Machines | R-Series M-Line
CNC Rack Milling Machine R-Series
The KESEL R-Series is the rack milling machine for the most demanding gearing up to module 32. The X2T dual-table system makes it the most productive machine in its class — available in four sizes from R2500M to R5500M.
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The Kesel R-Series machines are not merely revised versions of our previous models, but a completely new series. With an entirely new hybrid bed and slide construction, a worldwide first and unique dual-table system, a new milling head with a new counter bearing, and the option for fully automated material loading and unloading, the R-Series is a true “game changer.”
Available in four size variants from the R2500M to the R5500M and optionally equipped with our powerful F1-HSK or the more compact F2-SK milling head, there is a suitable configuration for every application. The R-Series machines are capable of producing gearing up to module 32 on workpieces up to a maximum length of 5,500 mm. Equipped with the latest SINUMERIK ONE control system from Siemens, the R-Series is prepared for the challenges of today and tomorrow.
Specifications
| Parameter | Value |
| Working range | |
| 1-Table Version | 2,940 mm to 5,940 mm |
| Clamping Area | 1-Table Version | 2,500 to 5,500 x 400 mm |
| Clamping Area | X2T Dual-Table System | 2 x 1,250 to 2 x 2,750 x 400 mm |
| B-Axis (Swivel Axis Helical Gearing) | +/- 25° |
| X-Axis (horizontal, table axis) | |
| X2T Dual-Table System | ± 800 mm to ± 2,300 mm per table |
| Y-Axis (vertical, milling depth) | 250 mm |
| Z-Axis (horizontal, feed) | 620 mm |
| Milling Head F2-SK | |
| Speed | max. 315 rpm, infinitely variable |
| Milling arbor taper | SK 50 |
| Cutter Width | 200 mm |
| Max. cutter diameter | 250 mm |
| Min. Cutter Diameter | 133 mm + 2 x milling depth |
| Power | 43 kW S6 40% |
| Type | F2-SK, gearbox with high drive power |
| Milling Head F1-HSK | |
| Speed | max. 450 rpm, continuously variable |
| Milling Arbor Taper | HSK-125B |
| Max. cutter width | 250 mm |
| Max. cutter diameter | 310 mm |
| Min. Cutter Diameter | 170 mm + 2 x milling depth |
| Power | 45 kW S6 40% |
| Type | F1-HSK, gearbox with high drive power |
| Control system | Siemens SINUMERIK ONE |
| Clamping System | Magnetic clamping plate, alternatively hydraulic workpiece clamp or hybrid clamping device |
| Quality Class | Gearing quality Q7 according to DIN 3962 Part 1 |
| Coolant and chip management | |
| Capacity | 1,200 Liters |
| Coolant lubricant | Emulsion |
| Chip Discharge | with magnetic conveyor, pre-separation via magnetic filter roller |
| Electrical connection data | |
| Voltage | 3 x 400 V |
| Current | 60 A |
| Dimensions and weight | |
| R2500M | Length 8,600 x Depth 4,300 x Height 2,700 mm / ≈ 26 t |
| R3500M | Length 9,600 x Depth 4,300 x Height 2,700 mm / ≈ 29 t |
| R4500M | Length 11,200 x Depth 4,300 x Height 2,700 mm / ≈ 32 t |
| R5500M | Length 13,600 x Depth 4,300 x Height 2,700 mm / ≈ 35 t |
Options
- X2T Dual-Table System
- Cutter Changing Device
- SW3K Chip Extraction System
- Automation with Robot Cells
What makes the R-Series M-Line stand out
Milling
The R-Series machines can be equipped with either the F1-HSK or the F2-SK milling head. Both models are based on backlash-free drive units with intelligently controlled power transmission, ensuring consistently maximum smooth running and tooth quality. The F1-HSK, our latest model, has the additional advantage of an HSK spindle taper, which, in conjunction with our new counter bearing, enables up to 350% higher concentricity and superior rigidity.
X2T Dual-Table System
In addition to the conventional single-table configuration, the R-Series is also available with the world’s first X2T dual-table system. The X2T system consists of two tables, each capable of holding half of the machine’s maximum material length. With this system, milling can be performed on one table while the second table is simultaneously loaded and unloaded. The result is up to a 2.7-fold increase in productivity! And should the machine’s maximum milling length be required, the tables can be coupled in less than 3 minutes, offering incredible manufacturing flexibility.
B-Axis
Helical profiles of up to ± 25° can be milled.
Clamping Systems
The R-Series is available with a variety of clamping options suitable for all types of workpieces, including magnets, vises, and hybrid solutions.
Automation
All R-Series models can be supplied with fully automatic loading and unloading cells to enable smooth machine operation with minimal operator intervention and extremely reduced non-productive times. With an integrated cleaning system and separate raw and finished part magazines for effortless and quick material access, the R-Series automation is the perfect solution for maximizing ROI.
FAQ – frequently asked questions
The X2T system is the world's first dual table for a rack milling machine. The two tables allow loading and unloading on one table while milling is performed on the other. The result? The machine is almost never idle, which can more than double your productivity!
Yes! There are 4 models in the R-Series: the R2500M, R3500M, R4500M, and the R5500M. The number refers to the maximum length of the rack that can be milled with the machine.
Yes. The SW3K chip extraction system not only integrates seamlessly into the R-Series machines but can also be installed in older Kesel models such as the RM-, RMS-, and RMX-machines.
The robotic loading and unloading cell can be configured to load and unload over 360 racks without operator intervention. This allows you to run a night shift with limited operator supervision, increase operating speed, and avoid many safety risks associated with manual operation.
Our standard machines operate with a water-based emulsion coolant. This is an incredibly effective coolant that enables excellent surface finish and tool life. If you prefer oil as a coolant, please speak to our team about possible options.
All R-Series rack milling machines are capable of milling up to +/- 25°. To speed up operation, the machines are also equipped with a fixed positioning at 19°31' 41"".