G-H series horizontal grinding machines for gears, rotors and screws
Our aim is simple: to bring an economic surplus to your daily manufacturing life
The new G-H series of grinding machines for gears, shafts, worms, rotors and screws. One universal solution adapted to your specific application – now for workpieces up to 500 mm in diameter Based on the widely acclaimed S 375 G, the new G-H series presents numerous enhanced features and extends the traditional series to include new model versions. Although EMAG SU grinding machines are based on a modular design concept, we craft each and every machine with a wide range of options to suit your individual needs, guaranteeing you the efficient manufacturing of top quality parts. This modular, extremely versatile and universal series is ideally suited to single pass creep feed profile grinding of external spur and helical gears, crown gears, shafts, worms, rotors and screw threads. Optionally it is also possible to grind spur or helical internal gears. We offer you an ad hoc solution for any of the above applications so that your machine is constructed with the right options for you. All machines are then supported by special software packages, translating our know how into your manufacturing success.
G-H series 3
Horizontal machines
G 375 H Profile grinding machine up to Ø 375 mm
G 500 H Profile grinding machine up to Ø 500 mm
GP 500 H Profile grinding machine with two electro-spindles
GR 500 H Screw and rotor grinding machine with one ceramic wheel
GRX 500 H Rotor grinding machine with two grinding wheels
GT 500 H Screw and rotor grinding machine with two grinding wheels
GW 3600 H Profile grinding machine for screw-type workpieces up to 3600 mm 4 G-H series
The new G-H series features an array of innovations and components shared by all machine variants
New common features at a glance + Ribbed steel structure for
A heavily ribbed structure eliminates the risk of vibration or push and pull phenomena caused by moving machine components. To ensure maximum thermal stability, the machine bed is flooded with recirculating coolant. A new evacuation system transfers swarf from the work area to the filtration unit. Any residue is flushed by additional coolant nozzles so that even the most resistant swarf nests are easily discharged, guaranteeing a clean work area at all times.
optimum vibration damping
In terms of work range, workpiece diameter, X-axis travel and Y-axis travel have all been increased. Standard grinding spindle power has practically doubled and even more spindle options are now available.
+ Direct drives and linear
Direct and linear drives, and digital scales and encoders, supported by a sturdy base and prismatic guides, make for unbeatable quality.
+ Recirculating coolant, addi tional flushing and direct swarf evacuation for optimum thermal stability motors + Quick-change adapter for spindle drives + HSK adapter for fast tool changes + Precision-ground slides for linear movements + Higher work range + Longer X- and Z-axis travel
G-H series 5
G 375 H
at a glance The EMAG SU horizontal grinding machine G 375 H is based on a modular design concept, with a wide range of options and it is engineered to suit your individual needs, guaranteeing you efficient, top quality manufacture. This universal machine is ideally suited to grind external spur and helical gears, crown gears, worms, rotors for air compressors and screws for hidraulic pumps with form-grinding wheel and single index profile grinding.
Rotor grinding with a corundum wheel 6 G-H series
Optionally it is also possible to grind spur or helical internal gears. We can offer you ad hoc solutions for any of the above applications so that your machine is manufactured with the right options for you. The G 375 H is supported by special software packages, which translate our know-how into your manufacturing success. Particular attention has been paid to the state-of-the-art solutions that allow a fast and cheap tool change.
Grinding of helical internal gear
+ High stability of the process thanks to the high stable structure + High reliability thanks to direct motors + Eccellent quality of the end products thanks to the high precision of the machine + Versatile and Flexible production + Short setup time to switch from a type of production to another
Grinding large module gears with electroplated CBN grinding wheel
+ - +
+ + +
+ A Tool head swivel C Workpiece table rotation B1 Tool spindle rotation B2 Dressing spindle rotation B3 Dressing spindle rotation for internals (Opt.) B4 Tool spindle rotation for internals (Opt.) X Radial travel Z Axial travel
-
-
+
-
+
+
Dressing process by machine axis interpolation G-H series 7
G 500 H
The G 500 H is the universal and extremely flexible base machine of the G series and it is ideal for single pass creep feed grinding of external spur and helical gears, crown gears and shafts, worms, rotors and screw-type workpieces up to 500 mm in diameter. Optionally it is possible to grind spur or helical internal gears.
