5-axis

Machining
Centers
 Technology
Gleason and HELLER: Ushering in a New Era
in Large Bevel Gear Production
Highly productive new 5-axis machining
center technologies are on the brink
of bringing long-sought productivity,
­flexibility and economy to production
of larger bevel gears in lower volumes
and smaller lot sizes.
For producers of mid-size and larger bevel
gears, where production volumes are low,
lot sizes smaller and part ­changeover
­increasingly frequent, the idea of
­producing gears on a highly versatile
­machining center has always been a
­tantalizing possibility. Up until now,
though, bevel gear jobbers in particular
Productivity
In addition to the capabilities of a machine,
its functionality and process stability
are among the decisive factors for its
­productivity.
With the Gleason-HELLER F and C series,
Gleason is now able to meet its customers‘
productivity demands also in terms of
­machining of large bevel gears.
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have had a difficult choice: either make the
significant investment in dedicated bevel
gear cutting machines that are exceptionally
productive but at the expense of flexibility,
or consider using standard 5-axis machining
centers that are highly flexible, but too slow
to be truly economical day to day.
Bringing together the best of both worlds
Now, Gleason and HELLER have forged
an alliance designed to finally solve these
long-standing challenges, and bring to
­market new process solutions delivering
much more productivity, flexibility and
economy to large bevel gear production –
all from a single source.
Flexibility
Cutting costs through complete machining –
the F and C series provide the response to
this trend in the machine tool industry.
Being able to perform as many tasks as
possible with the same machine provides
flexibility now and in the future.
The alliance draws from the unique strengths
of both companies: the exceptional
processing capabilities and renowned
stability and inherent rigidity of the H
­ ELLER
machining center platform; Gleason’s bevel
gear process expertise and, in particular, its
powerful CAGETM bevel gear design
software (critical to quickly and easily
optimizing both gear design and processing
downstream); and the final critical element,
HELLER’s unique uP-Gear Technology,
a new patent pending technology featuring
a suite of software developed for bevel
gear production in conjunction with highly
productive 5-axis machining centers.
Production precision
The combination of high capacity and
highest machining quality characterize the
Gleason-HELLER products.
Absolute encoded, direct measuring systems,
high-resolution rotary encoder and
YRT bearing with integrated measuring
system ensure long term precision.
 Machine Concept

5-axis machining centers

FT 4000, FT 8000 and FT 16000
Strong basis for high cutting capacity Proven 5-axis kinematics
✓✓ Robust machine bed provides the ✓✓ Horizontal based machine concept.
foundation for efficient damping of ✓✓ 5-axis kinematics to reach every position
machine movements and process forces. between horizontal and vertical.
✓✓ Compact cast iron column with optimized ✓✓ Three linear axes: X, Y, Z combined with
topology for minimal deflection and two rotary axes: B and C (in addition the
­optimal distribution of cutting forces. tool spindle axis C1).
✓✓ Statically and dynamically optimized ✓✓ Tool provides: X, Y and C axes.
design through structural mechanics ✓✓ Workpiece: Z and B.
simulation provide optimized ✓✓ Swivel head: C-axis with 45° kinematics.
resilience and thermo-
symmetry Y+
✓✓ Rotary worktable with
rigid direct torque
drive.

C Head
C1 Tool X+

Z+ B Work
FT 8000

PCU 100
Rigid swivel head
✓✓ High torque power cutting unit (PCU).
✓✓ Transmission provides extreme rigidity
and damping.
✓✓ Robust housing in cast iron.
✓✓ Coolant supply directly through the
spindle.
✓✓ HELLER zero-spindle system.
✓✓ Perfectly suited for steel, cast iron and
high-strength materials.
✓✓ Spindle – tool interface: HSK-A.
Perfect workshop solution
✓✓ FT – for table loading optimal for gear
machining.
✓✓ Workshop machine for manual loading
designed for a wide range of parts and
materials produced in small batches.
✓✓ Optimum access to the work area through
three-part work area door, reduced effort
for loading and process monitoring.
Optional
✓✓ FP – with pallet changer, pallet pool and
magazine.
✓✓ C series with turning capability.

