S40The Allrounderfor complex grinding jobs.

S40

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Advantages

S40 – Dimensions• Distancebetweencentres

1000/1600mm(39.4”/63”)• Heightofcentres175/��5mm

(6.9”/8.9”)• Maximumworkpieceweight

130/150kg(�86/330lbs)

Hardware• Turretwheelheadwithautomaticswivel,

1degindexing• Completemachiningwithuptofourgrinding

wheels• High-resolution0.0001-degBaxisforgrind-

ingcylindricalandtaperedpartsinoneworkpieceprogram

• Caxisfortheworkheadenablingformandthreadgrinding

• Fullenclosurewithslidingdoors• Granitan®S103mineral-cast

machinebase

Software• ExtremelyeasyprogrammingwithStuder

Pictogramming• ProgrammingsoftwareStuderGRINDfor

producinggrindinganddressingprogramsonaPC

• ReducedsetupanddressingtimeswithStuderQuick-Set

• Standardisedinterfacesforloaderandperipheraldevices

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The S40 CNC universal cylindrical grinding ma-chine is designed for grinding complex work-pieces in small and large-batch productions as well as individual components. It is built with a distance between centres of 1000 mm or 1600 mm and centre heights of 175 mm and 225 mm. Due to its modular system design, it can be pre-cisely adapted to individual requirements. The Granitan® S103 machine base forms the basis for assembling the high-technology components to build a cylindrical grinding machine that guaran-tees the highest levels of precision, performance and reliability over many years.

The full enclosure with two large sliding doors makes setting up easy and convenient, and also allows the use of emulsion or oils as a cooling lubricant. The defined loader interface enables the fitting of handling devices for automation, which – together with our know-how – results in

high productivity. The S40’s area of application is further enhanced by features like the vertical spindle on the wheelhead or the R axis on the longitudinal table.

The practical Studer grinding software with its proven pictogramming allows even less experi-enced users to quickly optimize the potential of this machine. The StuderGRIND software is also available; this enables efficient programming of special applications, such as form and thread grinding. The systematic development, produc-tion, assembly and testing of Studer products are carried out in a process-oriented manner and in strict compliance with the VDA 6.4 and ISO 9001 directives.

The Allrounder for complex grinding jobs.

Range of parts for external, internal and form grinding

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conventional machine base

machine base produced in Granitan®

oscillation frequency

ampl

itude

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1 | Vibration characteristics of Granitan ® compared to cast iron

2 | Guideways with patented surface structure

3 | Machine base with X and Z guideways

4 | Machine base with longitudinal and cross slides

5 | Z axis with circulating ball screw and three-phase servomotor

- Vibration-damping

- Thermalstability

- Non-wearing

Granitan®mineral-castingS103machinebase

The material structure developed by Studer and which has proved its superb efficiency over many years is produced in the company’s own plant us-ing the most modern industrial techniques.• The excellent dampening proprieties of the

machine base ensures outstanding surface quality of the ground workpieces. The service life of the grinding wheel is also increased, leading to reduced downtimes.

• Temporary temperature fluctuations are ex-tensively compensated for by the favorable thermal behavior of Granitan®, resulting in high dimensional accuracy at all times.

• The V and flat guideways for the longitudinal and cross slides are moulded directly into the machine base and are provided with a non-abrasive Granitan® S200 slideway coating. The patented knobbed structure of the guide-ways largely eliminates the slip-stick effect or floating of the slides observed on conven-tional guideways.

The guideways offer the highest possible ac-curacy through the entire speed range with high load capacity and dampening levels. Thanks to the robust and maintenance-free design, these excellent guideway character-istics are more or less completely retained.

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Longitudinalandcrossslides

The longitudinal and cross slides are manufac-tured from high-quality gray cast iron and have highly precise, ground V and flat guideways, with the distance between the guideways optimally suited to the machine’s overall rigidity. The slides rest completely on the guideways of the machine bed through the entire travel range. This provides the cornerstone for the excellent inherant grind-ing straightness of 0.0035 mm (0.000,14”) over 950 mm (37.4”) measured length. The slides are advanced by 40 mm (1.57”) diameter circulating ball screws connected to a three-phase servo-motor via torsion-resistant, bellow-type cou-plings. These axes achieve high process speeds, on the one hand, while on the other hand the

- High-accuracyaxismovements

- Auxiliaryscaleforsetupandresetting

- Effectivecoveringoftheguideways

short auxiliary times also guarantee maximum precision with in-feed movements of 0.0001 mm (0.000,004”). These axes can be equipped with rotative or linear measuring systems, depending on requirements.

The top of the longitudinal slide has a surface that is ground over its entire length and acts as a support for the workhead, the tailstock, as well as accessories and devices. A setup scale, recessed in the table, makes it easy to set up and reset the position of workhead, tailstock and ancillary equipment. An additional T-slot with ground surface enables optimal utilization of dressing devices.

