New Gleason OPTI-GRIND™ process delivers 40% Productivity gain, improved quality for large gear profile grinding

March 25, 2010

Gleason’s latest generation of Profile Grinding Machines now can be equipped to perform a revolutionary new process called OPTI-GRIND, which significantly improves productivity and quality levels for fine finishing cylindrical gears as large as 6 meters in diameter, and up to module 16.

The new OPTI-GRIND process enables end users to achieve both ‘optimum’ productivity, and  ‘optimum’ surface finishes, by simultaneously using multiple dressable grinding wheels for profile grinding rather than just the single grinding wheel that is typically used.  

The new process offers end-users a number of variations to choose from to meet their specific applications.  For example, when optimum productivity is required, OPTI-GRIND is up to 40% faster because it uses three grinding wheels to rough grind four tooth flanks simultaneously, as compared to the typical process of a single wheel roughing only two tooth flanks at once. OPT-GRIND then is used to finish grind conventionally, with a single wheel that has been dressed to produce the desired surface finishes and flank modifications.

OPTI-GRIND’s multiple-wheel configuration offers significant advantages for gear producers serving the wind power and other industries requiring optimum surface finishes.   Where a single dressable wheel must be designed for compromise in order to perform both roughing and finishing, the multiple wheel configuration of OPTI-GRIND makes it possible to utilize wheels designed for maximum roughing productivity, up to 40% faster than a single dressable wheel.  Then a finishing wheel is designed to produce the desired tooth modifications including grinding of the root without burning, and to deliver surface finishes up to four times finer than what would be possible conventionally.

In addition to the new multiple wheel design, the OPTI-GRIND process relies on the use of the latest Siemens 840D CNC and Gleason Windows® based Intelligent Dialogue software to greatly simplify setup and operation.   For example, a grinding technology database recommends and optimizes the production methodology for any of the OPTI-GRIND process variations before machining starts, enabling even less experienced operators to produce high quality parts more productively. 

The OPTI-GRIND process is one of many unique technologies offered in Gleason  Profile Grinding Machines for workpiece diameters up to 6 meters.

Gleason Corporation’s mission is to be The Total Gear Solutions Provider™ to its global customer base.  Gleason is a world leader in the development, manufacture and sale of gear production machinery and related equipment. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, wind power, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in Rochester, New York; Rockford, Illinois; Dayton, Ohio; Plymouth, England; Munich and Ludwigsburg, Germany; Studen, Switzerland; Bangalore; India, and Suzhou, China and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region.

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