Grinding MetalTech Report: September

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Large working envelope
The TX7+ features flexible software and tooling and a large work envelope, making it a capable machine to manufacture complex tools, rotary medical instruments, standard and key hole press punches, and components for medical, aerosapce and automotive industries.

It features an automatic wheel changer that allows for up to eight grinding wheels to be used in one set-up.

C & B Machinery
Clamp bore grinding
The clamp bore grinding machine for micro finishing clamps parts on the ID and rotates them as the grinding wheel (s) plunge feeds. A gauging system re-checks each face for equal stock removal, and an in-process gauge provides accurate size control and SPC capabilities. It is designed with servo controlled precision spindles, and an automatic part transfer from station to station.

Universal cylindrical grinder
The CGP-1224 universal cylindrical grinder is designed with a distance between centres of 600 mm (23.5 in.) with a swing over the table of 320 mm (12.5 mm). Chevalier claims the machine is ergonomically designed for easy operation and high precision. It is built with lightweight, friction-free hydrostatic spindle bearings and is equipped with a ballscrew driven AC digital servo motor. It has a wheelhead repeatability of +/-0.000050 in. (0.001 mm). It is capable of performing different grinding operations, including straight, shoulder, longitudinal, end surface, taper and internal processes.

Grinding small components
The VLC 100 G vertical grinding centre is designed for small chucked components with a maximum diameter of 100 mm. It uses an onboard pick-up system to load itself, and while one workpiece is being machined, the operator or the automation system is putting the raw parts on the conveyor belt. Two grinding spindles (internal and external) can be used to perform different grinding operations or to handle rough and finish work.

Hydrostatic B Axis
The Kellenberger Kel-Varia CNC universal cylindrical grinding machines feature a direct-drive workhead for grinding of large, heavy parts. A torque drive allows heavy parts to be quickly accelerated and braked with zero backlash during bidirectional movements for increased productivity. A large spectrum of parts and a wide range of geometries can be processed using combinations of cylindrical grinding, OD and ID out-of-round grinding, thread grinding and jig grinding all in one set-up. C axis operation allows precise grinding of grooves and satellite and centering bores. 

The (C-axis) option of interpolating the X and C axes make it possible to use the cylindrical grinding machine for non-round shapes such as polygons, free contours and eccentric forms. The rotary encoder with a resolution of 0.00001° is installed directly on the workhead spindle. Jig grinding capability offers a complete part in one setup, an additional process that would have been done on a second grinding machine.

The swiveling hydrostatic, direct drive B axis provides simultaneous interpolation of the X, Z and B axes with a resolution of 0.00002°. This CNC controlled B axis allows complete grinding ofparts in a single set-up. 

There are more than 28 wheelhead configurations to choose from with multiple grinding wheels for external, face and internal grinding. 

KAPP Technologies
Niles ZE 1200 Grinder
The Niles ZE series gear profile grinding machine is designed for precise grinding of external and internal gears with tip diameters from 400 mm to 1,200 mm. The machine comes equipped with a tailstock, a Siemens Sinumerik 840 D CNC control and on-board measuring. The machine can use dressable ceramic tools and non-dressable CBN tools. It takes up a small footprint with the need for special preparation (e.g. isolated and reinforced) for a foundation. It is designed with a wide door opening providing the operator good access to the machine from the shop floor. Hydrostatic guiding in the rotary table and column provides for small travel without a “stick-slip” effect.

5 axis multi-tasking grinder
The G7 i Grinder five axis horizontal machining centre offers a single-platform solution for grinding, drilling and milling of aerospace blades, vanes, turbine disks and other complex grinding applications. Its multifunctional configuration paired with five axis capabilities enables aerospace manufacturers to eliminate setups, work in process, stack-up errors, and fixture costs. It also simplifies the manufacturing process with NC-controlled intermittent dress.

The G7 employs a 12,000 rpm HSK-63A spindle capable of handling tough-to-cut materials, such as Inconel. The machine provides X, Y and Z axis travels of 690 by 650 by 730, respectively, accommodating workpieces with a maximum diameter of 535 mm. This ability enables machining of parts one size larger than the G5. An infinite C axis rotation and maximum B axis rotation of 270° offer full access to three dimensional parts for single setup production capabilities. A two axis Programmable Coolant Nozzle (PCN) lets the G7 accommodate variations in wheel diameter and changes in cutting direction while maintaining ideal coolant flushing conditions. 

Hydrodynamic wheel spindle
The GA-26T grinding machine supports OD grinding in high volume, automated production environments. The T-series machine holds the work stationary while the grinding wheel traverses back and forth. Available in angle and plain head, the design is cost effective for production lines with small to mid-sized parts, claims Okuma. 

The machine can simultaneously dress and load, features a fixed table construction and a compact design. It has an offset radial load equal to one micrometer per 100 kg (.000018 in./100 lb) and a rotating accuracy of 0.01 micrometers (.0000004 in.). The grinder is controlled by the Okuma OSP control and is capable of simultaneous two axis control.

Six-station wheel, nozzle changer
SmartChanger, a six-station wheel and nozzle changer, is an addition to the company’s multi-axis tool grinding machines. It’s designed for grinding specialty and custom rotary cutting tools, modification/regrinding or for continuous production grinding. The six-station wheel changer with HSK50E arbors has been tested for repetitive concentricity of less than two microns. The wheel changer changes wheel packs during automatic tool change without loosing cycle time, claims Rollomatic. 



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