
+ Positioning towards point of grinding action + Adjustable to different wheel sizes + Special nozzle outlet for efcient application

savings

+ Coolant pressure and volume adjustable + Long-term savings of operation cost

Optimum results with less energy saving cost in the long run
The coolant nozzle automatically follows the movement of the tool head. For different wheel sizes it can be adjusted modularly to apply the coolant fluids exactly to the contact point between tool and workpiece. The adjustable output angle and the flat but wide coolant jet secure the optimum application of a coolant film on the grinding wheel. The risk of grinding bur is significantly reduced without wasting coolant and energy.

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Automation options: Maximum productivity with minimum auxiliary times.

The G 400 is available with several standard automation solutions. The modular pick-and-place portal loader allows the easy linking and integration in existing production processes. It hands workpieces to an integrated workpiece magazine or directly to your existing workpiece conveyor band. Optionally a pallet storage solution can be integrated seamlessly. The light but stable construction of the portal loader with its low masses allows high acceleration rates and fast change times. The setup of the loader is problemfree since all axes are CNC controlled. Since the loader is retracted from the workarea during the grinding process it is protected from swarf, oil and heat. In the long run it proofs itself very reliable. Especially advantageous is the possibility to load ring gears or shaft-type workieces alike. With its rotary gripper joint and various gripper jaw options the standard portal loader can pick and place vertically or horizontally depending on the requirements of your automised workflows.

universality

Your advantages
+ Direct and fast automation options with minimum change time

speed

+ Automation systems protected against swarf and heat + Universal and exible to t all workpiece requirements + Easy integration into existing manufacturing lines

Portal loader waiting outside the workarea for a shaft to be ground, the next workpiece readily in its gripper. 14 G 400

The G 400 is also available with a fast, two- or four-station ring loader. Workpieces are precentred time-parallel to the grinding process. For ultimate flexibility of your manufacturing cell you may add a robotic loader.

C1 Rotation pre-centring unit Q Ring loader Vertical gripper movement hydraulically activated

Q
integration exibility

Flexibility for the tasks of tomorrow

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Simple maintenance and fast servicing

Self sufcient units, like automatically lubricated parts and automatic maintence intervals, bring down the overall time spent for regular maintenance. With all service components located in clearly visible and easily accessible spots servicing itself is much easier and less time consuming than ever before.

Integration of most auxiliary units in machine hull Self-sufcient auxilary units Convenient access for maintenance and service Automatic maintenance intervalls

Your advantages
+ Fast and simple installation and setup + Less maintenance + Simplied and more efcient maintenance + Less machine downtime due to service interventions + Fast and simple servicing

prevention

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safety

access

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control

simplicity

Latest control technology ready for direct networking, USB interface included

Your advantages
+ Faster data transfer to machine

Power requires control. Latest Siemens drive technology and Samputensili menu guidance guarantee you maximum process security
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Modular software packages including prole correction modules Samputensili menu-guided operator interface True Windows environment + Easy and intuitive operation + Fast data validation and error correction + Safe operation + Fast and efcient online updating and trouble-shooting

We build machines for efcient, error-free and safe manufacturing, for daily use and for people
The vertical G-series is equipped with the latest Siemens CNC Sinumerik 840 D. With the comfortable Samputensili menu-guided operator interface running in a true Windows enviroment the user is guided through the manufacturing process via easy and intuitive entry and demonstration screens, supported by validation and error correction software. In case of unlikely emergency situations, improved safety features protect operator and expensive tools alike. The machine is already prepared for network or internet connection giving you direct access to our online service supporting remote diagnostics and easy software upgrades.

1) Gear data input for worm grinding grinding cycle 2) Worm wheel input data page 3) Worm wheel grinding cycle input data page 4) Prole wheel grinding cycle input data page G 400 19

Layouts & dimensions G 400

Coolant ltration unit Knoll VL 20 G 400

Workholding solutions

The G 400 is already prepared for the clamping of workpieces either in hydraulic or mechanic execution. Changing from hydraulic to mechanic clamping and vice versa is actuated by a simple switch and the exchange of the appropriate workholding system. Various standard clamping systems of renowned workholding specialist can be used to avoid costly specics and secure the maximum efciency when applying changes. A pneumatic tailstock arbor allows the machine to clamp workpieces with almost no vibration for improved grinding quality results.
Hydraulic clamping (samples shown for Knig and Mitec)

Mechanical clamping (samples shown for Emuge and Hainbuch). G 400 21

Technical data G 400

Workpiece diameter, max. Module with generating grinding worms Profile depth with electroplated CBN weels Workpiece length, max. Workpiece weight, max. Centre distance work spindle - tool spindle Tangential travel, max. Axial travel, max. Tailstock stroke, max. Tool spindle speed, range Tool spindle swivel range Grinding tool diameter Usable tool length, max. Work spindle speed, range Radial feed Axial feed Tangential feed Motor power tool spindle drive Total connected load of machine/with filtration unit Control CNC axes Machine weight with/without peripherals, approx. Machine dimensions, L x W x H (without automation) mm mm mm mm kg mm mm mm mm min-1 degree mm mm min-1 mm/min mm/min mm/min kW kVA - no. kg mm 380 0.7 - 8.0 1.0 - 25 450 200 43 - 308 220 400 550 0 - 20,000 +/- 45 140 - 220* 180 0 - 800 0 - 7,000 0 - 7,000 0 - 7,000 48 110 / 140 Siemens 840 D 6 11,000 / 15,000 3,850 x 2,400 x 2,750

* Smaller grinding tool bore diameters require specific clamping devices. Technical data is subject to change.

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310

265 Stroke X

45 380

Stroke Tailstoke

345

400 Stroke Z

140 15

460

550

111

200

135 Distance between Table-Dressing unit

99

571

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SAMP S.p.A. Via Saliceto, 15 40010 Bentivoglio (BO) Italy Tel.:+39 (051) 63 19 411 Fax:+39 (051) 37 08 60 info@sampspa.com Samputensili France S.a.r.l. 79 rue de la Tour 42000 Saint Etienne Cedex France Tel.: +33 (0477) 92 80 50 Fax:+33 (0477) 93 72 03 info@samputensili.fr Samputensili GmbH Marienberger Str. 17 09125 Chemnitz Germany Tel.:+49 (0371) 576 251 Fax:+49 (0371) 576 255 info@samputensili.de

Samputensili Beijing Room 1801/1802, Jing Tai Tower, No. C24 Jian Guo Men Wai Avenue 100022 Beijing, P.R. China Tel.:+86 (010) 6515 6349 - 6515 6350 Fax:+86 (010) 6515 7150 beijing@samputensili.cn Samputensili Japan Co. Ltd. 324-4 Nozomigaoka, Meito-Ku 465-0046 Nagoya Japan Tel.:+81 (052) 771 5077 Fax:+81 (052) 771 5078 info@samputensili.co.jp SU Korea Co. Ltd. 4 MA- 319 Sihwa Industrial Complex 703-12, Sung-Gok Dong An-San City Kyungki-Do, Rep. of Korea Tel.:+82 (031) 497 18 11 Fax:+82 (031) 497 18 15 samputensili@naver.com

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G400_en_v.09.00