Klingelnberg P 100

$2,000,000 - $3,000,000+ Updated 2026-03-17

Key Specifications

Max Workpiece ⌀

1,000 mm (39.37 in)

max module

25 mm

min module

3 mm

max face width

150 mm (5.91 in)

bevel gear system

Palloid and Cyclo-Palloid

grinding method

Continuous generating bevel gear grinding

Overview

The Klingelnberg P 100 is a large-capacity CNC bevel gear grinding machine designed for precision hard-fine finishing of Palloid and Cyclo-Palloid spiral bevel and hypoid gears up to 1,000 mm (39.37 in) in diameter. Manufactured by Klingelnberg GmbH in Hückeswagen, Germany, the P 100 serves the heaviest segments of the bevel gear market — large industrial drives, mining equipment gearboxes, heavy commercial vehicle drive axles, marine propulsion systems, and large wind turbine pitch and yaw drives — where gear quality, load capacity, and surface integrity on large, high-value bevel gear sets are absolute requirements. As the largest model in the Klingelnberg P series grinding range above the P 65, the P 100 provides a grinding solution for bevel gears that exceed the capacity of most competitive grinding platforms.

The P 100 employs Klingelnberg's Cyclo-Palloid continuous generating bevel gear grinding method, using a dressable grinding wheel in a synchronized generating motion with the workpiece to refine the tooth surface after case hardening. The generating grinding process on the P 100 corrects hardening distortions, achieves tight profile and lead tolerances (DIN 1–4 / AGMA 12–14), and produces smooth tooth surfaces (Ra < 0.6 µm) essential for the fatigue life, efficiency, and noise performance of large, heavily loaded bevel gearsets. Klingelnberg's KIMOS (Klingelnberg Integrated Manufacturing and Optimization System) controls the entire grinding workflow, from ease-off design and contact pattern simulation through NC program generation and closed-loop quality correction with Klingelnberg's large bevel gear measuring centers.

The P 100 is built on an extremely rigid, thermally compensated machine base sized for 1,000 mm workpieces and the corresponding machine forces. The workpiece table accommodates ring gears with a maximum external diameter of 1,000 mm and a maximum table load of approximately 5,000 kg, enabling in-place machining of large, heavy bevel ring gears without disassembly from their mounting fixtures. The grinding spindle is direct-driven at speeds up to 4,000 RPM with active thermal management to prevent thermal expansion from affecting tooth surface geometry during long grinding cycles on large, multi-tooth gearsets. The on-machine CNC diamond dressing system reshapes the grinding wheel profile to implement ease-off topography corrections defined by KIMOS, including complex modifications to control contact pattern position under operating load and misalignment.

Klingelnberg has designed the P 100 with Industry 4.0 connectivity at its core. The machine connects to Klingelnberg's Closed Loop manufacturing management system via KIMOS, sharing measurement data, process parameters, correction histories, and production statistics with enterprise-level quality management and production planning systems. OPC-UA and MTConnect protocols enable integration with customer MES and SCADA platforms for real-time monitoring of grinding cycle progress, wheel wear status, and quality trends across multi-machine production environments. For large industrial customers operating multiple P 100 machines in parallel, Klingelnberg provides fleet monitoring and remote diagnostics capabilities through its global service infrastructure.

The P 100 occupies a market niche with few direct competitors — large bevel gear grinders of this capacity are produced by only a handful of companies globally. Gleason offers the Phoenix 650G and Phoenix 280G for smaller bevel gears, and Oerlikon's G 60 addresses a portion of this range. For 800–1,000 mm diameter bevel gears, the P 100 has limited direct competition from comparable CNC bevel gear grinding platforms. New P 100 machines are priced from $2,000,000 to $3,000,000+ depending on configuration, automation, and metrology integration — reflecting the engineering complexity, structural scale, and specialized manufacturing required for machines of this class. The P 100 is procured by companies with substantial large bevel gear production requirements who can amortize this investment across a consistent volume of high-value gear sets.

Full Specifications

Parameter	Value
Max Workpiece Diameter	1,000 mm (39.37 in)
Max Module	25 mm
Min Module	3 mm
Max Face Width	150 mm (5.91 in)
Bevel Gear System	Palloid and Cyclo-Palloid
Grinding Method	Continuous generating bevel gear grinding
Grinding Spindle Speed	Up to 4,000 RPM
Spindle Drive	Direct-drive grinding spindle
Table Diameter	1,000 mm (39.37 in)
Max Table Load	5,000 kg (11,023 lb)
Dressing	On-machine CNC diamond dressing
Workpiece Types	Large spiral bevel and hypoid ring gears and pinions
Axes	7 CNC axes
CNC Control	Siemens SINUMERIK with KIMOS
Machine Weight	45,000 kg (99,208 lb)
Gear Quality	DIN 1–4 / AGMA 12–14

