Category Archives: Grinding

New Holroyd cutter grinding centre introduced for larger diameter helical cutting tools

A newly developed ‘large diameter’ CNC cutter grinding machine from Holroyd Precision Ltd is all set to bring considerable advantages to organisations that wish to achieve even greater levels of accuracy and repeatability when finish milling some of the world’s largest helical rotors.

blogCutter grinding

Called the CS700E Tool Management Centre, the new machine has been designed especially for the grinding of high-accuracy profile forms on finish milling cutters of up to 700mm in diameter, and follows on from the company’s highly successful CS500E (500mm max. diameter) model.

Generating considerable interest
“The new CS700E machine is generating considerable interest,” comments Holroyd Sales Manager, Mark Curran. “Indeed, a major compressor manufacturer that has only recently purchased its second Holroyd 8EX rotor milling machine (for producing rotors of up to 850mm in diameter), has already placed an order for a CS700E.”

Complete control of cutting tool technology
“The accuracy of any helical screw form relates directly to the accuracy of the cutting tool that is used to create it,” continues Mark Curran. “Through the development of the CS700E Tool Management Centre, we are enabling producers of larger helical components to benefit from complete control of all aspects of the cutting tools they use. The CS700E produces high accuracy profile forms on a wide range of tool materials, from traditional high-speed steel, to exotic materials such as carbide and ‘AS’ finish machining systems.”

Automatic dressing capability
The CS700E Tool Management Centre incorporates automatic dressing stations to ensure optimum integrity of the grinding wheel at all times. The stations are equipped to dress aluminium oxide, CBN and diamond grinding wheels, while use of HSK-A160 arbors (as fitted to 8EX rotor milling machines), enable rapid wheel changeover times and further enhance accuracy.

Advanced touch screen programming
At the heart of the CS700E is Holroyd’s user-friendly advanced touch screen programming system. This provides complete control over production accuracies, as well as invaluable on-screen modification of profile forms for the rapid evaluation of new profile shapes during the development and prototyping stages. Profile modifications are easily made thanks to the menu-driven system, which provides control of the cutting profile, with on-screen modification of profiles.

Automatic touch probing
Automatic touch probing of the tool profile during the grinding cycle is another major benefit provided by the CS700E. Following probing, the actual tool profile is graphically superimposed over the theoretical profile and displayed within user-defined tolerance bands to ensure that all cutter blades are ground within tightly controlled limits. Indexing and multi-pass grinding/trimming cycles are also fully automated.

HSK-A160 arbor
Cutters with up to 29 blades can be sharpened on the CS700E Tool Management Centre. The cutter indexing process is carried out automatically. The cutter is located on an HSK-A160 arbor for precise positioning on the 8EX rotor milling machine, or on other rotor millers employing the same arbor. The maximum profile height is 120mm.

Intelligent design features
Designed and built at Holroyd’s UK-based machine tool development centre, the CS700E features an ergonomic design, a solid cast iron base for outstanding rigidity and excellent thermal stability. Total machine guarding offers flood-cooling capability. There are large sliding doors for ease of set up and separate rear/side access for workpiece loading. The CS700E is also equipped with a recirculating oil mist removal system.

www.holroyd.com

Great interest at EMO

Many customers visited the UNITED GRINDING Group at the world’s largest machine tool trade fair.

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Giancarlo Kessler, the Swiss ambassador to Italy, together with a delegation of the Swiss industry association SWISSMEM in conversation with United Grinding Group CEO Stephan Nell.

In parallel with the EXPO world exhibition the largest trade fair for machine tools, EMO, took place in October 2015 in Milan, Italy. Under the slogan “Let’s build the Future”, 1600 compa-nies from 42 countries presented visitors with new and proven products from the world of metalworking.

The UNITED GRINDING Group presented 15 machines on its exhibition stand, including three world innovations with the STUDER S121, the WALTER HELITRONIC VISION 400L and the EWAG LASER LINE PRECISION. The Group also provided an insight into its range of product-supporting services on a Customer Care stand.

More than 5000 visitors from 50 countries took the opportunity to find out about the Group’s innovative ability. These also included Giancarlo Kessler, the Swiss ambassador to Italy, who visited the stand with a delegation of the Swiss industry association SWISSMEM. The orders generated at the trade fair by the companies of the UNITED GRINDING Group also far ex-ceeded expectations.

