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Home / IMTS 2014: Abrasive Machining, Sawing, Finishing

IMTS 2014: Abrasive Machining, Sawing, Finishing

Here are solutions for applications requiring high tolerance and precision surface finish, including grinding technology, sawing and cutoff machines and a variety of finishing systems, such as lapping, balancing, honing and polishing machines. You’ll also find advancements in abrasive size, shape or composite materials, and nano-materials for improved surface finishes in more constrictive areas.

Booth N-7200: The peeling grinding method, well proven on other types of the ShapeSmart® series from Rollomatic, provides the ability to grind tools with extreme length /diameter ratio as well as complex profiles. 
Booth N-7353: The GPV-10 Cylindrical Grinder (shown) and the GAV-10 Angular Cylindrical Grinder from Shigiya are designed to grind small workpieces with precision. An innovative gate structure ensures accurate grinding by counter measuring against vibration, thermal displacement and noise. A top beam securely connects the upper portion of the two columns. The superior rigidity of these machines ensures extreme precision after a cold start, and even during post-process grinding. 
Booth N-7353: Grinder speeds on the GSU-40B Universal Grinder from Shigiya can be changed steplessly on the AC servo motor within a range of 15 to 600 rpm. A user-friendly and flexible interactive programming system automatically determines the optimal rotational speed for each workpiece.
Booth N-7163: The new diamond impregnated composite hub wheel brushes from Brush Research Manufacturing are ideal for producing edge radii on hard materials including diamond, CBN, Ceramic and Glass. They are ideal for polishing the flute relief on carbide and high speed steel drills, end mills and reamers and producing an edge radius on carbide inserts. A polished flute relief on end mills and reamers greatly enhances chip removal and promotes better finishes and longer tool life. An edge radius on carbide inserts prevents fracturing and premature insert wear. 
Booth N-6800: The new Mägerle MFP 100 flexible grinding center from United Grinding is available as a 5-axis or 6-axis system and stands out for its high working speed and expandable tool changer system that can hold up to 60 tools. Among the industry’s most precise and versatile surface and profile machines, the MFP 100 can grind, mill and drill heavy, complex parts in a single clamping.
Booth N-7200: The GrindSmart 628XW® with SmartChanger® from Rollomatic has a 6-station wheel changer with HSK50E arbors, tested for repetitive concentricity of less than two microns, and a 20 hp synchronous direct-drive grinding spindle that offers constant rpm with no chatter marks in flutes, as opposed to conventional asynchronous motors. (first view)
Booth N-7200: The GrindSmart 628XW® with SmartChanger® from Rollomatic has a 6-station wheel changer with HSK50E arbors, tested for repetitive concentricity of less than two microns, and a 20 hp synchronous direct-drive grinding spindle that offers constant rpm with no chatter marks in flutes, as opposed to conventional asynchronous motors. (second view)
Booth N-7200: The SmartChanger® on the GrindSmart 628XW® from Rollomatic changes wheel packs during automatic tool change without losing cycle time.
Booth N-7200: The ShapeSmart® NP3 single-wheel cylindrical grinder from Rollomatic is particularly suited as a versatile peel grinder for manufacturing blanks for the cutting tool industry, precision punches and other similar parts. (first view)
Booth N-7200: The ShapeSmart® NP3 single-wheel cylindrical grinder from Rollomatic is particularly suited as a versatile peel grinder for manufacturing blanks for the cutting tool industry, precision punches and other similar parts. (second view)
Booth N-7200: The modified GrindSmart 528XW® with SmartChanger® from Rollomatic performs fluting with a Tyrolit D54 XP-P grinding wheel and a razor-sharp cutting edge with the polish wheel to achieve feed rates of 80 mm/min first pass, 160 mm/min second pass, and a cutting speed of 18 m/s. (first view)
Booth N-7200: The modified GrindSmart 528XW® with SmartChanger® from Rollomatic performs fluting with a Tyrolit D54 XP-P grinding wheel and a razor-sharp cutting edge with the polish wheel to achieve feed rates of 80 mm/min first pass, 160 mm/min second pass, and a cutting speed of 18 m/s. (second view)
Booth N-6563: Bluco specializes in modular fixturing for machining, welding, inspection and assembly.
Booth N-6740: The lifehone from Gehring is alternatively equipped with a six- or eight-sided inner column so that an operator can fix up to seven honing spindles to insure short cycle times and multistep processes. 
Booth N-6740: The innovative powertrainhone from Gehring uses a modular design system comprised of standardized functional components that can be combined with tailor-made honing centers in a groundbreaking configuration that enables new freedom and flexibility in production when compared to modern hone systems with a conventional layout.
Booth N-7472: The new Band Saw Blade Simulator Program from Simonds will significantly improve the performance, productivity and ROI of a shop’s sawing operation and turn the conventional method of specifying band saw blades by catalog selection upside down. 
Booth E-5510: The PLC-controlled SV-20 from Sunnen utilizes a color touch screen, with a toggle switch to jog for fast setup. The swiveling operator panel can be adjusted for viewing from a variety of positions. A hand wheel on the machine allows left/right positioning of the column on its 760 mm (30 in) X-axis. The machine comes standard with a 208 L (55 gal) internal coolant system equipped with two standard canister filters. The rotary servo tool feed system can be used with two-stage hone heads to complete roughing and finishing without stone changes for faster processing times.
Booth E-5510: PG Bore Gages from Sunnen can be used to examine the entire bore for diameter, taper, barrel, bell mouth, out-of-round and lobing. A sliding faceplate with adjustable stops permits end-to-end examination of bores. Stops can be set to allow examination of a particular section of the bore, with accuracy right up to the edge of ports, lands and ends. 
Booth N-6748: Ceramic grain Burr-Rx brushes from Weiler are especially well-suited for deburring tough materials such as Inconel, stainless steel, and titanium, but with an assortment of filament configurations and product fill densities, there is a high performance tool available for use on practically any material.
Booth N-7358: The Bunting Magslide is fitted with powerful magnets that reliably move ferrous parts and material in the manufacturing environment.
Booth N-7358: Bunting Magnetic Lifters make moving heavy metal items on the factory floor safe, simple, and quick. 
Booth N-7429: The OMP KR3 Fully Automatic Circular Miter Saw from Pat Mooney can replace up to three band saw machines in high production shops, retaining amazing speed and burr-free cut quality. Its upcut design provides a large cutting capacity of 8.5 in and the ability to cut angles in the automatic cycle from 75 deg to the left to 60 deg from the right. The miter function is fully automatic and allows for multiple different angle cuts to be programmed within the same job. (first view)
Booth N-7429: The OMP KR3 Fully Automatic Circular Miter Saw from Pat Mooney can replace up to three band saw machines in high production shops, retaining amazing speed and burr-free cut quality. Its upcut design provides a large cutting capacity of 8.5 in and the ability to cut angles in the automatic cycle from 75 deg to the left to 60 deg from the right. The miter function is fully automatic and allows for multiple different angle cuts to be programmed within the same job. (second view)
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COMPACT VERTICAL CNC GRINDERS
In Booth N-7353, GPV-10 and GAV-10 Vertical CNC Grinders from Shigiya USA Ltd. (Schaumburg, IL), a world-class manufacturer of cylindrical grinders, feature compact footprints to accommodate a range of production line layouts. In fact, the main body of these machines is approximately 1 sq m, or about half the size of an existing Shigiya GAC-20 Grinder. Contributing to GPV-10 and GAV-10 accuracy is an original non-concentric hydrodynamic bearing for the wheel spindle. Mounted on the wheel side of the wheelhead, this bearing maintains low processing heat by optimizing the bearing clearance and the wedge angle. Infeed is performed by the table moving toward the wheel.