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

Strengths & Limitations

Strengths

1,000 mm maximum workpiece diameter and 5,000 kg table load provide one of the largest CNC bevel gear grinding capacities available, serving large industrial, mining, marine, and wind turbine bevel gear applications with few alternatives
Klingelnberg KIMOS closed-loop system integrates ease-off design, grinding programming, and inspection data for automatic correction of large, complex bevel gear sets — essential for maintaining quality on high-value workpieces where scrap is not acceptable
Continuous generating grinding method produces superior tooth surface consistency across the full face width compared to plunge grinding methods, important for uniform load distribution in large, heavily loaded bevel gearsets
On-machine CNC diamond dressing enables full topological modifications including crowning, bias correction, and pressure angle adjustments, allowing the P 100 to achieve specified contact patterns on large industrial gearsets without repeated trial-and-error iterations
Industry 4.0 connectivity via KIMOS, OPC-UA, and MTConnect supports fleet monitoring and integration with enterprise manufacturing systems, valuable for large industrial customers managing multiple large bevel gear production machines
Klingelnberg's specialization in bevel gear technology across cutting, grinding, and measurement provides unmatched application engineering depth for large bevel gear development and production challenges

Limitations

At $2,000,000–$3,000,000+, the P 100 is accessible only to companies with substantial large bevel gear production volume and capital resources — it is not a general-purpose machine or an entry-level bevel gear investment
45,000 kg machine weight requires heavy-duty foundation engineering with reinforced concrete pads and crane access, adding significant facility preparation costs to the machine purchase cost
Klingelnberg's Cyclo-Palloid technology ecosystem creates complete dependency on Klingelnberg for cutters, grinding tooling, software support, and machine service — shops using Gleason face-hobbing systems cannot share tooling or software with the P 100

Best For

Large industrial gearbox manufacturers grinding spiral bevel sets for cement mill drives, large conveyor drives, sugar mill drives, and heavy process industry right-angle gearboxes with gear diameters exceeding 600 mm Mining and extraction equipment manufacturers grinding large bevel gear sets for grinding mill drives, kilns, excavator final drives, and large hoisting and winding machines Marine and offshore gearbox producers grinding large bevel gear sets for offshore crane drives, thruster angular drives, and specialized marine reduction gearboxes Heavy commercial vehicle and off-highway machinery manufacturers grinding large drive axle bevel gears, transfer case bevel sets, and large differential gears for trucks, buses, and heavy construction machines

Frequently Asked Questions

01 What is the maximum bevel gear size the Klingelnberg P 100 can grind?

The P 100 grinds bevel gears up to 1,000 mm (39.37 in) in maximum external diameter with a maximum module of 25 mm and maximum face width of 150 mm. The workpiece table supports loads up to 5,000 kg. This capacity covers the large spiral bevel gears used in heavy industrial drives, mining equipment, large marine drives, and heavy commercial vehicle axles. Bevel gears exceeding 1,000 mm diameter are extremely rare and are typically processed on bespoke custom grinding equipment or large universal gear grinding machines with special fixturing.

02 How does the P 100 differ from the smaller P 40 and P 65 in the Klingelnberg range?

The Klingelnberg P series covers bevel gear grinding from small automotive gears up to large industrial gears. The P 26G handles gears to approximately 260 mm; the P 40 covers up to 400 mm; the P 65 covers up to 650 mm; the P 100 covers up to 1,000 mm. All use the same KIMOS software platform and Cyclo-Palloid grinding technology, and all support the same closed-loop quality system. The P 100 is physically much larger (45,000 kg vs. 14,000 kg for the P 40), substantially more expensive, and requires more elaborate facility preparation. Application engineering for large gears on the P 100 is also more complex due to the scale of the workpieces and forces involved.

03 Can the P 100 grind hypoid gears as well as straight and spiral bevel gears?

Yes, the P 100 is capable of grinding hypoid gears — bevel gears where the pinion axis is offset from the ring gear axis. Hypoid geometry requires additional machine axis adjustments to achieve the correct tooth form and ease-off on both the ring gear and pinion, with different settings for each member of the hypoid set. KIMOS handles the hypoid geometry calculations automatically from the design parameters. Large hypoid gears are used in automotive truck and bus drive axles and in some industrial right-angle drives requiring compact layout with offset axes.

04 What is the typical cycle time for grinding a large bevel gear on the P 100?

Cycle times on the P 100 are highly variable depending on the number of teeth, module, face width, material hardness, stock removal, and ease-off complexity. A large industrial bevel ring gear with 60 teeth, module 20, and 130 mm face width may require 4–12 hours of grinding time per part, depending on the stock removal and quality requirements. The high cost per part of large bevel gears justifies these long grinding cycles; the priority is quality and avoiding scrap rather than minimizing cycle time. Wheel dressing adds to total machine time for complex ease-off profiles requiring multiple dress passes.

05 What kind of foundation is required for the P 100?

The P 100's 45,000 kg mass requires a heavy reinforced concrete foundation designed by a structural engineer specifically for the machine load and dynamic forces during grinding. A typical P 100 foundation requires a concrete pad 400–600 mm thick with reinforcing, extending beyond the machine footprint, isolated from the surrounding factory floor with expansion joints to prevent vibration transmission. Overhead crane access rated for at least 5,000 kg is required for workpiece loading and unloading. Temperature-controlled installation environment (typically 20°C ±2°C) is recommended for achieving rated machine accuracy.