6 | T groove and clamping surface for fitting dressing tool holders, etc.

7 | Setup scale

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1 | High-precision B axis assembly

2 | Evaluation of repetition precision of the B axis

3/4 | Turret wheelhead left/right/ internal

5-10 | Wheelhead examples

Turretwheelhead

The most important component for complete ma-chining is the wheelhead with its integrated B axis. This swivels automatically, making it possi-ble to use up to four grinding wheels. This means that workpieces can be completely machined in the same clamping. And all of this, with minimal idle times while ensuring greater precision.

The basic position of the B axis is set by the 1-deg Hirth gear, and the simultaneous fine-posi-tioning via a special cam adjustment device. The 0.0001-deg resolution guarantees outstanding values for positional stray (repetition) and posi-tional deviation (angular deviation).

* test result

** guaranteed range

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Combinations of up to four external grinding wheels and three internal grinding wheels pro-duce 30 basic configurations, with the option of using belt-driven internal grinding spindles at speeds up to 60 000 rpm or high-frequency internal grinding spindles up to 120 000 rpm. Dynamic or automatic balancing systems and frequency converters for the individual external grinding spindles enable the wheelhead variants to be attuned even more to optimize the grinding process. A vertical spindle for grinding longitudi-nal keyways can also be fitted to the wheelhead as a special solution.

- Customisedconfiguration

- Completemachining

- Grindingofcylindricalandtaperedparts withthesamegrindingwheel

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Workhead

The versatile universal workhead enables both live spindle grinding and grinding between cent-ers. The machine can also be fitted with a spe-cially designed chuck workhead for chuck appli-cations. The workheads are equipped with roller bearings, are low-maintenance and have an ex-cellent roundness accuracy of under 0.0004 mm (0.000,016”), which can be optionally improved to under 0.0002 mm (0.000,008”) during live spindle operations. The fine adjustment allows for taper corrections in the 1 µm range during live spindle operations. Like the tailstock, the work-

- Highroundnessaccuracy

- Lowmaintenance

- Aircushionunderworkhead

head is also equipped with a pneumatic lifting device to facilitate movement during setup and resetting.

Option: Roundness of < 0.0002 mm (0.000,008”) during live spindle grinding operations. With the hydrodynamic bearing up to < 0.0001 mm (0.000,004”).

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1 | Chuck workhead

2 | Roundness value (test certificate)

3 | Fine adjustment for taper corrections

C-axisforformandthreadgrinding

Complete machining also entails form and thread grinding operations to an ever increasing extent. These processes are made possible by the posi-tion and speed-controlled C-axis. The standard C-axis with measuring system on the drive motor is suitable for thread grinding. A direct measuring system is mounted on the workhead spindle for maximum form accuracy (high-precision C-axis). Acceleration and grinding forces are absorbed without difficulty through the high dynamic ri-gidity of the axis drives.

4 | External and internal thread grinding

5 | Form and die grinding

6 | Wheel contact situation during form grinding

Form and thread grinding The Studer S40 enables axis-parallel grinding of conventional to high accuracy threads. Poly-gons, eccentrics, control cams, cams etc. can be manufactured cost-effectively and in the highest precision with High Speed Machining (HSM).

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Tailstock

The generously dimensioned barrel, designed for the use of Morse 3 taper centers, glides in the tailstock housing. The center pressure can be adjusted with the delicate precision required for grinding high-precision workpieces. The tail-stock can be equipped with a hydraulically actu-ated barrel retraction for workpiece changeover The fine adjustment enables taper corrections in the range below 1 µm when grinding between centers. A pneumatic lifting process facilitates movement during setup and resetting.

- Tapercorrections

- Barrelflooding

In order to guarantee optimum thermal stability, the tailstock is flooded with cooling lubricant, as are the barrel and the diamond holder. The ma-chine is also equipped with an optional synchro-nous tailstock for direct driving of workpieces between centers.

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Dressing

A sharpened grinding wheel is a prerequisite for economical and high grinding quality. Studer offers a large selection of dressing devices for attaining the dressing process optimally and flexibly to the specific workpiece, tool and ma-terial properties. The grinding wheel profile and dressing parameters are easily defined via macros. Another Studer speciality are the grind-ing wheel reference points (T numbers). These

permit programming with nominal dimensions, which makes it much easier to create grinding programs.

A software package with extended dressing functions is available for fine-tuning the dressing process.

