Milling worms and rotors on horizontal and vertical gear cutting machines

Profile milling of worms and rotors

Geometric precision

Worms, lobes and rotors are characterized by complex profile shapes and helical structures. In order to be able to produce these profiles with precision, the machines must ensure extremely precise milling processes. This is made possible by highly dynamic drive systems that ensure precise movement of the tool spindle and workpiece even at high cutting speeds. The directly driven work tables of the EMAG SU machines minimize play and vibrations, which leads to significantly higher accuracy in the production process. 

High rigidity and vibration damping

Considerable cutting forces occur during profile milling, especially when machining heavy or large-dimensioned workpieces such as rotors and worm shafts. To withstand these forces and enable precision milling, EMAG SU machines are equipped with a heavy and heavily ribbed machine base. This structure ensures high inherent rigidity and excellent vibration damping effects, which further improves the machining quality. 

Flexible tool configuration

The machines must be able to accommodate different tools for the desired process. This requires flexible tool receptors with the ability to efficiently use a wide variety of tools - from disk cutters for rotors and worms to very wide profile cutters for lobes. EMAG SU machines are designed for this and offer a variety of tool configurations to optimally meet the different requirements for worm, lobe and rotor milling. 

Automation and process integration

A high degree of machine automation is essential for economical batch production. EMAG SU offers solutions such as robots, NC-controlled ring loaders (only for vertical machines), stacking cells and gantry automation solutions that enable smooth integration into production processes. Automation reduces non-productive times as workpieces are loaded and unloaded without manual intervention. This leads to a significant increase in productivity. 

Profile milling machines from EMAG SU

EMAG SU offers a wide range of solutions for profile milling of worms and rotors, all designed for maximum precision and flexibility: 

•  CLC 260 H-FR and CLC 500 H-FR: The horizontal profile milling machines have been specially developed for machining large worms and rotors. The milling head is equipped with a belt drive for high torque on the milling spindle. The milling arbor with HSK interface enables fast cutter changes.
• The CLC 300 FR is a vertical profile milling machine that is characterized by its compact design. A key feature of the CLC 300 FR is its advanced loading system. The machine is equipped with a ring loader, which enables automated and precision workpiece feeding. Additional processing steps can be integrated in the 90° position of the ring loader. 

In addition to profile milling machines, EMAG SU also offers profile grinding machines to cover the comprehensive spectrum of gear cutting technology.