Quick-change spindles and ceramic tool technology, combined with a flexible dressing unit and modular software packages guarantee rapid format change and unmatched process versatility.
at a glance + Universal solution for a wide range of gears, shafts and screw-type workpieces + Flexible manufacturing of small or large lots + Creep feed grinding + Integrated checking
8 G-H series
X Radial travel Z Axial travel A Tool head swivel C Work spindle rotation B1 Tool spindle rotation (externals) B4 Tool spindle rotation for internals (option) B2 Dressing spindle rotation (ext.) B3 Dressing spindle rotation for internals (option) W Tailstock axial travel (opt.) Dressing process by machine axis interpolation G-H series 9
GP 500 H
at a glance + Roughing and finishing in a single setup without the need for tool change The GP 500 H mounts an additional NC axis, allowing you to work with two separate spindles instead of just one. Both spindles can accommodate one grinding wheel or even two-wheel sets. Single gearings are roughed on the first spindle and finish ground on the second, with one grinding wheel mounted on each spindle. Two gearings on one shaft can be roughed and finished with wheel sets on each spin-
10 G-H series
dle without the need for tool changes. Spindle variants are available with different power outputs and speeds for different grinding wheel sizes. Even internal gear manufacture no longer requires tool change thanks to this new twin drive principle.
+ Profile grinding of gears, shafts with separate gearings, rotors, worms and screwtype workpieces + Internal grinding with the twin spindle principle + Fast format changes via quick-change adaptors + Modular Softwares
X Radial travel Y Tangential travel (automatically) Z Axial travel A Tool head swivel C Work spindle rotation B1/B10 Tool spindle rotation (upper position) B5/B50 Tool spindle rotation (lower position) B4 Tool spindle rotation (internal) B6 Tool spindle rotation (external) B2 Dressing spindle rotation for externals B3 Dressing spindle rotation for internals (option) W Tailstock axial travel (opt.) Dressing process by machine axis interpolation G-H series 11
GT 500 H
The GT 500 H gear grinding machine is ideal for both prototyping tasks and efficient grinding of medium and large batches of rotors for compressor and screws for idraulic pumps. Thanks to an additional tool shifting Y tangential axis, it can works with two different grinding wheels, one dedicated to roughing and one dedicated to finishing.
12 G-H series
All screw profiles can be generated by a NC diamond dressing device of your choice and, thanks to this machine's superior flexibility, you can also apply the most appropriate technology for the given task and even combine different kinds of roughing and finishing processes to maximise efficiency. Plus, with the grinding wheel electrospindle high performances, the GT 500 H will realise the lowest possible cycle times and has vast potential to accommodate future generations of grinding tool abrasives.
at a glance + Highly efficient grinding with CBN or ceramic tools + Flexible manufacturing of small or large lots + Integrated checking + Loading and unloading automation solutions available
A B1 B2 B7 C W X Y
Tool head swivel Tool spindle Rotation Dressing Spindle Rotation Coolant nozzle travel Work spindle rotation Counterstock Axial travel Radial travel tool head Wheel spindle tangential travel Z
Dressing process by interpolation machine axis interpolation G-H series 13
GR 500 H
at a glance + Dedicated version for the manufacture of rotors and screw-type workpieces The GR 500 H has been specifically designed for efficient high precision grinding of a wide range of screw-type profiles including worms, ball screws, rotors, hydraulic pump screw. The high performance grinding spindle is generously motorised and the machine is designed with an appropriately sized coolant filtration system meaning you can grind workpieces from solid as well as hardened steel. With a dressing unit for ceramic bonded grinding wheels and an integrated checking unit, the GR is perfect for the prototyping and
14 G-H series
for the production of the smallest lots or mass production applications alike, making it a very flexible asset.
+ Powerful main spindle for high stock removal rates
Connection to a portal loader and direct communication with an external measuring unit enhance the efficiency of your production process.
+ Specific software packages for rotor and screw production are also available
The GR 500 H comes with a specific software package for screw-type workpieces, developed and tested under real manufacturing conditions.
+ Specific dressing unit + Standard and special workpiece support solutions + Automation by portal loader or robotic device
X Radial movement Z Axial movement A Helix adjustment angle C Workpiece rotation B1 External spindle rotation B2 Spindle rotation of external dressing Dressing process by interpolation machine axis interpolation G-H series 15
GRX 500 H
The GRX 500 H is a larger version of the GR. The machine is suitable for the manufacture of very large screws and rotors. Especially adapted to grind with CBN, the GRX 500 H also makes working with dressable ceramic wheels or even combinations of the two easy. An integrated measuring unit also makes the correction on board.
