Machines | R-Series G-Line
R-Series CNC rack grinding machine
The KESEL R-Series G-Line is the world’s first rack grinding machine with the X2T dual-table system. Simultaneous setup and grinding increases productivity by up to 2.7x—while delivering industry-leading dimensional accuracy and full automation capability.
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With a completely new design and comprehensively optimized high-performance technology, Kesel’s R-Series grinding machines set a new standard in high-quality, high-productivity rack and profile grinding. From the newly developed grinding head to the revised coolant and chip management system, R-Series machines deliver both industry-leading dimensional accuracy and unbeatable surface finishes.
Looking for even more productivity? The world’s first X2T dual-table system, an integrated chip extraction system, and the option to fully automate the machine provide multiple options and methods to achieve a profitable competitive advantage.
Kesel R-Series grinding machines. The next generation of rack and profile grinding.
Specifications
| Parameter | Value |
| Working range | |
| Clamping range | 1 table: 470 x 2,510 mm; 2 tables: 470 x 1,250 mm (2x) |
| B-axis (swivel axis/helical gearing) | +/- 25° |
| Table system | Table 1 and Table 2 are coupled and driven by two linear drives; alternatively, Table 1 and Table 2 can be moved independently with two drives per table. |
| X1 axis (horizontal, Table 1) | 1 table: 2,940 mm; 2 tables: +/- 800 mm |
| X2 axis (horizontal, Table 2) | 2 tables: +/- 800 mm |
| Y axis (grinding head, vertical axis) | 290 mm |
| Z axis (feed axis, horizontal) | 600 mm |
| Dressing unit travel ranges | |
| X3 axis (horizontal) | 140 mm |
| Grinding head | |
| Max. grinding wheel width | 127 mm |
| Max. grinding wheel diameter | 400 mm |
| Min. grinding wheel diameter | 243 mm |
| Type | S98 |
| Control system | Siemens SINUMERIK ONE |
| Clamping system | Magnetic clamping plate, alternatively hydraulic clamping device |
| Quality | Achievable gear quality to DIN 3962 Part 1: Q5 |
| Coolant and chip management | |
| Fine filtration via | belt filter fleece |
| Fill volume | 6,500 liters |
| Integrated coolant monitoring | |
| Coolant lubricant | Emulsion |
| Electrical connection data | |
| Power supply, coolant system | Rated current | 130 A |
| Power supply, coolant system | Voltage | 3 x 400 V |
| Power supply, machine | Rated current | 200 A |
| Power supply, machine | Voltage | 3 x 400 V |
| Dimensions and weight | |
| Installation dimensions | approx. L: 6,850 x W: 7,500 x H: 3,216 mm |
| Machine weight | approx. 28,500 kg |
Options
- X2T Dual-Table System
- Grinding wheel changing device
- SW3K Chip Extraction System
- Automation with Robot Cells
What sets the R-Series G-Line apart
Grinding
The S98 grinding head delivers maximum performance across the full grinding wheel width of up to 127 mm. With an integrated, automatic balancing unit, the S98 is not only extremely powerful, but also absolutely precise. The new compact design was developed to minimize maintenance effort while increasing positioning accuracy.
The S98’s air-cooled dressing spindle reduces energy consumption during dressing while maintaining its market-leading precision. With grinding wheels up to a maximum width of 127 mm and a diameter of up to 400 mm, the R-Series offers very high productivity while maximizing the usable wheel diameter.
X2T Dual-Table System
In addition to the classic single-table version, the R-Series is also available with the world’s first X2T dual-table system. The X2T system consists of two tables, each of which can accommodate half of the machine’s maximum length. With this system, one table can be machined while the second table is loaded and unloaded at the same time. The result is an increase in productivity of up to 2.7x! And if the machine’s maximum grinding length is required, the tables can be coupled in less than 3 minutes—for ultimate manufacturing flexibility.
B-Axis
Available as either a manual or fully automatic axis, it features a swivel range of +/- 25°, enabling grinding across the full spectrum of racks.
Coolant and filtration management
The intelligent coolant management system supplied with R-Series machines operates fully automatically and increases operating efficiency. Coolant volumes and pressures are continuously monitored and maintained via the control system. More complex coolant applications, such as volume and pressure changes during roughing and finishing, can also be programmed very easily.
Automation
All R-Series models can be supplied with fully automatic loading and unloading cells to enable smooth machine operation with minimal operator involvement. With an integrated cleaning system and magazines for easy and fast material infeed and outfeed, R-Series automation is the perfect solution for maximizing ROI.
FAQ – frequently asked questions
We offer a maximum clamping surface of up to 400 mm. Depending on the workpiece dimensions, the corresponding number of racks can then be clamped and machined as a bundle. Example: With a workpiece width of 19 mm, this is 21 racks in a bundle.
R-Series G-Line rack grinding machines are capable of grinding racks to DIN Q5. We offer multiple adjustment options so that you receive the machine configuration that meets the requirements of your market.
Yes. As with all machines we manufacture, we consider it just as important that they feature perfectly matched coolant and chip management systems. The system supplied with the R-Series G-Line rack grinding machines generates volume and pressure exactly where it is needed.
R-Series G-Line rack grinding machines are supplied with an integrated 2-axis diamond dressing wheel. For modules above 14, we also offer a table-based dressing tool for grinding larger modules.
R-Series G-Line rack grinding machines can be supplied with a fully automatic loading and unloading cell. Just like material loading, automation ensures that the clamping system remains free of chips at all times.
In addition to the conventional single-table configuration, R-Series G-Line rack grinding machines are also available with the X2T dual-table system. This can significantly reduce machining times and increase productivity by more than double.