“We are very pleased with how the trade fair went. In addition EMO is always an inspiring experience, where it’s easy to detect the mood in the industry”, said Stephan Nell, CEO of the UNITED GRINDING Group. The next EMO will take place in Hannover from 18 to 23 September 2017.

www.grinding.ch

Performance, flexibility and cost effectiveness

Rollomatic presented its GrindSmart 528XF for the first time at GrindTec 2014 in Augsburg. Since then, a number of tool manufacturers all over the world are using this innovative and flexible tool grinding machine, which has established an outstanding new benchmark thanks to its innovative design and precision. One major advantage of the GrindSmart 528XF over other machines available on the market is that it has the capability to grind extremely long drilling tools with diameters of less than 3 mm.

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GrindSmart®528XF allows tool manufacturers to grind drilling tools with an extreme length-to-diameter ratio of 200 × D. Photos: Rollomatic SA.

With the GrindSmart 528XF, Rollomatic, the Swiss grinding machine manufacturer from Le Landeron, is taking the process of grinding drills with extreme length-to-diameter ratios to a completely new level. Not long after GrindTec 2014, the leading trade fair for grinding technology, the first customers worldwide were won over by its outstanding performance. The GrindSmart 528XF has been designed for grinding tools with diameters of 0.5 to 12 mm and thanks to a new, innovative guiding system, even a length of 200 × D is possible –with a repeatability accuracy of less than 2 µm!

Extreme dimensions are no problem!
Small drill diameters require extremely small coolant holes which must be detected by the machine. “Very often super long drill are designed with mini coolant holes,” explains Philippe Uebelhart, Managing Director at Rollomatic SA. “For this purpose, a CCD camera that can detect coolant holes with a diameter as small as 0.05 mm can be easily integrated in the GrindSmart 528XF.”

With this new machine model, tool manufacturers will also benefit from a wide-ranging, flexible selection of tools that can be ground. “Whether we’re dealing with high-performance drilling tools or standard and specialty milling cutters including those with stepped-down necks, the GrindSmart 528XF is the solution and it offers a unique selling point on the market ,” says Philippe Uebelhart.

The GrindSmart 528XF is fitted as standard with a compact tool loader and loading magazine for up to 1,000 workpieces as well as with a compact grinding wheel changer that can accommodate up to six wheel packs. In addition, to save time the machine can change the wheel packs and the tools simultaneously. Philippe Uebelhart “The many unique selling points of this machine will help our customers to safeguard their competitive edge on the tool market.”

Rollomatic SA
Z.I. Prés-Bugnons
2525 Le Landeron
Switzerland

Damien Wunderlin
Phone: +41 32 7521700
Fax: +41 32 7521717
[email protected]
www.rollomaticsa.com

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…brought to you by Eurotec-Online.com

Linear motor tool grinders

After much anticipation ANCA launched the new FX Linear range of CNC tool grinders at the Prodex exhibition in Basel in November on the Springmann booth. The range includes 3 models and represents not just a completely new design of machine and colour for ANCA, but also a significant number of new technologies – including cylindrical linear motors for the first time.

The Linear FX7 is the premium of the FX range of tool grinders. It offers exceptional benefits of profitability, flexibility and precision, all with a wide work envelope and a small floor area.
The Linear FX7 is the premium of the FX range of tool grinders. It offers exceptional benefits of profitability, flexibility and precision, all with a wide work envelope and a small floor area.

The models in the range include the FX3 Linear – an entry level model, FX5 Linear which replaces the existing FastGrind machine and the FX7 Linear which replaces existing GX7/RX7 machines.

High-end solution
The FX Linear is a compact machine with a large working envelope. The grinding wheel is positioned on the C-axis centreline which together with the compact design reduces the effects of temperature influence on machine elements. This assists in the thermal stability and rigidity of the machine. The FX machine range includes new generation RN33 software, latest generation AMD5x control system and a high performance CNC.

Linear motor for better results
The FX Linear machines use LinX Linear Motors for accurate axis motion. These have been designed for a lifetime of operation in harsh grinding environments. Their design is fully sealed to IP67 and is impervious to the effects of grinding contamination. With no mechanical moving parts there is no loss of machine accuracy over time due to wear. Higher axis speed and acceleration provides reduced cycle times, resulting in productivity increases for tool manufacturers. High levels of machine precision and performance are achieved, enabling superior tool accuracy and surface finish.

