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K300 hobbing machine: a universal solution for gear manufacturing
According to the German Automobile Manufacturers Association (VDA), German automakers invest a total of 23.5 billion euros annually in research and development, with approximately half of that allocated to the development of new drive systems, including clean diesel engines and electric motors. As these innovations continue to shape the automotive industry, they also create new challenges for sub-suppliers and contract manufacturers. In particular, gear manufacturing must adapt to evolving requirements, such as varying materials, complex geometries, and smaller batch sizes. The KOEPFER K300 gear hobbing machine offers a highly flexible solution, capable of machining gears with a maximum modulus of 4 using different techniques tailored to various materials.
Gears are essential components in vehicle production, playing a critical role in powertrains, steering systems, control mechanisms, and auxiliary drives like seat adjusters. As hybrid and electric vehicles become more prevalent, the demand for gears continues to grow. Automotive gears can be made from a wide range of materials, from high-strength steels to lightweight plastics. This diversity brings flexibility to production but also increases complexity for subcontractors, who must constantly evaluate which manufacturing solutions can meet future needs. With changing batch sizes, geometries, and material compositions, the ability to adapt quickly is crucial.
“The K300 was designed to address this challenge,†explains Jörg Lohmann from KOEPFER, an EMAG subsidiary. “After extensive analysis, we developed a universal machine that can support multiple stages of gear production.†The K300 is capable of machining a wide range of workpieces, from small pinion shafts to large helical gears, all with the same machine. It can handle various materials, including alloy steel, aluminum, copper, bronze, and even plastics. One of its key advantages is its rapid setup time—just 20 minutes, thanks to a quick-change clamping system for the spindle, tailstock, and hobbing head. The machine’s NC technology allows for easy programming and automatic control, making it user-friendly and efficient.
The ergonomic design of the K300 ensures that operators can work comfortably, reducing fatigue and increasing productivity. It is suitable for both dry and wet machining, with a tilting hob design that optimizes chip flow in both environments. The machine’s advanced anti-vibration structure, made from polymer granite, combined with a thermally stable frame, ensures consistent performance and precision during operation.
In addition to its mechanical features, the K300 incorporates high-tech solutions such as a “closed box†machine base, a rigid frame, and thermal symmetry design. These elements contribute to superior gear quality and process stability. The machine supports a variety of cutting methods, including high-performance hobbing, scraping, and hard milling, as well as plunge and tangential hobbing for worm gears. It also includes NC tools for tasks like assembly, deburring, and sensor positioning, ensuring accurate and efficient machining.
With up to 15 active NC axes, the K300 delivers high throughput and flexibility. Its quick-loading device, equipped with V-calipers, is ideal for handling workpieces under 10 kg. A range of automated workpiece transport systems, such as chain libraries, gravity tracks, and conveyor belts, further enhances its versatility. Whether you're producing small or large batches, the K300 is designed to meet your needs efficiently and reliably.