1| Tailstock

2| Dressing tool holder

3| Fine adjustment for taper corrections

4| Rotary dressing device

5| Diamond holder behind the tailstock on the table (225 mm centre height only)

6| Dressing parameter dialogue image

7| Swivel dressing device

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4 | Pictogramming

5 | Quick-set

6 | Programming software StuderGRIND

1 | PCU – process control unit

2 | Machine control with accessories such as the Sensitron air-gap bridging device, balancing device and external measurement controls

3 | Internal view of the control cabinet

Machinecontrolandoperation

The S40 is equipped with the extremely reliable Fanuc 16i-TA, which is optimally attuned to the drive elements.

The control cabinet is bolted to the machine bed at the rear of the machine and contains separate power and control compartments. The layout of the elements complies with the relevant safety norms and is EMV-tested.

All controls are clearly and ergonomically ar-ranged. An important role is played by the man-ual control unit, which facilitates setup close to the grinding process.

A special function – the Sensitron electronic con-tact detection device – reduces downtimes to a minimum.

- PCUmanualcontrol

- ControlcabinetEMV-tested

- Ergonomicallyarrangedcontrols

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Programming

The sophisticated mechanical engineering con-cept of the S40 is completed by a grinding soft-ware program developed in-house by Studer and continuously further optimized in collaboration with customers. This software offers:• Pictogramming: The operator strings the indi-

vidual grinding cycles together – the control unit generates the ISO code.

• Quick-Set: The software for grinding wheel alignment reduces resetting times by up to 90%.

• Microfunctions: Free programming of grind-ing and dressing process sequences for opti-mization of the grinding process.

- Moderntechnology

- Pictogramming

- ProgrammingsoftwareStuderGRIND

• StuderGRIND: Programming software for special applications such as form and thread grinding and profiling the grinding wheel for complex workpiece forms; the program is cre-ated on the PC and transferred directly to the machine control.

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1 | Customised system machine

2 | Work area with workpiece handling

3 | Post-process measuring station

4 | Teleservice

5 | Deployment of engineers on the customer’s premises

6 | Operating worldwide

7 | Training on simulators

Process-optimizedcompletesolutionsguaranteegreaterefficiencyandreliabilitythroughout.

Loading systems are available for the Studer S40, which can be precisely adapted to the ma-chine application and the machining processes thanks to their modular design. The correspond-ing peripherals ensure seamless integration into the respective production process. The handling systems used communicate with the machine via the standardized loader interface and enable even complex handling tasks to be solved.

- Automaticproduction processes

- Integratedqualitycontrol

- Standardisedloaderinterfaces Comprehensive quality control is possible during the grinding process. This entails: in-process, post-process, recording, evaluation and correc-tion. This type of quality assurance is crucial dur-ing grinding, but especially match grinding.

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Accessoriesandservices

There is an extensive range of accessory equip-ment available for all Studer cylindrical grinding machines, including centers, dressing tools, grind-ing wheels, clamping devices, internal grinding spindles, in-process gauging devices, etc.

The Studer Training Department organizes cours-es for hundreds of customers every year special-izing in programming and machine use – a sound basis for optimum use of your Studer machines.

Maintenance courses are tailored to the respec-tive requirements of the maintenance depart-ments. On request, they can also take place on the customer’s premises. Studer specialists col-laborate in grinding problems, in order to achieve the optimal solution

The after sales service is able to speak the user’s language and operates on a worldwide basis. This ensures that the service technicians do not have to travel far to make customer visits. The well thought-out service offer enables them to support the user to operate the machine in an optimal manner. And spare parts availability is guaranteed for a minimum of 10 years after in-stallation.

- Commissioning

- Training

- Productionsupport

- Warrantyextension

- Maintenance

- HelpLine

- Repair

- Spareparts

- Teleservice

- Inspection

- Overhaul

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Main dimensions

Distance between centres 1000/1600 mm (39.4”/63”)

Centre height 175/225 mm (6.9”/8.9”)

Max. workpiece weight between centres 130/150 kg (286/330 lbs)

Cross slide: X axis

Max. travel 275 mm (10.8”)

Speed 0.001– 5000 mm/min (0.000,04 – 197 ipm)

Resolution 0.0001 mm (0.000,004”)

Longitudinal slide: Z axis

Max. travel 1050/1650 mm (41.4”/65”)

Speed 0.001–10 000 mm/min(0.000,04 – 394 ipm)

Resolution 0.0001 mm (0.000,004”)

Swivelling workpiece table (175 mm centre height only)

8.5 deg/6 deg

Wheelhead

Fitting taper dia. 63 mm (2.5”)

Drive power 7,5 kW (10 hp)

Grinding wheel left, dia. x width x bore 400 x 63 (80F5) x 127 mm[16” x 2.5” (3.15” F5) x 5”]

Circumferential speed 35 m/s (6890 sfpm)

Swivel range –15 to + 225 deg

Hirth gear resolution 1 deg

Swivel time for 180 deg 6 s

Internal grinding device for high-frequency spindles

Spindle dia. dia. 120 mm (4.72”)

