VDM 1000 TM / H Complete Gear Manufacturing

MAG Gear Technology 

VDM 1000 TM / H 

Complete Gear 

Manufacturing 

Christian Albrecht 

Product Leader Gear Technologies 

Juy 2011

VDM 1000 TM/H 

At a Glance … 

• Next generation VDM 900 – 1400 turning machines. 

• Vertical design. 

• Highly productive turning with 4-axes (C, X, Y, Z). 

• C axis integrated in spindle box, variable speed. 

• Technology modules for milling, drilling, turn-milling 

(B axis). Milling module with 380 Nm @ 36 kW. 

• Technology module for face, OD and bore grinding. 

• Technology module for gear hobbing (A & Y axes). 

• Technology module for flexible gear milling (B axis + 

software module). 

• Modular tool system HSK 100 or Capto C8. 

• Siemens 840D solutionline. 

• CAD-CAM interface for virtual process simulation. 

• Optional automated workpiece change with palett 

system. 

• Optional automated tool change with magazine. 

Example shown: Automated by Fanuc robot (70 kg 

capacity) with CELLRO (CAPTO) tool system. 

Christian Albrecht VDM 1000 TM / H Feb 21, 2011 2


Benefits at a glance 

• Turning, milling, drilling, threading, hobbing, 

chamfering/deburring in maximum 2 

clampings. 

• Prototyping with gear turn-milling and high 

produtivity cutting with hobbing. 

• Hard gear skive hobbing incl. gear centering. 

• Integrated chamfering/deburring. 

• Automated tool and workpiece change 

options. 

• Less processing time. 

• Less machine investment. 

• Less floor space. 

• Higher quality due to less workpiece 

reclampings. 

• One control with one common HMI. 

H 

TM 


VDM 1000 TM 

Standard Design 


With turret 

and 5-axis turn-mill head 



Standard Designs 

1 main spindle 

1 tool turret on the left side 

2 main 

spindles 

2 tool turrets 

1 main spindle 

1 tool head on the left side 

1 tool changer/magazine 



Modular Concept 

• Vertical turning center as Base machine 

- Modular expendable to 4-axes (2 turrets) 

- One or two turn tables 

- 2-axes milling spindle with tilting unit 

- Vertical RAM for heavy turning processes 

- Gear hobbing module. 

2 axes 

4 axes 

• Process integration 

Modules for turning, milling, hobbing, grinding. 

VDM 1000– 11 VDM 1000– 12 

4 axes 

pendular 

Turning 

revolver 

RAM 

Y-side 

adapter 

B-axis head 

VDM 1000– 22 



Slide Concept (X) 

• One Slide for left and right side 

• Size guiding system X-axis BG 65 

• Size guiding system Z- Achse BG 

65 

• Counter balance 

• Second redundant break system 

in the Z- axis 

• Guiding system distance X-axis 

1000 mm 

• Guiding system distance Z-axis 

550 mm 

• Option: Prepared for the 

integration of a hydrostatic guide 

system 

Oil return 

Binary 

Saddel with 4 pockets 

Oil inlet 60-100 bar ISO 

VG 46-220 

Head with integrated hydraulic control 

Pressure guide 

Tear guide 

1000 



FE Analysis 

X- axis with concrete filling / : 

9800 kg 

Workpiece 

2,500 kg 

250 kgm² 

Base with concrete filling / 

11000 kg 

C- axis 

2,300 kg 

370 kgm² 



Technology Module Turning 

• for static and driven tools 

• for left and right side of the 

machine 

• 0.7 sec from position 1 to 2 

• Electrical driven, life tools, max. 

speed 3,000 U/min 

• Coolant pressure, max. 25-70 bar 

(standard) 

• Tool system VDI 60 

• Torque, max. 

– 63 Nm (S1 / 100%) 

– 100 Nm (S6 / 25%) 



Double X-slide 

• Twin Slide concept 

• Two slides for special 

technology tasks e.g.: 

grinding head + 

motorspindle, revolver + 

motorspindle 

• Integrated measuring 

probe for part control 

• Z-slide with grinding 

spindle for grinding tools 

Z-slide with 

grinding spindle 

for grinding tools 

Z-slide with motorspindle 

for angular tool holders 

incl. integrated Y-axis for 

the grinding of keyway 

grooves 



Technology Module Turning, Milling, Drilling 

Tool carrier 

• „One“ tool system for turning, milling and drilling 

• Spindle for pick-up of static and rotating tools 

HSK 100 or Capto C8 

• Max. torque: 380 Nm / 36 kW (S6 / 40%) 

