Products

construction and mining

Haul trucks in the mining industry use bevel gears to transmit several thousand kW of power.

Requirements:

Trucks designed for high-production mining and heavy-duty construction machines generally use rear-wheel drives, which are subjected to extreme conditions. A Caterpillar 797B ultra class haul truck has a payload capacity of just under 623 tons. The bevel gears they use transmit nearly 2,400 kW to the rear axle. They are larger than bevel gears used in the automotive industry, and are only made in small batches.

Solution:

The Oerlikon Spiral Bevel Gear Cutting Machine C 60 is designed for the highest possible cutting forces, which are produced when cutting bevel gears on this order of magnitude. Klingelnberg's closed-loop concept guarantees compliance with the narrowest tolerances, thus effectively eliminating costly rejects. With the horizontal arrangement of the tool spindle and programmable loading and unloading positions, this is the most user-friendly machine on the market.

Machine specifications
Oerlikon Spiral Bevel Gear Cutting Machine C 60
Machine specifications
Oerlikon Spiral Bevel Gear Grinding Machine G 60

THE KLINGELNBERG ADVANTAGE

  • Klingelnberg has developed and perfected the dry-cutting process for spiral bevel gears.

  • KIMoS covers all aspects of spiral bevel gear design and optimization throughout the process chain.

  • The entire process chain for bevel gears – from design, to production, to measurement – is available under one roof.

  • The closed-loop concept for the entire bevel gearing process chain is unrivaled on the market.

  • Klingelnberg's tool system ensures the highest productivity and lowest possible cost per unit.

  • The patented TwinBlade by Klingelnberg method, ideal for the production of bevel gears that require grinding. TwinBlade by Klingelnberg is the most productive cutting process on the market.
  • Complete solutions for all tool-related questions: Klingelnberg continually perfects the tool system and offers a just-in-time grinding service for customers.

  • Supplier of machines with integrated, automatic contour deburring for complete process steps.

  • Klingelnberg knows the requirements for machine loading better than anyone specializing only in automation. The integrated Klingelnberg solution has led to tremendous advances in production and process quality.

  • Application expertise for all of the different work steps involved in bevel gear production.

  • Klingelnberg offers training courses to pass this expertise and knowledge on to customers.

Klingelnberg supports all indexing methods, regardless of whether they have originally been manufactured only on a certain machine or a certain tool.

Name of method

Indexing method

Tooth form

Tool

Cyclo-palloid

Continuous

Constant tooth

Cutter head

Palloid

Continuous

Constant tooth

Conical hob

N-method

Continuous

Constant tooth

Cutter head

SPIROFLEX / SPIRAC

Continuous

Constant tooth

Cutter head

TRI-AC / Pentac-FH

Continuous

Constant tooth

Stick blade cutter head

Hypoflex

Continuous

Straight-tooth

Stick blade cutter head

Kurvex

Single-indexing

Constant tooth depth

Cutter head

Arcoid

Single-indexing

Conical tooth depth

Stick blade cutter head

5-cut

Single-indexing

Conical tooth depth

Form blade or stick blade cutter head

Completing

Single-indexing

Conical tooth depth

Form blade or stick blade cutter head

Wiener 1- / 2- trace

Single-indexing

Constant tooth depth

Form blade or stick blade cutter head

Semicompleting

Single-indexing

Constant tooth depth

Form blade or stick blade cutter head