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October 2020

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Redesigned Gear Making Technology and Multifunctional Machine Tool Platform

Bourn & Koch has announced two flagship gear manufacturing machines, the 400H and Fellows 10-4 retrofit, a newly redesigned and re-engineered Blanchard 22AD-42, and a new multifunctional machine tool platform, the MT3. Each of these machines has new features and functions designed for increased productivity and quality.

Bourn & Koch 400H

The Bourn & Koch 400H horizontal gear hobber is designed to provide high quality gears in a compact footprint. The 400H can produce AGMA Class 10 gears on parts up to 406.4 mm in diameter with a standard axial travel of 1,930 mm. A max. 6.4 mm module gear can be cut on the machine.

In recent years, Bourn & Koch has focused on refining the programming software for its gear hobbing machines. The latest iteration of its gear hobbing human machine interface (HMI) allows for users to conversationally program the machine via 19.5" touchscreen interface for entering all gear data and tool data. Up to six surfaces can be programmed on one gear with up to six cuts per surface, allowing for maximum control over the hobbing process. The HMI also features an Expert Mode that allows for even more control over the process for experienced operators.

The 400H has available 5:1 and 12:1 hob heads with six axes of CNC control. The machine comes standard with a programmable CNC tailstock, automatic hob shift and hob swivel. The 400H's work spindle is driven by an integral motor and is compatible with tooling from Barber-Colman gear hobbers, making the upgrade to CNC a less costly endeavor.

Fellows 10-4 Retrofit

"The Fellows 10-4 Retrofit gear shaping machine is an update to modern technology on a classic piece of American machine tool ingenuity," said a company spokesperson. "Bourn & Koch has had a long history of providing high quality new and remanufactured models of Fellows gear shapers. This latest offering to the market provides the same quality that we have become known for in a more compact, maintainable and economical package."

The 10-4 Retrofit features a FANUC 35i CNC control, making effective use of Macro Executor to provide a familiar programming interface for those who have been using Fellows gear shapers for decades. The machine's new guarding package and smaller hydraulic unit reduce the footprint by 16 sq. ft. The machine comes standard with a mechanical guide and T-slot worktable. Additional custom workholding options are available based on application. The machine is now more adjustable via numerous improvements in design. The table infeed and work spindle are now converted over to direct drive design as well, further reducing the number of mechanical components and increasing machine accuracy to produce high quality shaped gears.

Redesigned Blanchard 22AD-42

"Blanchard is a name synonymous with surface grinding. Bourn & Koch's newly redesigned Blanchard 22AD-42 takes the rugged, heavy-duty design of the rotary surface grinder and updates it to today's standards," said the spokesperson.

The new machine comes with a full stainless steel enclosure featuring an automatic roll up door. The new enclosure design is leak proof, allows for easy mist collection and has the potential for automation. One of the most notable features of the new Blanchard 22AD-42 is the power dresser, which allows operators to dress the grinding wheel at a pre-programmed amount with the push of a button. Many upgrades to the machine's design were incorporated as well, including direct drive updates to the grinding spindle and work table, the addition of polymer concrete for vibration damping, a base flushing system to aid in cleanliness and a new Blanchard grinding HMI that is easy to learn and program.

The machine comes standard with a 50 HP spindle motor with the option to upgrade to 100 HP, effectively doubling the machine's productivity.

MT3 Multifunctional Machine Tool

The newest addition to Bourn & Koch's line-up of American-made machine tools is the MT3, a multifunctional machine tool platform capable of performing grinding, milling, turning and drilling/tapping machining operations on a workpiece in one set-up. The machine is primarily designed as a value engineered vertical cylindrical grinder, supplementing Bourn & Koch's current VBG offering in that arena.

The MT3 comes standard with a 42" diameter T-slot worktable and precision grinding spindle with an HSK-50A connection. The machine's spindles are interchangeable via the innovative HBK-200 clamping system, allowing for the right spindle to be used for the application. The machine will be equipped with custom workholding from Advanced Machine & Engineering to manufacture a hob spindle cartridge from one of Bourn & Koch's 400H hobbers in one set-up.

The machine is expandable from a vertical grinder to a "one and done" machine tool system, incorporating various spindles and tools into an added optional cell that are automatically changed via FANUC R2000 robot and Bourn & Koch' Alien Claw end of arm tooling, allowing for quick change of most tools and spindles. A spindle rack and disc style tool changer are incorporated into the cell to manage the various tools and spindles for the required operations.

The machine is programmed via combination of Bourn & Koch's grinding HMI and FANUC Manual Guide-i, employing a FANUC 0i CNC control for all machine functions. A virtual Y-axis allows for the machine to perform standard milling functions. The MT3 spindle features a FANUC Beta-il 160M motor capable of producing 30 kW from 2,000-10,000 RPM, providing ample power and range for a wide variety of grinding, milling and drilling/tapping applications.

This machine platform is modular with future plans for a vertical gear hobbing machine and a 5-axis machining center in the works.

Virtual demonstrations are currently available.

For more information contact:

Bourn & Koch Inc.

2500 Kishwaukee Street

Rockford, IL 61104


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