Speed range 24 000 –120 000 rpm

Internal grinding unit for belt-driven spindles

Spindle dia. dia. 100 mm (3.9”)

Speed range 20 000 – 60 000 rpm

Options:

Driving power 9 kW (12.3 hp)

Grinding wheel right, dia. x width x bore 400 x 40 x 127 mm (16” x 1.57” x 5”)

Grinding wheel left, dia. x width x bore 500 x 63 (80F5) x 203 mm [20” x 2.5” (3.15” F5) x 8”]

Grinding wheel right, dia. x width x bore 500 x 63 (80F5) x 203 mm [20” x 2.5” (3.15” F5) x 8”]

Circumferential speed 50 m/s (9840 sfpm)

Constant cutting speed

B axis, infinitely variable fine adjustmentPositional stray (repetition) +/–1”Positional deviation (angular deviation) within 5”Active length positioning on grinding headIntegrated, automatic grinding wheel balancing system

0.0001 deg

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Universal workhead for live spindle grinding or external grinding between centres

non-swivel swivel

Hydrodynamic bearing

Speed range 30 –1000 rpm 30 –1000 rpm

Fitting taper Morse 5 Morse 5

Spindle feedthrough dia. 30 mm (1.18”) dia. 30 mm (1.18”)

Drive power 1 kW (1.4 hp) 2.8 kW (3.8 hp)

Load during live grinding 100 Nm (74 ft lbs) 100 Nm (74 ft lbs)

Max. workpiece weight between centres 130 kg (286 lbs) 130 kg (286 lbs)

Roundness accuracy during live grinding 0.0003 mm (0.000,012”)(Option: 0.0002/0.0001 mm)

0.0003 mm (0.000,012”)(Option: 0.0002/0.0001 mm)

Universal workhead ISO50 Chuck workhead ISO50

For live or external grinding between centres For live or external grinding with rotor centres

Roller bearing

Speed range 1–1000 rpm 1–1000 rpm

Fitting taper/cylindrical external holding device ISO50/dia. 110 mm (4.32”) ISO50/dia. 110 mm (4.32”)

Spindle feedthrough dia. 50 mm (1.97”) dia. 50 mm (1.97”)

Drive power 3.8 kW (5.2 hp) 3.8 kW (5.2 hp)

Load during live grinding 180 Nm (134 ft lbs) 250 Nm (186 ft lbs)

Max. workpiece weight between centres 150 kg (330 lbs)

Roundness accuracy during live grinding 0.0004 mm (0.000,016”)[Option: 0.0002 mm (0.000,008)]

0.0004 mm (0.000,016”)[Option: 0.0002 mm (0.000,008)]

C axis for form grinding–standard, indirect measuring system 0.0001 deg 0.0001 deg

–high-precision, direct measuring system 0.0001 deg

Tailstock

Fitting taper Morse 3/Morse 4

Travel of barrel 35 mm/60 mm (1.37”/2.36”)

Diameter of barrel 50 mm/60 mm (1.97”/2.36”)

Fine adjustment for taper corrections ± 40 µm/± 80 µm (0.0016”/0.0032”)

Options:

Hydraulic barrel retraction with foot control

NC tailstock with 148 mm stroke

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The information given is based on the technical levels of our machine at the time of this brochure going to print. We

reserve the right to further develop our machines technically and make design modifications. This means that the

dimensions, weights, colours, etc. of the machines supplied can differ. The diverse application possibilities of our

machines depend on the technical equipment specifically requested by our customers. The equipment specifically

agreed with the customer is therefore exclusively definitive for the equipping of the machines, and not any general

data, information or illustrations.

Control

Fanuc 16i -TA

Guaranteed working precision

Straightness of surface line

Measured length 950 mm (37.4”) 0.0035 mm (0.000,14”)

Measured length 1550 mm (61”) 0.005 mm (0.000,20”)

Connection values

Total connected load 30kVA

Air pressure 5.5 bar (80 psi)

Extraction capacity for cooling lubricant mist 1100 m3/h

Total weight

Distance between centres 1000 mm 6500 kg (14 300 lbs)

Distance between centres 1600 mm 7200 kg (15 840 lbs)

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2250

/88.

58“

4713

/185

.6“

1995

/78.

5“M.: 1:50

3687/145“

4717/185.7“

6017/236.9“

5187/204.2“

M.: 1:50

4713

/185

.6“

2017

/79.

4“

1) 2)

1) 2)

3)

Distance between centres 1000 mm (39.4”)

Distance between centres 1600 mm (63”)

08.2

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Prin

ted

in S

witz

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ISO 9001

VDA6.4certified

Fritz Studer AGCH-3602 ThunTelephone +41-33-439 11 11 · Telefax +41-33-439 11 12www.studer.com