Liebherr LGe 500

$800,000 - $1,200,000 Updated 2026-03-15

Key Specifications

Max Workpiece ⌀

500 mm (19.7 in)

max module

8 mm

max workpiece weight

30 kg (66 lb)

max stack height

350 mm (13.8 in)

grinding spindle speed

Up to 10,000 rpm

grinding process

Generating grinding (continuous generating); optional profile grinding

Overview

The Liebherr LGe 500 is a CNC gear grinding machine designed for high-precision finishing of cylindrical gears up to 500 mm (19.7 in) in diameter and module 8 mm. As part of Liebherr's gear technology division based in Kempten, Germany, the LGe 500 represents the mid-range of their generating gear grinding lineup — large enough for automotive transmission gears, industrial gearbox components, and aerospace reduction gears, while maintaining the accuracy and surface finish quality required for noise-critical applications. Gear grinding is the final finishing operation that determines gear quality class, and the LGe 500 consistently achieves DIN quality class 2-4.

The machine uses generating grinding (continuous generating) with dressable or CBN grinding worms as the primary process, combined with an optional profile grinding mode for non-standard tooth forms and internal features. The high-speed grinding spindle operates at up to 10,000 rpm, enabling aggressive stock removal during roughing passes and fine finishing cuts that achieve surface roughness values below Ra 0.3 µm. Liebherr's twist-free grinding technology controls the flank surface topology to minimize transmission error and gear whine — a critical requirement for EV powertrains where gear noise is no longer masked by engine sound.

The integrated automation concept features a ring loader that handles workpiece loading and unloading with cycle times as short as 3-5 seconds for the part change, maximizing spindle utilization. The machine accommodates workpiece weights up to 30 kg (66 lb) and stack heights up to 350 mm (13.8 in), covering the majority of automotive and industrial gear sizes. An optional in-process measurement system using Klingelnberg or similar gear inspection technology provides closed-loop correction between the grinding process and actual gear quality.

Liebherr's proprietary LHGearTec software handles the complete gear grinding process from parameter calculation through topological modifications. The software includes gear design databases, grinding wheel specification tools, and process simulation that predicts surface finish and cycle time before cutting metal. The Siemens 840D sl CNC platform provides the underlying motion control.

New Liebherr LGe 500 machines are priced between $800,000 and $1,200,000 depending on automation level, measurement integration, and tooling package. This positions the LGe 500 against the Reishauer RZ 260, Kapp Niles KX 260, and Gleason 260GMS in the mid-size gear grinding segment.

Full Specifications

Parameter	Value
Max Workpiece Diameter	500 mm (19.7 in)
Max Module	8 mm
Max Workpiece Weight	30 kg (66 lb)
Max Stack Height	350 mm (13.8 in)
Grinding Spindle Speed	Up to 10,000 rpm
Grinding Process	Generating grinding (continuous generating); optional profile grinding
Grinding Wheel Diameter	Up to 300 mm (11.8 in)
Gear Quality	DIN class 2-4 achievable
Surface Finish	Ra < 0.3 µm
Dressing System	Integrated CNC dressing with diamond rolls
Automation	Ring loader with 3-5 second part change
CNC Control	Siemens Sinumerik 840D sl with LHGearTec software
Machine Weight	Approx. 14,000 kg (30,865 lb)
Measurement	Optional in-process gear measurement

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

Strengths & Limitations

Strengths

500 mm workpiece diameter capacity with module 8 covers the full range of automotive transmission gears and medium industrial gears in a single machine
DIN quality class 2-4 capability with Ra < 0.3 µm surface finish meets the most demanding noise and accuracy requirements including EV powertrains
Twist-free grinding technology controls flank topology to minimize transmission error — critical for the low-noise requirements of electric vehicle gear sets
Ring loader automation achieves 3-5 second part changes, maximizing spindle utilization and enabling true high-volume production grinding
LHGearTec software provides complete process planning, simulation, and topological modification in a single integrated package
Optional in-process measurement with closed-loop correction ensures every gear meets spec without offline inspection delays

Limitations

At $800K-$1.2M, the LGe 500 is a substantial investment justified only by consistent gear grinding volume — low-volume shops should consider outsourcing
Gear grinding requires highly trained operators and application engineers for process optimization — the learning curve is steep compared to general machining
500 mm maximum diameter excludes large industrial gears found in wind turbines, mining, and heavy equipment — those require the LGe 700 or larger
CBN grinding wheel costs are significant ($2,000-$8,000 per wheel), though the per-part cost advantage over dressable wheels increases with volume

Best For

Automotive transmission manufacturers grinding helical and spur gears for passenger vehicle and light truck powertrains Electric vehicle powertrain producers requiring twist-free ground gears with ultra-low noise characteristics Industrial gearbox manufacturers producing reduction gears, planetary sets, and pinions up to 500mm diameter Aerospace gear manufacturers grinding high-precision reduction gears for helicopter transmissions and turbine accessory drives Contract gear grinding shops needing a versatile platform that handles both automotive volumes and diverse industrial gear work

Frequently Asked Questions

01 What is twist-free grinding and why is it important for EVs?

Twist-free grinding is a process control technology that manages the lead crowning and flank topology during generating grinding to eliminate the helical twist pattern that naturally occurs in the generating process. This twist creates a specific transmission error pattern that produces gear whine. In internal combustion vehicles, engine noise masks this whine. In EVs with no engine noise, gear whine becomes the dominant sound, making twist-free grinding essential for acceptable NVH (noise, vibration, harshness) performance.

02 What is the difference between generating grinding and profile grinding?

Generating grinding uses a threaded grinding worm that meshes with the gear in a continuous rolling motion — it's fast and ideal for standard involute tooth profiles. Profile grinding uses a shaped grinding wheel that grinds one tooth space at a time — it's slower but can produce non-standard tooth forms, modifications, and internal gears. The LGe 500 primarily uses generating grinding for production but offers profile grinding capability for special tooth forms.

03 How does the Liebherr LGe 500 compare to the Reishauer RZ 260?

Both are top-tier generating gear grinding machines. The Reishauer RZ 260 is slightly more focused on high-volume automotive production with its dual-spindle option and exceptionally fast part change times. The LGe 500 offers a larger 500mm diameter capacity versus the RZ 260's ~260mm, making it more versatile for industrial and aerospace gears alongside automotive work. Liebherr's LHGearTec software is highly regarded for process development. Pricing is comparable.

04 What gear quality classes can the LGe 500 achieve?

The LGe 500 routinely achieves DIN quality class 3-4 in production conditions, with class 2 achievable under optimal conditions with well-controlled blanks. For reference, DIN class 4 is typical for automotive transmission gears, class 3 for precision industrial gears, and class 2 for instrument and aerospace gears. Actual achievable quality depends on blank quality, fixturing, grinding wheel condition, and environmental temperature stability.

05 What maintenance does the LGe 500 require?

Key maintenance items include grinding spindle bearing inspection (annually), dressing system calibration (quarterly), coolant system maintenance (monthly), filter changes, and ring loader mechanism service. Grinding wheel dressing is part of normal operation, not maintenance. Liebherr offers service contracts ranging from basic phone support to comprehensive on-site preventive maintenance. Budget $40,000-$70,000 annually for service contracts and consumables.

06 Can the LGe 500 grind worm gears?

The LGe 500 is designed primarily for cylindrical spur and helical gears using the generating grinding process. Worm gears require different kinematics and are typically ground on dedicated worm grinding machines. Liebherr does offer worm gear grinding solutions in their broader product line. For shops needing both cylindrical and worm gear grinding, separate dedicated machines are the standard approach.