• Max spindle speed 5500 rpm 

• The unit is directly mounted on the Z-slide 

Pivoting: indexing 5Hirth 

gearing, max. 105 

or stepless with reduced 

power 

Application in MAG models 

• VDM 550 

• VDM 1000 (Predecessor VDM 900 - VDM 1400) 





Y Slide Adapter 

Slide adapter for Y axis 

• One system for Y slide 

• Installation position optionally 

vertically or horizontally 

• Max. work travel 150 mm 

• Size of the guiding system 

55mm 

• Servo drive with brakes 

Y 

Y 



RAM 

• Hydrostatic guide system 

• Stroke 750 mm 

• Speed, max. 4000 rpm 

• Cross- section 250 x 250 mm 

• Tool system Capto C8 / KM 80 

(planned HSK 100) 



Technical Data / Base Machine for Turning 

X 

Z 

Y 

B 

Base Machine: 

C 

C 

Turning diameter, max. 1,150 mm 

Swing diameter, max. 1,450 mm 

Workpiece height, max. 1,400 mm 

Speed (X), max. 25 m/min 

Stroke (Z), max. 950 mm 

Machine dimens. L x W x H 7 x 3,5 x 4,1 m 



Machine Configuration for Gear Cutting 

5ax Unit for: 

- Milling 

- Drilling 

- Tapping 

- Turning 

Hobbing Unit (H400) 

Tool magazine 

High precision 

Table 



Work Spindle Concept with Parallel Drive Shafts 

Drive concept for high speed turning 

One main drive 

Speed, max. 900 U/min 

Torque 40% ED 12,900 Nm 

Power 40% ED 105 kW 

Workpiece weight 8,000 kg 

Bearing diameter 440 mm 

Encoder std accuracy 12 “ 

Drive concept for gear hobbing 

2 servo drives with integrated CNC- axis for 

synchronised positioning. 

Speed, max. 630 rpm 

Torque / 40% ED 25,000 Nm 

Power / 40% ED 84 kW 

Workpiece weight 8,000 kg 

Bearing diameter 635 mm 

Encoder accuracy 

for gear-hobbing 3 “ 

2x 28 kW 

(at 100% ED) 

Option: 

C- axis 

for 

positioni 

ng 

requirem 

ent 

Preloaded drive 

concept, preloading 

force is adjustable 

via closed loop 



Option Gear Hobbing 

Z Vertical travel 600mm 

X Radial travel 300 mm 

Y Tangential shift 200 mm 

A Hob head swivel +/- 30 deg 

B Hob spindle rotation 

C Work table rotation 

Z 

Integrated H 400 

hobbing module 

C 

A 

B 

Y 

X 



Hob Head 

• Reliable technology from MAG 

hobbing machine components 

• Extremely stabile and stiff execution 

• Cutting forces are guided into the 

tool column 

• Full-scale gear hobbing 

Drive Power 

Torque 

Spindle speed 

Hob diameter 

Hob length 

31 kW 

290 Nm 

300-3.000 rpm 

130 mm 

300 mm 

Interface for hob clamping: 

collet ø 32 / SK 25 

HSK A-80 / cylindrical 

HSK A-80 / SK 25 



Turning, Milling and Gear Cutting on one machine 

Turning, milling, drilling, 

hobbing and subsequent 

chamfering/deburring 

with carbide endmills. 



Technical Data / Option Gear Cutting / Gear Milling 

Option Hobbing of cylindrical gears 

• Workpiece diameter, max. mm 300 – 800 

• Module, max. mm 8.0* 

• Tool spindle speed rpm 800 – 3,000 

• Hob diameter, max. mm 180 

• Hob length, max. mm 210 

• Axes travel speed mm/min 5,000 

• Hob head swivel (A), max. deg +/- 30 

• Vertical travel (Z), max. mm 600 

• Horizontal travel (X), max. mm 300 

• Tangential travel/shift (Y) mm 200 

Option Turn-milling (B-Y axis) 

• B-axis swivel, range deg +/- 105 

• Y-travel, range mm +/- 150 

• Tool spindle speed max. rpm 5,500 

• Torque max. Nm 380 

• Tool length, max. mm 500 

* Larger modules with limited feeds and speeds. 