For more efficient handling, you can link the GRX 500 H to an external robot device and connect it directly with an external measuring unit. Like the GR, the GRX 500 H comes with a rotor-specific software package, developed under real manufacturing conditions.
at a glance + Special machine version for the manufacture of large rotors + Extra powerful main spindle for high stock removal + Double tool setup for roughing and finishing on one spindle + Tried and tested rotor manufacturing software + Integrated measuring + Connection with measuring unit by means of external PC software for the closed-loop manufacturing checking
16 G-H series
A B1 C B2 B7 X Y Z W Z2
Tool head swivel Tool spindle rotation Work spindle rotation Dressing spindle rotation Coolant nozzle travel Radial travel Tangential travel Axial travel Tailstock axial travel (opt.) Tailstock slide travel (opt.) G-H series 17
GW 3600 H
The GW 3600 H is a special machine for the high precision grinding of long screw-type profiles, such as extruder screws for plastic injection moulding or ball screws. Equipped with a powerful grinding spindle for large grinding wheels and workpiece supports adapted to each application you will produce worry-free screws up to a length of 3600 mm. With its optional dressing units for ceramic bonded grinding wheels the machine is prepared for flexible mass production requirements. You will receive your GW 3600 H together with the appropriate software and the required grinding and dressing tools to make your screw production soar.
The machine can be also equiped with an in-machine tool magazine, the GW3600H-TC. With this option it is possible to drastically reduces the cycle time when a tool change during the same cycle is required. Moreover, the machine can be equipped with an automatic NC hydraulic stady rest for creep feed grinding of threaded components.
at a glance + Special machine version for the manufacture of extra long screw-type workpieces + One powerful grinding spindle + Specific dressing unit for large grinding wheels + Specific screw manufacturing software packages + Standard and special workpiece support solutions + Grinding tool magazine + NC-controlled oil nozzles + Automatic hydraulic steady rest systems sliding along part length
18 G-H series
A B1 C B2 X Z
Tool head swivel Tool spindle rotation Work spindle rotation Dressing spindle rotation Radial travel tool spindle Axial travel tool spindle
1
2
1 Single point diamond dressing 2 Diamond roll dressing G-H series 19
Be flexible today and prepared for tomorrow, using electroplated CBN or dressable ceramic tools All machines in the G-H series (with the exception of the GR and GW series) are engineered to mount both dressable ceramic or electroplated CBN grinding wheels. Depending on your lot size and in-house requirements in terms of flexibility, efficiency, tool costs and surface requirements, you are free to choose the tool technology that best suits you.
Electroplated tools designed for you Either ceramic or electroplated CBN grinding tools are available from EMAG SU including rough ing and finishing tools which are backed up by our extensive application know how. 20 G-H series
Basic spindle variants for internal and external profile grinding with dressable and electroplated wheels
GP 500 H
Electro spindle with counter-support for two or one grinding wheel
GR 500 H Spindle for profile grinding
(lower size on request)
Ø12-150mm Ø40–80mm Ø80–150 mm Ø150–220 mm Ø220–300 mm Ø280-360 mm (G500H)
Ø34–50mm
19 kW Ø80–300 mm
Ø34–50mm
Ø60–90mm
10 kW Ø20-220 mm
Ø60–90mm
Ø100–150mm
5,5 kW Ø12–150mm
Ø100–150mm
Ø34–50mm Ø60–90 mm
up to 345 (CBN Wheel) 270-400 (Dressable wheel)
External Wheel range
GT 500 H GRX 500 H
External Power / Wheel range
Internal Wheel range
Single or double spindle for profile grinding
(lower size on request)
External Power / Wheel range
Internal Wheel range
External Wheel range
G 375 H G 500 H
GW 3600 H Spindle for profile grinding
External Wheel range
Ø330–500 mm
GW3600H Ø 330-500 mm
GW3600H-TC Ø 240-360 mm G-H series 21
Depending on your application, the machines in the G-H series are equipped with various options. EMAG SU dressing units utilise universal dressing rolls and generate profiles calculated by the machine software. An integrated "touch" sensor checks the contact between the roll and the wheel, allowing the activation of the dressing passes and controlling the good quality of the dressing. Using the right workpiece support is fundamental to prevent bending or
options
vibration during the grinding process. Whether you work with rotors, circulating ball spindles, pumps or extruder screws, we find the right solution to guarantee the quality you need. The correlation between stock removal and the ability of a machine to supply a consistent flow of pure coolant is essential for trouble-free production and constant top quality. We recommend and supply you with the right filtration unit for your application
at a glance
+ Different dressing options depending on the application + Coolant filtration units for steel and cast iron machining + Workpiece support systems customised for perfect fit + Integrated on-machine inspection and closed loop manufacturing with automatic profile correction + Various high-performance grinding spindles
From left to right: Coolant filtration unit for steel or cast iron machining Double flank dressing Dressing unit for internal profile grinding wheels Workpiece support for long workpieces 22 G-H series
Wireless integrated measuring unit for gears and shafts. This unit automatically swivels into the work area for use and then retracts to a standby position once inspection is complete. With EMAG SU software modules, it is possible to check profile, lead, pitch and concentricity.
