Steel stocking and cutting saw
Katsa has three automated cutting machines for the sawing of bar steel up to Ø820 mm. We stock the most commonly used gear component material and diameters to facilitate prompt deliveries. We have large stocks of, in particular, 18CrNiMo7-6 and 42CrMo4 materials. We also stock material with classification approval.
Katsa has gear hobbing machines in different sizes for precision gear cutting up to Ø2000 mm. The main hobbing capacity is based on Gleason-Pfauter P1200/1600 machines.
For internal gear cutting, we use gear shaping method. Our latest machine acquisition is the Liebherr LSE1200, taken in use in September 2016.
By using modern gear grinding machines we achieve the precision class 3 DIN 3962. The largest of our several profile grinding machines is the Gleason-Pfauter P1600G. To meet serial production demands, Katsa provides gear grinding with the Reishauer RZ1000 gear grinding machine up to module 8-10.
Katsa’s gear profile inspection machines allows for a maximum workpiece of Ø1500 mm. The measuring reports (DIN3962/ISO1328) show the results for gear profile and flank direction as well as pitch and run out.
The final inspection of gearwheels includes, in addition to a general final inspection, possibilities to conduct surface tempering inspection with the Barkhausen method, magnetic particle inspection (MT) and liquid penetrant inspection (PT) in order to find any surface flaws. We also conduct ultrasonic inspections (UT) on turned components and, in special cases, on gearing. Katsa has EN 473 NDT Level 2 qualifications for MT and UT inspections.
Katsa’s service covers the maintenance and repair of bevel, worm, planetary and helical gear units and their combinations. Gearbox refurbishment starts with the external cleaning, followed by the disassembling of the gear unit. The service and measurements are documented. When needed, Katsa manufactures replacement components, sources bearings and seals and repairs the slightly worn components. Finally, the gear unit is assembled, tested and painted to correspond to a new unit.