Springmann SA
Machines-Outils
Route des Falaises 110
CH-2008 Neuchâtel
Tel 032 729 11 22
Fax 032 725 01 01
[email protected]
www.springmann.ch

You can read all the recent articles published on Eurotec about Springmann here.

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…brought to you by Eurotec-Online.com

Compact All-rounder at AMB

In grinding technology, the trend is still full-sequence machining. Especially with workpieces with complex geometries that need to be finished on grinding machines with high degrees of freedom, this reduces queue time and work-in-process inventory. At the same time, less re-chucking means more precision. High quality production parts and tools for milling, indexable inserts and step drills are all examples of this.

Multigrind® CU: Only 1600 millimeters wide but full of concentrated HAAS grinding technology.
Multigrind® CU: Only 1600 millimeters wide but full of concentrated HAAS grinding technology.

At AMB, HAAS Schleifmaschinen GmbH in Trossingen, Germany is presenting the new, compact all-rounder that completes its machine series: Multigrind® CU.  To be discovered till tomorrow in Stuttgart.

New generation of machines
While the largest machine in the HAAS series, Multigrind® CB, can accommodate grinding wheels with diameters of up to 300 mm and pro-cess workpieces with diameters of 340 mm to 500 mm, the medium-sized HAAS machine, Multigrind® CA, was engineered for grinding wheels of up to 250 mm and workpieces of up to 260 mm. Multigrind® CU accommodates wheels of up to 225 mm and workpieces of up to 180 mm.

CU takes up half the space of its predecessor
The new CU’s width is 50 mm less than its predecessor, the AF machine. Since the coolant system and its two large tanks are integrated into the machine bed, the new model requires less than half the space of the old AF. The robot function was external to the machine in the past, but the HAAS developers have successfully integrated it into the CU. A masterful solution to customers’ need for compactness.

New design
The compact design also required a new axis concept, so the developers came up with a special solution. “At HAAS, we don’t focus on making or buying what we need cheaper,” said Hans-Dieter Braun to explain the HAAS philosophy. As the head of Development and Engineering, he is primarily responsible for developing the new machine. “We develop intelligent concepts that allow us to save on axes by means of multiple axis configuration without any negative impact on performance or functionali-ty, for example,” he added. The new machine’s axis arrangement follows the classical gantry principle, in which the X-, Y- and Z-axes are positioned at the top the Y-axis running along the side of the machine bed. Both the A-axis for rotating the workpiece and the machine table are attached to the C-axis. The C-axis also rotates the circular tool magazine, which is installed under the table. The part gripper that can load the machine from four integrated pallets is installed on the Z-axis so that it can travel in the X, Y and Z directions without any additional axes.
HAAS Schleifmaschinen GmbH plans to ship the first Multigrind® CU machines during the first six months of 2015.

The new patent pending HAAS tool changer below the table.
The new patent pending HAAS tool changer below the table.
Head of Engineering Hans-Dieter Braun is responsible for developing the new machine.
Head of Engineering Hans-Dieter Braun is responsible for developing the new machine.

At AMB, the HAAS booth in Hall 8, B71 will feature Multigrind® CU in the process of manufacturing an indexable insert. The “little sister” will demonstrate how universally applicable, highly flexible machines can contribute to boosting customer performance.

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Haas Schleifmaschinen GmbH 
Phone: + 49-7425-337-1859
Fax: + 49-7425-3371-50
[email protected]
http://www.haas-schleifmaschinen.de/en/

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…brought to you by Eurotec-Online.com

Higher productivity with metal bonds – but how do you dress them?

The integrated electro-discharge dressing technology WireDress® opens up brand new possibilities for grinding with metal-bonded grinding wheels and drastically cuts auxiliary times. According to Fritz Studer AG, it has been possible to increase grinding power in the grinding process by 30% and reduce grinding wheel wear by 70% in comparison with ceramic and resin bonds. Grinding wheels with very intricate con-tours can also be dressed.

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Metal-bonded grinding wheels offer particular benefits when machining difficult-to-machine materials such as high-alloy, hardened steels, tungsten carbides and ceramics. Such wheels offer superior dimensional and thermal stability and dissipate the heat produced by grinding more quickly. The grinding wheels consist of a sintered metal matrix with embedded diamond or CBN grains. They achieve very high removal rates, because the metal bond holds the abrasive grains very well.