The ultimate in measuring control, the EMAG SU closed loop system enables you to connect your machine to an external measuring unit to check and automatically correct workpiece profiles in a closed manufacturing cycle.
Closed loop manufacturing + Automatic stock division + Dressing of grinding wheel + Profile grinding of rotor + Profile inspection on-board or via external measuring unit (closed-loop) + Correction of any deviating values + Redressing of grinding wheel + Finish grinding of rotor
G-H series 23
Software for the most demanding applications made easy With the user-friendly EMAG SU menuguided operator interface running in a true Windows® environment, users are guided through the manufacturing process via easy and intuitive entry and demonstration screens and are supported by data validation and error correction software.
Easy and intuitive data entry interfaces Wheel profile calculation and visualisation Simple and direct profile correction options
Point by point rotor grinding wheel profile calculation Profile inspection with data view and graphics visualization
Layout 4300
2300
4900 3100
G 375 H
146.5
1660 3700
1185
4300
3200
410
1660
GRX 500 H
1660 4200
550
2300
1610
2960
1202
3000
2720 6200
782
GW 3600 H
1550
3100
2300
3100
4900
4900
G/GP/GR GT 500 H
146.5
3577 6460
G-H series 25
Technical data
G 375 H
G 500 H (HL)
GP 500 H (HL)
375
500
500
0.5 / 15
0.5 - 22
0.5 - 15
35
53
35
+/- 90
+/- 90
+/- 90
Workpiece length, max. (mm)
900
1,250 (2,100 HL)
1,250 (2,100 HL)
Axial travel, max. (mm)
650
900 (1,500 HL)
900 (1,500 HL)
Radial travel, max. (mm)
210 330 330
Tangential travel, max. (mm)
n/a
Workpiece diameter, max. (mm) Module range Profile depth, max. (mm) Tool head swivel range (degree)
+/-1
160
Tool spindle power (opt.) (kW)
23 / 28
23 / 28
5,5 / 10 / 19
Ceramic wheel diameter (mm)
40 - 300
12 - 360
12 - 300
Ceramic wheel thickness, max. (mm) CBN wheel diameter (mm) CBN wheel thickness, max. (mm) Dressing disc diameter, (mm) Tool spindle speed, max. (rpm) Work spindle speed (rpm) Workpiece weight, max. (Kg) Total connected load (kVA) Machine weight, including standard equipment (kg)
60 105 40 30 - 300
12 - 300
12 - 220
60
60
35
80 / 100
120 / 150
120 / 150
8,000 / 18.000*
6.000 / 40.000*
0 - 100
0 - 600
0 - 600
150
350
350
83
120
120
11.000
15.000 (16.000 HL)
15.000 (16.000 HL)
*) Depending on grinding wheel spindle. Technical data is subject to change without prior notification. Max. values depend on the application.
26 G-H series
10.000 / 40.000*
GT 500 H (HL)
GR 500 H (HL)
GRX 500 H
GW3600H (-TC)
310
400
420
250
17
n/a
n/a
n/a
40.0
53 / 80
100
20
+/- 55
+/- 60
+/- 55
+/- 90
1,150 (1,850 HL)
1,250 (2,100 HL) 1,650
900 (1,500 HL)
900 (1,500 HL)
3,800
1,500 3,600
330
330
385 390
220
n/a
220
n/a
48
23 / 35
48
35 (28)
270 - 400
330 - 500
270 - 400
500 (360)
120
120
160 90
345
n/a
345
120 single / 90 double
n/a
150 single / 110 double n/a
120
100 / 150
100 120
8.500
6.500
8.500
5.000 (10.000)
0 - 200
0 - 600
0 - 200
0 - 100
350
350
600
350
120
120
140
100
16.000 (17.000 HL)
15.000 (16.000 HL)
18.000
n/a
25.000
G-H series 27
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G-H-series_en_v010
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