grindstar - mmt productivity · replace turning with grinding grindstar. 1,0 2,0 3,0 4,0 5,0 6,0 2...
TRANSCRIPT
Replace turning with grinding
GRINDSTAR
1,0 2,0 3,0 4,0 5,0 6,0
JUNKER · GRINDSTAR2
GRINDSTAR – more efficient, faster, more accurate
2.2 sec.: Cutting 5.1 sec.: Profiling 6.9 sec.: Ejecting
Grinding
Time per part: 6.9 sec.
1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0 11,0 12,0 13,0 14,0 15,0 16,0 17,0 18,0
3JUNKER · GRINDSTAR
High-speed plunge grinding as an economical alternative to turning
GRINDSTAR attains extremely fast cycle times. This new grinding me-
thod can be used with either CBN or diamond abrasives resulting in
major savings, especially when used in mass production. The machi-
ne is equipped with an innovative new coolant system which allows
for tool live of up to 6 month. The machine availability is greater
than 96%.
Grinding process
This machine combines two different technologies – plunge-cut
grinding / profiling and separation / longitudinal grinding. The major
synergy effect lies in the combination of both technologies in a sin-
gle clamping. For efficient grinding of smaller series, it’s also possi-
ble to group together similar parts (or so-called workpiece families.)
This is done by combining several profiles onto one grinding wheel.
Another benefit to this strategy is that the life of the wheel is multi-
plied by the number of profiles on it.
3.5 sec.: Cut-off 9.1 sec.: Pre-turning 18.1 sec.: Profiling with parting plates
The GRINDSTAR machine concept replaces turning with dress-free, high-speed plunge
grinding. Resulting in big savings, especially when applied in mass production.
• Low part costs for batch sizes of 20,000 or more
• Long tool live for process reliability
• Parts free of cut-off burrs
• No clamping marks
• Fast cycle times with plunge grinding of the entire
contour
• Processing of exotic materials
• Machine availability > 96 %
Customer benefits
GRINDSTAR:Workpieces free of cut-off
burrs and clamp marks
Turning lathes:Require additional finishing for
cut-off burrs
Time per part: 18.8 sec.
Turning
t e c h n o l o g y
100
90
80
70
60
50
40
30
20
10
mm
JUNKER · GRINDSTAR4
Workpiece shapes
Using a profiled grinding wheel allows for the entire workpiece
contour to be ground with extremely fast cycle times. As a result,
parts show much higher dimensional accuracy and surface quali-
ty than they do with conventional turning.
GRINDSTAR – uniquely economical
Complete grinding on a single machine minimizes process risks and
down-times. Parts are 100% guaranteed to be free of cut-off burrs.
Convex and concave surfaces can also be produced. Exotic materials
can be ground. And grinding can be done both before and after
heat-treating.
Bar-fed parts
Material Diamond CBN
Carbide/carbide-steel alloy •
Construction steel/case-hardened steel/heat-treated steel •
High-speed steel •
Ball bearing steel •
Hot and cold work steel •
Spring steel •
High-alloy steel •
Special alloys (i.e. Hastelloy, Inconel) •
Cast iron • •
Wear-resistant build-up welds • •
Nimonic (OD grinding) •
Nimonic (parting grinding) •
Glass quartz, precious and semi-precious stones •
Ceramic oxide and ceramic materials •
Porcelain, soapstone earthenware •
Curable plastics, fiberglass reinforced synthetic materials •
5JUNKER · GRINDSTAR
Cost-effectiveness comparison
Cycle time Part cost comparison
Turning lathe GRINDSTAR
Energy cost 100 % 100 %
Investment cost 100 % 80 %
Labor cost 100 % 50 %
Floor space 100 % 40 %
Part cost 100 % 75 %
Costs per finished part are 25 % lower with GRINDSTAR.
Conveyor-fed parts
c o s t - e f f e c t i v e n e s s
JUNKER · GRINDSTAR6
Approach sensors (optional)Balancing system Pre-/in-/post-process measurement (optional)
The controls solution
GRINDSTAR controls
GRINDSTAR features a Fanuc 0i-D control system – the same type
of controls as a lathe uses. That means that there’s no major
retraining necessary. Programming is standard and is done
through DIN/ISO.
• Modern, efficient and reliable CNC controls
• 10.4“ LCD color screen
• Digital highly dynamic servo-motors with absolute encoders
• Tool compensation for direct input of print data
• Multi-lingual
Present worldwide – JUNKER Services
The experienced of the JUNKER Services team is your main
source of help with any questions or issues.
