Gear manufacturing companies use the HÖFLER Porta 3500 CNC Spur/Helical Internal/External Gear Grinding Machine for several highly technical reasons, rooted in its advanced capabilities and performance. Here are the key technical reasons:

Precision and Accuracy:

1. High Precision Grinding:
   • The HÖFLER Porta 3500 can achieve grinding accuracies up to DIN 1-2 for both profile and lead. This high level of precision is critical for the performance of gears, particularly in applications where minimal backlash and high load capacity are required.
   • The machine’s CNC control system, typically a Siemens 840D, allows for precise control over all grinding parameters, ensuring consistency and repeatability in gear production.
2. Advanced CNC Control:
   • The Siemens 840D CNC control system offers sophisticated algorithms for gear grinding, enabling complex gear geometries to be produced with high precision. This includes both spur and helical gears, as well as internal and external gears.
   • The CNC system facilitates automatic adjustment and compensation for tool wear, thermal expansion, and other variables, maintaining high accuracy throughout the grinding process.

Versatility and Capability:

3. Wide Range of Gear Types:
   • The machine’s ability to handle spur, helical, internal, and external gears makes it extremely versatile. This versatility is crucial for gear manufacturing companies that need to produce a variety of gear types for different applications, from automotive to aerospace.
   • The capability to grind gears with a maximum diameter of 3500 mm and face widths up to 1400 mm allows manufacturers to produce large gears required in heavy industries like wind power and mining.
4. Helical Angle Adjustment:
   • The A-axis allows for the grinding of helical gears with a helix angle adjustment range of ±45 degrees. This flexibility is essential for manufacturing helical gears with different helix angles, which are often required to optimize gear meshing and load distribution in high-performance applications.

Efficiency and Productivity:

5. Integrated Dressing Unit:
   • The CNC-controlled dressing unit ensures precise wheel shaping, which is essential for maintaining the desired gear profile and surface finish. This feature enhances productivity by reducing the downtime required for manual dressing of grinding wheels.
   • Continuous dressing capability ensures that the grinding wheel maintains its cutting efficiency, leading to faster cycle times and higher throughput.
6. Automatic Loading System:
   • The optional automatic loading and unloading system reduces manual handling and increases the overall efficiency of the production process. This automation is particularly beneficial in high-volume production environments where minimizing cycle time is critical.

Robustness and Reliability:

7. Heavy-Duty Construction:
   • The HÖFLER Porta 3500 is designed to handle workpieces weighing up to 30,000 kg. Its robust construction ensures stability and vibration damping during the grinding process, which is crucial for maintaining high precision and surface finish.
   • The machine’s structure and components are engineered to withstand the stresses associated with grinding large and heavy gears, ensuring long-term reliability and consistent performance.

Advanced Features:

8. Cooling System:
   • An integrated cooling system ensures that the workpiece and grinding wheel are kept at optimal temperatures, reducing thermal deformation and maintaining tight tolerances. This is especially important for high-precision applications where even small thermal variations can impact gear accuracy.
   • The cooling system also helps to extend the life of the grinding wheel by preventing overheating and excessive wear.

Conclusion:

The HÖFLER Porta 3500 CNC gear grinding machine is an indispensable tool for gear manufacturing companies due to its exceptional precision, versatility, efficiency, robustness, and advanced features. These capabilities allow manufacturers to produce high-quality gears that meet stringent industry standards and performance requirements, making it a vital asset in the production of gears for a wide range of applications.

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