VDM 1000 H 

Software Structure for Hobbing Function 

Completely integrated 

software module for gear 

hobbing. 

machining 

NC 

Axis movement, 

coupling, 

emergency retract 

know-how 

machine 

functions 

NC-Program 

PLC 

control and 

monitoring of 

machine 

functions 

HMI 

NC-program 

generation 

enable 

signals 

automated 

loading 

correction 

values 

gear data 



Software Structure / Data Processing 

Data Input 

Workpiece data 

Diameter 

Helix angel 

Normal module 

Workpiece 

program in NC 

Tool data 

Hob diameter 

Hob length 

Cutting parameters 

Cutting direction 

Cutting speed 

Samputensili HMI 

– validity check and calculation of program parameters 

– Integrated tool management with tool life surveillance 



Gear Cutting Test Data and Result 

Workpiece data 

Diameter 548,49 mm 

Normal module 6.0 mm 

Face width 65 mm 

Material 18 CrNiMo 7-6 

Number of teeth 85 

Nominal angle of incl. (r +) 20 

deg 

Helix angle 18 deg 

Hob data 

Outside diameter 130 mm 

Chip flutes 17 

Number of starts 2 

Helix angle 20 deg 

Quality class AA DIN3968 

Tool material 

M 35 + TiN 

Pitch angle (re +) 6,19 deg 

Process data 

Process 

Wet machining 

Coolant 

6% oil, 300 l/min 

Feed rate 2,3 mm/workpiece revolution 

Tool speed 122 rpm 

Main drive speed 2,9 rpm 

Depth of cut, total 15,6 mm 

Cutting speed 50 m/min 

Utilization ratio hob drive ~ 43 % 

Utilization ratio main drive ~ 17 % 

Cutting time : ~16,5 min 

Length of chips approx. 8 – 12 mm 



Complete Process Chain for Gear Cutting 

First clamping position: 

OP10: Turning 

OP20: Drilling and winding 

Second clamping position: 

OP10: Turning 

OP20: Hobbing 



Productivity Comparison 

Turning, Drilling, Threading, Gear Hobbing 

-30% 

1. Setting up Fixture/Tool 

2. Loading and Rigging 

3. Turning 

4. Unloading / Cleaning 



7. Turning or Drilling 




11. Drilling or Turning 




15. Hobbing 


Result 

Time reduction 

against single 

process 

Single machines 

Turning: First clamping 19 min 

10 min 

1.5 min 

6 min 

1.5 min 

Turning: Second clamping 14.6 

- 

1.5 min 

11.6 min 

1.5 min 

Drilling and winding at MC 16.3 min 

10 min 

1.5 min 

3.3 min 

1.5 min 

Hobbing 

24.3 min 

10 min 

1.5 min 

11.3 min 

1.5 min 

74,2 min 

Complete machining 

Turning: First clamping 17.5 min 

10 min 

1.5 min 

6 min 

- 

Drilling and winding 

5.8 min 

- 

- 

3.3 + 1.0 min = 4.3 min 

1.5 min 

Turning second clamping 13.1 min 

- 

1.5 min 

11.6 min 

- 

Hobbing 

16.2 min 

- 

- 

11.3 + 3.4 min = 14.7 min 

1.5 min 

52,6 min 



Gear Hobbing / Results 

Single cut process 

Multi Task process 

No of machines 3 1 

Set-up time, min 30 min 10 min 

Loading/rigging, min 6 min 3 min 

Cutting process, min 32.2 min 36.6 min 

Unloading/cleaning, min. 6 min 3 min 

Cycle time first piece 74.2 min 52.6 min 

Cycle time following pieces 44.2 min 42.6 min 

Time reduction per workpiece: 

1.6 min 

• Multi-task process reduces cycle times 

• Productivity increase by minimizing non-productive times. 



Flexible Gear Cutting 

• Flexible gear cutting for 

prototypes, small lots and 

repair requests. 

• Gear milling with endmills via 

additional B- axis. 

• Very process-safe machining 

with stable optimum cutting 

values e.g. contained depth 

of cut of 0,05 mm. 

• Tool costs < 2000 €. 



Turn-milling of Gears / Application Example 

Helical gear 

Module 16.0 

31 teeth 



Turn-milling of Gears 



Tool Changer & Magazine Options 

• Capto C 8 or HSK 100 

• Disc magazine with 24 + 40 positions 

• Fast tool change < 10 sec. 

• Single tool weight max. 35 kg 

• Tool length, max. 500 mm 

• Integrated modular tool magazine up 

to 120 tools 



Summary 

• Reduced overall investment. 

• Reduced processing time. 

• Reduced personal resources. 

• Reduced floor space. 

Particular advantageous for the manufacture of for 

small lot sizes of heavy gears reducing high set-up and 

transfer times. 

Integrated manufacturing solutions reduce the ‘cost 

per workpiece’.

VDM 1000 TM / H Complete Gear Manufacturing

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