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Manufacturers of large gears for wind power and other industries strive to minimize part-production time while optimizing surface finishes. New profile grinding technology from Gleason, called Opti-Grind, is said to significantly improve productivity and quality levels for cylindrical gears as large as 6 meters in diameter. It does this by using multiple parallel wheels simultaneously for profile grinding instead of just a single grinding wheel that is typically used.

The Opti-Grind option is available on new profile grinding machines ranging from the company’s P 400 G model its P 6000 G. When optimum productivity is required, the Opti-Grind system can be as much as 40 percent faster using the multiple wheels to rough-grind four tooth flanks simultaneously compared to a single wheel roughing only two tooth flanks at once. The system can then finish-grind conventionally using a single wheel that has been dressed to produce the desired surface finishes and flank modifications (including grinding of the critical root area without burning).

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It is said to provide three times better surface finish than conventional processes with the potential to eliminate subsequent processes such as polishing or super finishing.

Gleason’s Windows-based Intelligent Dialogue software is used in conjunction with a Siemens 840D CNC to simplify setup and operation. A grinding technology database recommends and optimizes the production strategy before machining starts, enabling even less experienced operators to manufacture high-quality parts more productively, the company says.

Find more grinding-related articles at our Grinding Equipment Zone.