EMAG G 160

$500,000 - $750,000 Updated 2026-03-19

Key Specifications

Max Workpiece ⌀

160 mm (6.5 in)

max workpiece length

300 mm (12 in)

max face width

180 mm (7 in)

module range

helix angle

+95° / -45°

grinding wheel diameter

275 mm max / 210 mm min

Overview

The EMAG G 160 is a high-performance CNC gear generating grinding machine designed for finish grinding of spur and helical gears with workpiece diameters up to 160 mm (6.5 in) and modules from 0.5 to 4.0 mm. As the smallest machine in EMAG's G-series gear grinding lineup, the G 160 targets high-volume automotive gear production where cycle time and quality are equally critical — transmission gears, differential pinions, and e-drive gears that must meet DIN 3-5 quality after heat treatment.

The G 160 features a unique split X-axis architecture with dual workpiece spindles that virtually eliminates non-productive time. While one spindle is in the grinding position, the other is loading and unloading — achieving spindle changeover times under 2 seconds via high-dynamic linear motors rated at 30 m/s. This dual-spindle design means the G 160 spends nearly 100% of its cycle in cutting, a decisive advantage over single-spindle machines that lose 8-15 seconds per cycle to loading operations.

The grinding spindle operates at peripheral speeds up to 80 m/s, accommodating grinding wheels from 210 mm to 275 mm diameter with a maximum wheel width of 160 mm (6.5 in). The machine grinds workpiece face widths up to 180 mm (7 in) with helix angle capability of +95 to -45 degrees, covering the full range of automotive gear geometries including highly twisted helical gears. The compact footprint of 3,275 x 2,200 x 2,285 mm (129 x 86.5 x 90 in) enables high machine density in production facilities.

The Siemens SINUMERIK 840D sl control manages the grinding process including automatic wheel dressing, in-process measurement, and twist-control grinding for noise-optimized gear flanks. The G 160's combination of dual-spindle productivity, linear motor dynamics, and compact footprint makes it the preferred choice for automotive transmission manufacturers producing high-quality gears at volumes where every second of cycle time directly impacts production economics.

Full Specifications

Parameter	Value
Max Workpiece Diameter	160 mm (6.5 in)
Max Workpiece Length	300 mm (12 in)
Max Face Width	180 mm (7 in)
Module Range	mm
Helix Angle	+95° / -45°
Grinding Wheel Diameter	275 mm max / 210 mm min
Max Grinding Wheel Width	160 mm (6.5 in)
Grinding Spindle Speed	80 m/s peripheral
Workpiece Spindle Changeover	Under 2 seconds
Linear Motor Speed	30 m/s
Dressing Tool Diameter	123 mm (5 in)
CNC Control	Siemens SINUMERIK 840D sl
Floor Space Required	3,275 x 2,200 x 2,285 mm (129 x 86.5 x 90 in)
Workpiece Spindles	Dual (simultaneous load/grind)
Workpiece Dia Max	mmin
Workpiece Length Max	mmin
Face Width Max	mmin
Grinding Wheel Width Max	mmin
Grinding Spindle Speed Max	m/s
Dressing Tool Dia	mmin
Machine Dimensions L X W X H	mmin

Specifications sourced from emag.com — verified 2026-03-28

Strengths & Limitations

Strengths

Dual workpiece spindles with sub-2-second changeover virtually eliminate non-productive loading time, maximizing grinding utilization to near 100%
Linear motors at 30 m/s provide the axis dynamics needed for rapid positioning and high-speed generating grinding of fine-pitch automotive gears
80 m/s grinding wheel speed supports aggressive stock removal rates with CBN and conventional wheels for shortest possible cycle times
Split X-axis architecture enables independent positioning of grinding and dressing components for maximum stiffness and process flexibility
Compact 3,275 x 2,200 mm footprint enables high machine density — critical for automotive production lines with limited floor space
+95/-45 degree helix angle range covers even highly twisted helical gear geometries found in modern quiet-running automotive transmissions

Limitations

160 mm maximum diameter limits the G 160 to small gears — larger automotive and industrial gears require the G 250 or G 400
Module 4.0 mm maximum excludes medium and large-module gears used in commercial vehicle, industrial, and wind energy applications
Dual-spindle design adds mechanical complexity and increases maintenance requirements compared to single-spindle gear grinders
High acquisition cost relative to single-spindle alternatives is justified only at production volumes where the cycle time advantage provides return on investment

Best For

Automotive transmission manufacturers producing high-volume finish-ground gears requiring DIN 3-5 quality after case hardening Electric vehicle drive unit producers grinding precision helical gears for single and multi-speed e-drive reduction gearboxes Automotive differential gear manufacturers finish-grinding pinion and ring gear sets for noise-critical passenger vehicle applications High-volume gear producers where sub-2-second load/unload time provides measurable cycle time and throughput advantages Compact production cell builders requiring maximum grinding output per square meter of floor space

Frequently Asked Questions

01 How does the dual-spindle design reduce cycle time?

While one workpiece spindle is in the grinding position being machined, the second spindle is simultaneously unloading the finished part and loading a new blank. When grinding is complete, the two spindles swap positions in under 2 seconds via linear motors. This means the grinding wheel is cutting for virtually the entire cycle — unlike single-spindle machines that must stop grinding for 8-15 seconds per cycle to load and unload parts.

02 What is twist-control grinding?

Twist-control grinding is a technique that modifies the gear tooth flank geometry to compensate for the natural twist (lead crowning variation across the face width) that occurs during generating grinding with a threaded wheel. By controlling the twist, the G 160 produces gear flanks optimized for quiet meshing and even load distribution, which is critical for NVH (noise, vibration, harshness) performance in automotive transmissions.

03 What grinding wheel types does the G 160 support?

The G 160 supports both conventional (aluminum oxide) and superabrasive (CBN) threaded grinding wheels. Conventional wheels are lower cost but require more frequent dressing. CBN wheels hold form longer and enable faster grinding speeds, reducing cycle time but at higher tooling cost. The choice depends on production volume, required quality, and total cost-per-part economics.

04 How does the G 160 compare to the G 250?

The G 160 handles gears up to 160 mm diameter and module 4, while the G 250 extends to 250 mm diameter and module 7. Both share the dual-spindle concept, but the G 250 has a larger grinding wheel capacity and longer workpiece length. For small automotive gears under 160 mm, the G 160's more compact footprint and slightly lower cost make it the preferred choice.