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 Software

Gleason customers have long benefited
from powerful bevel gear design
software called CAGE™, which
empowers a gear design engineer to move
quickly and efficiently from a simple
drawing to a finalized gear design, with
optimized contact pattern, in a fraction of
the time it normally would take through
the normal trial and error process.
Now Gleason 5-Axis Gear Studio software
directly interfaces with the HELLER
uP-Gear CAM System, essentially
­providing all the required input data,
including any and all corrections and flank
modifications, so that the uP-Gear CAM
can design the milling process and create
the optimum NC part program with mini-
mal time and effort.
Powered by the Gleason software ­output
the uP-Gear CAM in c­ ombination with
the flexibility of the Gleason-HELLER
machining centers enables the user to take
advantage of the widest range of potential
flank ­modifications.
As a result, it is possible to further optimize
the flank geometry and the contact pattern
using the additional degrees of freedom
afforded by the Gleason-HELLER 5-axis
machining center and more easily achieve
the most desirable characteristics of even
very complex bevel gear designs.
For that kind of optimization, and also for
the flank corrections after measuring (only
if required) a newly developed Gleason
Correction software is used, which
­essentially closes the loop on quality.
The Gleason Correction software, working
in conjunction with Gleason inspection
equipment, can take hours out of the process
of measurement and correction. It generates
inspection files and new machine settings
based on the inspection (see Fig. below).
The Gleason 5-Axis Gear Studio software
easily allows converting a large variety
of existing Cyclo-Palloid D generate all
necessary information for the Gleason-Heller
5-axis machining center, including closed
loop correction information.

Processing:
Tools NC-Program Machine

275HC
Summary 280C
280CX
600HC
1000HC
Closed Correction Loop

Gear Milling PHOENIX®

Gear Design Inspection Corrections

Summary 275G
600G
Gleason
800G
Correction
Package

Gear Grinding PHOENIX®

FT/FP | CT/CP 4000

uP-Gear CAM FT/FP | CT/CP 8000
powered by Siemens NX
FP | CP 14000
FT | FP 16000

uP-Gear Technology Gleason-HELLER

Correction
Package
uP-Gear Correction Loop

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Software Control
Gleason and HELLER continue to
collaborate on making improvements in
cutter design, interference modeling,
improving part quality through enhanced
part grid ­modeling, i­ncluding the critical
root areas of the tooth, and many other
areas across the bevel gear manufacturing
­spectrum. Of particular ­importance is the
work HELLER is doing to develop,
exclusively for the uP-Gear Technology,
a special CAM application on platform of
Siemens NX (a Siemens 840D SL controller
is now standard on Gleason-HELLER
­machines). This new uP-Gear CAM
software joins for the first time three features
in one software package: process design,
NC part program generation and the
­visualisation. It includes specific routines
and modules for the machining of bevel
gears using the uP-Gear Technology.
Process
The Graphical User Interface (GUI) allows
the user to more easily design the
uP-Gear process and automatically create
NC ­programs. Of course the standard
­functionality of Siemens NX will also be
optionally available to optimize the
­programming of any other part type and
process whether forged part or cylindrical
blank, milling, drilling or even turning
operations etc.
The net result will be the user’s ability
to use a single CAM system for a
near-universal range of applications, all
performed on the Gleason-HELLER
machines.
Machining Features
The Gleason-HELLER five axis machining
center supports a variety of processes.
Beginning with an accurate alignment of the
part on the machine using a measurement
probe for highest possible part qualities.
­Semi-finishing, stock equalizing and
­finishing cycles for soft and hard machining
accommodate all customer requirements.
Part chamfering on gears and pinions
­eliminates sharp cutting edges on the
­workpieces, using the same machine tool.
Most recently, machining of straight bevel
gears has been implemented, allowing the
duplication of existing tooth geometries
produced on mechanical CONIFLEX®
­Machines and also Two-Tool Generator.
Workholding Solutions
Gleason offers a very flexible and highly
accurate zero-clamping workholding system
for the most efficient machining of a large
v­ariety of gears and pinions. This universal
design provides a very attractive solution to
reducing workholding costs to a minimum.
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 Technical Data

Technical Data FT/CT 4000 FT/CT 8000 FT 16000

Working Range
X axis mm 800 1250 2400
Y axis mm 800 1200 1600
Z axis mm 1000 1400 1600