The WireDress® technology allows free geometries and intricate contours with internal radii of 0.05 millimeters and external radii of 0.2 millimeters.
The WireDress® technology allows free geometries and intricate contours with internal radii of 0.05 millimeters and external radii of 0.2 millimeters.

Particularly effective: electro-discharge dressing
However, in addition to the advantages of metal bonds there are also disadvantages, as dressing these wheels involves greater expense and effort. Dressing with silicon carbide wheels, for example, often does not achieve satisfactory results, and intricate profiles are not possible. In addition, the grains are difficult to mechanically extract from the metal matrix and are sometimes damaged in the process. It is also not possible to create the high grain protrusion heights necessary to achieve the full efficiency of such grinding wheels. The extremely hard abrasive grains of metal-bonded grinding wheels also lead to heavy wear of the dressing wheels, which results in certain limitations in terms of geometrical precision.

Integrated dressing with wire erosion
With Studer-WireDress® Fritz Studer AG brings a brand new dressing device to the market, which uses the wire erosion principle and is completely integrated into the grinding machine and its control system. The grinding wheel never has to be removed for dressing. Thanks to the high proportion of grain space, the wheel is very free cutting. This allows much more grinding oil to enter the grinding slot, enabling a high feed with less workpiece deflection. The dressing intervals can be longer. However, as the dressing process requires so little expense and effort, very complex contours can also be dressed at shorter intervals. As the user can fully utilize the advantages of metal-bonded grinding wheels during rough and fine grinding, the Studer-WireDress® dressing system pays for itself in less than a year.

The dressing unit is a wire erosion machine in principle. A new development from STUDER for dressing metal-bonded diamond and CBN grinding wheels directly in the grinding machine.
The dressing unit is a wire erosion machine in principle. A new development from Studer for dressing metal-bonded diamond and CBN grinding wheels directly in the grinding machine.
Example of an MD25 grinding wheel Ø400 mm, complex profile dressed with WireDress® .
Example of an MD25 grinding wheel Ø400 mm, complex profile dressed with WireDress®.

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Fritz Studer AG
CH-3602 Thun
Tel. +41 33 439 11 11
Fax +41 33 439 11 12
[email protected]
www.Studer.com

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…brought to you by Eurotec-Online.com

 

 

New internal cylindrical grinding machine for short and long workpieces.

The new S141 from Studer has been redesigned from the ground up. However, the development also incorporates the know-how from many decades of grinding experience and consolidated state-of-the-art engineering knowledge. In addition to long-lasting and reliable quality and precision, the use of both cutting-edge and proven technologies, optimal ergonomics and ease of use were also important goals.

The machine grinds inside diameters up to 250 mm and can handle a workpiece length of 1300 mm.
The machine grinds inside diameters up to 250 mm and can handle a workpiece length of 1300 mm.

The machine’s ergonomic design and user friendliness are evident at first glance. Two generous sliding doors create optimal accessibility for both workpiece and grinding wheel change. Short changeover times and quick reprogramming of the control help to reduce auxiliary times, making the machine interesting for the production of individual components as well as small and large batches.  The series is available in different design lengths, for workpieces with maximum lengths of 300, 700 and 1300 mm. The S141 is the ideal machine for grinding chuck components, spindle shafts, spindle hous-ings, rotor shafts or axes. Many workpieces are in the areas of machine tools, drive elements, aerospace and toolmaking.

Highlights of the S141

  • The machine bed, comprising patented Granitan® S103 mineral casting with excellent damping characteristics, ensures outstanding surface quality of the ground parts.
  • The grinding spindle turret has four grinding spindles, including a maximum of two external grinding spindles. Internal grinding quills of lengths up to 265 millimeters can be used.
  • The workpiece table, for workpiece lengths of 300, 700 and 1300 mm depending on the machine, can be automatically swiveled from -10° to +20° via the machine control system for axis-parallel grinding of tapers.
  • The workhead can be driven directly or via a belt, as required.
  • The robust steady-rest specially designed for internal grinding enables simple setup and universal use.
  • The machine can be equipped with up to two pivoting dressing units with fixed or rotating dressing tools.
  • Two different intuitive operating systems, StuderWIN and StuderSIM, are available. Both operating systems are suitable for a wide variety of internal grinding applications and enable reliable programming of all basic cycles for grinding, dressing and process-supporting measurement.

Fritz Studer AG
CH-3602 Thun
Tel. +41 33 439 11 11
Fax +41 33 439 11 12
[email protected]
www.Studer.com