• Consulting
• Start-up
• Training
• Spare parts
• Help line
• Overhaul
• Maintenance
• Inspections
• Reconditioning
c o n t r o l s
7JUNKER · GRINDSTAR
Variable equipment and individual optionsEquipment
The machine is thoroughly designed for use with an inte-
grated manufacturing concept. The machine easily connects
to peripheral devices and automation solutions, making it
perfect for any user interested in high part quality and
economical production.
Low-manpower production
Another advantage of this concept is that it allows for efficient part
grinding directly from bar stock. This means low-manpower produc-
tion and significant cost benefits.
Options
• Steadies (2-42 mm)
• Balancing
• Approach sensors
• Measuring system
• C-axis (interpolation grinding)
• Bar feeder
• Part cleaning
• Automated part handling
• Coolant plant
• Mist collector
Technical data
Grinding spindle 2 x 30 kW
Grinding wheel diameter 520 mm
Max. cutting speed 170 m/s
Abrasive CBN / diamond
Work spindle 7.5 kW / 6.000 min-1
Secondary spindle 7.5 kW / 6.000 min-1
Work clamping Hydraulic
Coolant Standard grinding oil
Accuracies attainable IT 6 / Cmk > 2
Grinding length max. 400 mm
Bar capacity 2 – 42 mm
Axes: X1, Z1, X2, Z2 CNC
Max. feed rate X = 18 m/min; Z = 36 m/min
Connection power 75 kVA
Machine dimensions 2400 x 1800 x 2100 mm
Weight ca. 4.500 kg
e q u i p m e n t , o p t i o n s , t e c h n i c a l d ata
JUNKER Maschinen
Erwin Junker Maschinenfabrik GmbH Junkerstraße 2 77787 Nordrach, Germany
Phone: +49 (0)7838 84-0 Fax: +49 (0)7838 84-302 E-Mail: [email protected] www.junker-group.com
EUROPE
JUNKER Grinding Technology
Erwin Junker Grinding Technology a.s. Plant Holice Pardubická 332 534 13 Holice, Czech Republic
Phone: +420 466 003-111 Fax: +420 466 682 149 E-Mail: [email protected] www.junker-group.com
JUNKER Machine Tools
Junker Machine Tools & Technology (UK) Ltd. Hadleigh House 32 Sefton Road, Fulwood Park Sheffield S10 3TP, U.K.
Phone: +44 (0)114 230 34 53 Fax: +44 (0)114 230 93 82 E-Mail: [email protected] www.junker-group.com
NORTH AMERICA
ERWIN JUNKER High Performance Grinding Systems
Erwin Junker Machinery, Inc. 2541 Technology Drive, #410 Elgin, IL 60124, USA
Phone: +1 847 488 0406 Fax: +1 847 488 0436 E-Mail: [email protected] www.junker-usa.com
ASIA
JUNKER Maschinen
Erwin Junker Maschinenfabrik GmbH Shanghai Representative Office Room A-F, 13th Floor, North Gate Plaza No.99 Tianmu Road West Shanghai 200070, P.R. China
Phone: +86 (0)21 6380 6911 / 22 / 33 Fax: +86 (0)21 6381 1220 E-Mail: [email protected] www.junker.com.cn
JUNKER Maschinen
Erwin Junker Maschinenfabrik GmbH India Branch Office 205, 2nd Floor, Jewel Tower, Lane 5, Koregaon Park Pune 411 001, India
Phone: +91 20 261 538 96 Fax: +91 20 261 538 96 E-Mail: [email protected] www.junker.in
JUNKER Maschinen
Erwin Junker Maquinas Ltda. Centro Administrativo Rio Negro Edifício Jaçari – Bloco A 13º andar cj. 132/133 Alameda Rio Negro 585 CEP 06454-000 Alphaville – Barueri São Paulo, Brazil
Phone: +55 11 4153 9645 Fax: +55 11 4153 8954 E-Mail: [email protected] www.junker-group.com.br
SOUTH AMERICA
JUNKER Grinding Technology
Erwin Junker Grinding Technology a.s. Branch Office Prospekt Tolbukhina 17/65 150000 Yaroslavl, Russian Federation
Phone: +7 (4852) 20 61 21 Fax: +7 (4852) 20 61 21 E-Mail: [email protected] www.junker-russia.ru
7506
635
EN
Sep
tem
ber
201
0
W
e re
serv
e th
e ri
gh
t to
mak
e ch
ang
es in
th
e in
tere
st o
f te
chn
olo
gic
al p
rog
ress
.