Tool Spindle PCU 63 PCU 100 PCU 100

Speed maximum ED 40% rpm 10000 8000 8000
Torque ED 40% Nm 242 1146 1146
Power ED 40% kW 44 60 60
Spindle taper HSK-A/-T 63 HSK-A/-T 100 HSK-A 100

Tool Magazine
Standard (Option) Places 54 (80/160/240/409) 50 (100/150/265/425) 50 (100/150/265/425)
Tool diameter maximum mm 160 280 280

Rotary Table
Speed maximum rpm 100 60 10
C-Series machines rpm 1000 300 –

FT/CT 4000 FP/CP 4000 FT/CT 8000 FP/CP 8000 FT 16000 FP 16000
Workpiece Management Table load Pallet changer Table load Pallet changer Table load Pallet changer

Pallet / Table size mm Ø 720 500 x 630 Ø 1100 800 x 800 1250 x 1250
Loading capacity *) max. (Pallet 1)*** kg 1400 1400 3000** 2000 8000 8000
Loading in total (Pallet 1+2) kg – 2000 – 3000 – 16000

Workpiece Dimensions (max.)

Diameter mm 1020 900 1810 1250 2500 2000
Height mm 1500 1000 1400 1400 1800 1800
Pinion length mm 1090 655 1500 915 1500 1500
Pinion shaft diameter mm 150 235 225 235 385 385

Controller Type Siemens 840D SolutionLine

*) fixture & workpiece

**) option: dynamic parameters reduced (standard: 2000 kg)
***) balance weight on pallet 2 required

The information and specifications in this publication are subject to change without notice.

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 Features

Turning capability
✓✓ C series for combined processing:
milling, drilling and turning.
✓✓ Turning operations of inner
and outer contours.
✓✓ C-head clamping and spindle fixation for
torsional stiffness.
✓✓ HSK-T spindle taper for high precision
and repeatability of tool positioning.
✓✓ High torque worktable for
high productive processing.
✓✓ Integrated balancing function.

Worktable for pinion machining

✓✓ Worktable with center bore designed
for machining of long shaft pinions.
✓✓ Available for table loading machines.
✓✓ Pinion shaft can be placed in the
bore for optimal processing.
✓✓ Center bore total depth of 500 mm.

Tool management
✓✓ Automatic tool changer.
✓✓ Chain type (standard) and rack type
tool magazines available.
✓✓ Storage capacity for up to 425 tools.
✓✓ Tool taper HSK for highest precision.
✓✓ Quick and safe handling of turninig
and milling tools.
✓✓ Tool shank cleaning (optional).

Workpiece Management
✓✓ Automatic pallet changer.
✓✓ Workpiece setup parallel to machining.
✓✓ Standardized pallets, to be easily replaced
and placed on the machine.
✓✓ 5-point media interface for hydraulic
workpiece clamping (pallet changer).
✓✓ Combination with pallet pool (6 pallets)
or integration into various pallet magazine
systems possible.

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 Worldwide

Providing customized solutions for all major gear manufacturing processes on a global basis with an
industry-leading array of machines, tools, workholding, inspection and service products:

Bevel Gear Solutions up to 2,500 mm

✓ Cutting (Spiral and Straight) ✓ Blade Grinding

✓ Cutter Build ✓ Lapping

✓ Grinding ✓ Roll Testing

✓ Quenching ✓ Design Software

✓ Cutting Tools, All Processes ✓ Workholding

✓ Global Services

Cylindrical Gear Solutions up to 10,000 mm

✓ Hobbing, Gashing ✓ Combined Processes

✓ Power Skiving ✓ Chamfering/Deburring

✓ Shaping ✓ Profile Grinding

✓ Shaving ✓ Honing

✓ Threaded Wheel and Combined Grinding ✓ Workholding

✓ Cutting Tools, All Processes ✓ Global Services

Metrology Solutions All types of gears and gear tools

✓ Analytical Inspection ✓ Master Gears

✓ Functional Gages ✓ Workholding

✓ A2LA Gear Calibration Lab ✓ Global Services

Your monthly source for the latest in gear technology.

Register at www.gleason.com

1000 University Avenue • P.O. Box 22970 • Rochester, NY 14692-2970 USA

+1-585-473-1000 • sales@gleason.com

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