LGG 180 / 280 | Generating and profile grinding machines

LGG 180 - 280 / 400 M

A passion for surfaces.

Highlights

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Machine length - 3,000 mm
3,000 mm
Machine width - 2,200 mm
2,200 mm
Machine height - 3,000 mm
3,000 mm
Workpiece diameter - 180 - 400 mm
180 - 400 mm
Axial travel - 660 mm
660 mm
Shift distance - 230 - 270 mm
230 - 270 mm
Min. position above table - 90 mm
90 mm
Grinding head swivel angle - 45 °
45 °
Workpiece speed - 3,000 min-1
3,000 min-1

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Reliable

Short grinding times

Consistently high quality

Machine design

The LGG 180/280 generating and proﬁle grinding machine is suitable for machining gear components up to 180/280mm diameter. Diverse machining methods are available to address special customer needs. The generating and proﬁle grinding machine combines short grinding times with consistently high quality in high-volume operations.

Axes

_{X1 - radial movement of column slide | V1 - tangential movement of tool | Z1 - axial travel of grinding head | B1 - rotary movement of tool | C2 - rotary movement of workpiece | A1 - swivel movement of tool | Z4 - vertical travel of steady column | C3 - rotary movement of ringloader}

Features

High quality and reliability across the entire series
Fast loading thanks to an integrated ringloader
Chip-to-chip times
- Gears: As little as 4 seconds
- Shafts: As little as 6.5 seconds
Small space requirement
Easy to maintain

LGG 400 M

Liebherr also offers a manual generating and profile grinding machine for small batch sizes and outstanding flexibility.

Generating grinding max. workpiece diameter (mm): 280
Profile grinding max. workpiece diameter (mm): 400

External and internal grinding heads

The LGG machines are perfect for generating grinding and proﬁle grinding. As standard, the machines are equipped with an external grinding head and can be supplemented with an internal grinding head.

In both external grinding heads, the balancing systems are integrated in the spindle. High drive power and speeds offer big advantages for example, when using new grinding material. Simple and fast replacement of the grinding arbor is made possible by the use of modern tool holding. For collision-critical workpieces and for special tooth corrections, small grinding tool diameters are available.

GH 320

Speed (rpm): 7000
Grinding spindle drive power (kW): 28.5
Max. grindable module generating grinding (mm): 6
Dimensions of grinding worm (DxLxW) (mm): 275(320)x160x160

GH 240 / 200 CB

Technical data GH 240 CB

Speed (rpm): 12,000
Grinding spindle drive power (kW): 28.5
Max. grindable module generating grinding (mm): 6
Electro-plated CBN tools: Yes
Dimensions of grinding worm: (DxLxW): 240x200x76.2

Technical data GH 200 CB

Speed (rpm): 17,000
Grinding spindle drive power (kW): 28.5
Max. grindable module generating grinding (mm): 5
Electro-plated CBN tools: Yes
Dimensions of grinding worm: (DxLxW): 240x200x40 (76.2)

Fast and easy changeover

The adaptable internal grinding arm can be mounted quickly and easily on the external grinding head and are driven using the main drive. Other grinding arms can be provided on request.

In only 30minutes from external to internal grinding

Video

Gear manufacturing for aerospace

On-board inspection: Gear check in the machine

All grinding heads can be equipped with an optional swivel-in probe for gear checking.

Gear measurement

Proﬁle and lead
Concentricity, single and cumulative pitch
Twist check
Measuring system for grinding stock removal
Rolling measurement
Determining dimension measurement

Mobile or stationary meshing sensor

Technology

Prepared for the future

Type of gears

Asymmetric profile
Beveloid gears
Double helical gears
Cycloidal gears

Gear modification

Profile and lead modification
Free flank form

Cycloidal gears

For cycloidal drives, certain requirements must be met, such as dimensional precision, a high-quality surface, an excellent profile and pitch as well as rollers that fit perfectly to the inner ring. Liebherr has developed something new for cycloidal gears: Now, cam disks with an external gear can be produced via generating grinding using not only single but also perfectly adapted double clamping. Depending on the individual batch-size requirements, which means that besides conventional profile grinding, an additional grinding method for cam disks is now available to users.

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Generating grinding asymmetric gears

Asymmetric gears compensate for unequally distributed loads.

The advantages of asymmetric gears are obvious:

Reduced tooth root clamping forces and Hertzian flank stresses
Improved specific sliding
Increased surface durability and tooth root strength
Increased power density (load capacity in relation to gear size)
Longer service life
Increased efficiency
Reduced noise and vibration excitation
Increased operational reliability

Requirements when generating grinding asymmetric gears

Machine technology:

Centering of the dresser/grinding worm
Centering of the asymmetric grinding worm/workpiece
Initial profiling and tracking of the asymmetric profile at every dressing cycle
Precise control technology for dynamic tooth flank contact sequences

Technology:

Coordination of dressing and grinding parameters
Selection of appropriate grinding worm specifications

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Video

Topological modifications – twist-free grinding

Topological modifications

TF twist-free grinding
DFT deviation-free topological grinding
GER generated triangle-shaped end relief

Modifications for noise reduction

SSG noise-reduction shift strategy
NEO noise excitation-optimized modifications

Innovation

DIP – Dresser independent profile modifications

DIP is a versatile generating grinding method specially developed by Liebherr that uses dressable grinding worms. It allows profile modification on the workpiece when using profile rolls in the dressing process. In particular, profile angle modifications, crowning, as well as tip and root reliefs can be precisely specified and ground. It offers the advantage that using profile rolls makes the dressing process many times faster, and the surface of the worm is the same as for typical series production.

Generating grinding with small tools

Finishing grinding or polishing

Why modified and/or super-finished leads?

Motivation:

Improved wear behavior
Reduction of friction losses
Increased flank and tooth root strength
Increased efficiency
Longer service life (gear and gearbox)

Our solution: Finish grinding or polishing

Lower surface roughness can be achieved with finish grinding or polishing. This increases the power density and gear efficiency.

Generating or profile grinding with dressing-free CBN

CBN generating grinding

Short machining times (two-cut strategy)
No dressing required
Very low risk of grinding burn (short contact time, good thermal conductivity of CBN and steel basic body)
Universal tool design
Very long tool life
Robust process with high process stability
Module range 1.0 - 5.0mm
External gears with a high toothed length
Large batches, perfect for three-shift operation

01/02

CBN profile grinding

Very high profile quality
Pressure angle can be corrected by CNC (A, V and X axes)
Long tool life
Grinding of non-generating profiles and complex geometries
Module range 1.0 - 8.0mm
External and internal gears
Collision-critical gears (discs Ø < 30mm)
Small and medium-sized batches

Integrated centrifugal device

Automation

Manual loading or loading via robot NC lifting station

Bay with L door for manual loading or loading via robotNC lifting station

Plastic chain conveyor

External automation system with plastic chain conveyor

LPC 3600

External automation system with LPC 3600 palletizing cell

Easy to operate

The new optimized control panel LHStation & LHMobile

With the control panel, Liebherr intelligently divides the programming and operation of the machine between two system parts: The large, fixed monitor unit LHStation for data input and process monitoring and the standardized, mobile handheld terminal LHMobile with context-sensitive user guidance during setup. Both units have a multi-touch surface as well as tactile elements for optimum operating speed and operating safety.

01/03

Technical data

Machine length	3,000 mm
Machine width	2,200 mm
Machine height	3,000 mm
Axial travel	660 mm
Min. position above table	90 mm
Grinding head swivel angle	45 °
Workpiece speed	3,000 min-1