KAPP NILES KX 500
Key Specifications
workpiece diameter max
module generating
module profile
max face width
max helix angle
min grinding wheel diameter
Overview
The KAPP NILES KX 500 is a large-capacity CNC generating and profile grinding machine designed for finishing gears up to 500 mm tip diameter. Built by KAPP NILES in Coburg, Germany, the KX 500 is the bigger brother of the KX 300 P, extending the same proven grinding technology to the medium-to-large gear sizes found in industrial gearboxes, wind turbine drives, mining equipment, and heavy commercial vehicle transmissions.
The machine handles modules from 1 to 12 mm in generating mode and 1 to 15 mm in profile mode, covering a broad range of industrial gear applications from medium-pitch automotive components to heavy-duty mining and energy sector gears. Maximum face width is 440 mm with helix angles up to 45 degrees. The tool spindle features counterbearing support and can accommodate grinding wheels from 25 mm to 350 mm diameter, providing the flexibility to grind gears with tight clearance requirements as well as conventional open-geometry parts.
At approximately 14,000 kg, the KX 500 has substantial mass for vibration damping and thermal stability during the long grinding cycles typical of larger gears. The Siemens Sinumerik 840D control runs KAPP NILES' proprietary grinding software for complete process control, including standard involute profiles and complex modifications such as topological crowning, bias corrections, tip/root relief, and profile angle corrections. Integration with KAPP NILES' in-process measurement probing system enables closed-loop quality control without removing the workpiece.
The KX 500 competes with the Liebherr LCS 500, Reishauer RZ 400, and Gleason Genesis 400GX. KAPP NILES differentiates on grinding flexibility: the combination of generating and profile grinding modes, the ability to use very small grinding wheels via auxiliary spindles, and comprehensive topological modification capabilities make it the choice for shops that grind diverse gear types rather than running one part family at maximum throughput. New KX 500 machines typically price between $700,000 and $1,200,000 depending on automation, measurement systems, and configuration.
Full Specifications
| Parameter | Value |
|---|---|
| Workpiece Diameter Max | 500 mm (19.69 in) |
| Module Generating | 1 - 12 mm |
| Module Profile | 1 - 15 mm |
| Max Face Width | 440 mm (17.3 in) |
| Max Helix Angle | 45° |
| Min Grinding Wheel Diameter | 25 mm (0.98 in) |
| Max Grinding Wheel Diameter | 350 mm (13.78 in) |
| Tool Spindle | With counterbearing, dressable and non-dressable tools |
| Axes | 6 CNC axes |
| Grinding Methods | Generating (continuous) and profile (single-index) |
| CNC Control | Siemens Sinumerik 840D |
| In Process Measurement | Integrated probing system (closed-loop capable) |
| Loading | Manual or automated |
| Machine Weight | 14,000 kg (30,865 lb) |
| Quality Achievable | DIN 3-5 (AGMA 12-14) |
Specifications sourced from static.machinetools.com — verified 2026-03-28
Strengths & Limitations
Strengths
- 500 mm diameter capacity with modules up to 15 mm covers medium-to-large gears for industrial, wind energy, mining, and heavy vehicle applications
- Auxiliary spindles support grinding wheels down to 25 mm diameter for interference-prone gear geometries that larger wheels cannot access
- Both generating and profile grinding on one machine provides maximum flexibility — switch methods without moving the workpiece
- 14,000 kg machine mass delivers excellent vibration damping for the long grinding cycles typical of large gears
- Comprehensive topological modification capabilities handle complex profile corrections including bias, crowning, and asymmetric modifications
- Integrated in-process measurement with closed-loop control maintains gear quality without removing parts for CMM verification
Limitations
- Capital cost of $700K-$1.2M is a major investment, requiring significant gear grinding volume to achieve payback
- Single-spindle design means loading and grinding happen sequentially — dual-spindle competitors like Gleason offer higher throughput for production runs
- 14,000 kg machine weight requires substantial foundation preparation and limits placement flexibility on the shop floor
- KAPP NILES' proprietary software platform has a significant learning curve for operators transitioning from other gear grinding brands
- Service presence outside of Europe may involve longer response times — North American and Asian shops should consider proximity to regional support
Best For
Frequently Asked Questions
01
The primary difference is workpiece capacity: the KX 500 handles gears up to 500 mm diameter (vs. 300 mm) with modules up to 15 mm (vs. 10 mm) and face widths up to 440 mm (vs. 320 mm). The KX 500 is a physically larger and heavier machine at 14,000 kg vs. 9,500 kg. Both share the same grinding flexibility (generating + profile modes, small wheel capability, counterbearing spindle) and software platform. Choose based on your maximum gear size requirements.
02
The KX 500 routinely achieves DIN 3-5 quality (AGMA 12-14) in production conditions. With optimized setups, CBN tooling, and closed-loop measurement, DIN 2-3 quality is achievable for critical aerospace and precision applications. The in-process measurement system catches quality deviations in real time, enabling corrections before parts go out of tolerance.
03
New KX 500 machines price between $700,000 and $1,200,000. A base machine with manual loading sits near the lower end, while a fully equipped machine with automated loading, in-process measurement, dressing systems, and expanded software packages approaches $1.2M. The wide range reflects the modular configuration options. Used KX 500 machines from the 2000s-2010s can appear in the $250K-$500K range.
04
The KX 500 is primarily designed for external gear grinding. Internal gears require specialized grinding machine configurations due to the wheel-workpiece geometry. KAPP NILES offers the KX I series specifically for internal gear grinding applications. If you need both internal and external gear grinding, discuss your requirements with KAPP NILES to determine whether one machine can serve or if dedicated machines are needed.
05
Generating (continuous) grinding uses a threaded grinding wheel that meshes with the gear in a hobbing-like motion — fast and efficient for standard involute gears. Profile grinding uses a formed grinding wheel shaped to match one tooth space, grinding one gap at a time (single-index). Profile grinding is slower but more versatile for non-standard profiles and complex modifications. The KX 500's ability to do both modes on one machine is a significant flexibility advantage.
06
The KX 500 supports diamond roll dressing for generating grinding wheels and single-point diamond dressing for profile grinding wheels. The dressing system is CNC-controlled for repeatable wheel profiles. Both dressable vitrified-bond wheels and non-dressable CBN/diamond wheels are supported. The choice of dressing method and wheel type depends on the gear module, material, and production volume requirements.
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Comparisons
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