These vertical grinders are loaded with features that promote ease of use, including a wide machine opening that allows for flexible automation of loading/unloading and easy maintenance. What’s more, an electrical control panel hinged on the rear of the machines swings open wide to ensure enough working space for easy wheel change. The wheel changer of the GAV-10 enables for smooth wheel change, easier operation and reduced operator fatigue. Removal and attachment of the grinding wheel are performed by the vertical movement of the air cylinder. The arm can be manually moved back and forward with ease. The grinding wheel of the GPV-10 is not angled and does not require a wheel changer to be changed.

Both the GPV-10 and the GAV-10 feature a ø 100 mm swing over table, and 150 or 200 mm distance between centers. Wheel sizes are ø 305 mm OD x 25 mm W x 127 mm ID or ø 355 mm OD x 25 mm W x 127 mm ID.

A demonstration of the Shigiya grinding machines.

Shigiya also offers its versatile and precise GSU Series of Universal Grinders that feature a wheelhead NC swivel function which enables the operator to select from 9 different wheelhead installation patterns. Using the correct wheelhead installation pattern and specifications allow a variety of multi-grinding tasks to be performed and reduce the number of processes. For additional flexibility, two grinding wheels can be mounted onto two wheel spindles of the GSU, contrasted with conventional machines where two grinding wheels are mounted onto one spindle. The wheelhead is swiveled at high speeds by a direct drive system, and provides high positioning accuracy without backlash.

The GSU is designed with non-concentric hydrodynamic bearings that use hydrodynamics to secure the optimal wedge angle, and provide high precision rotation of the wheel. The bearings are ground with an exclusively developed grinder to ensure high rigidity and precise rotation. The GSU tailstock is mounted with a large diameter spindle to further ensure high precision heavy grinding. Heat expansion of the workpiece during grinding is offset by a helical compression spring. To avoid thermal displacement in the machine caused by a rise in the lubrication oil’s temperature, wheel spindle lubrication oil is stored in an isolated tank.

Shigiya offers an optional closed type hydrostatic slide wheelhead feed and a work spindle rotation direct drive to enable an operator to actually perform eccentric OD and non-concentric OD grinding (polygonal grinding) using the C-X axis control. Two models of the GSU Series are available. The GSU-30B features a ø 300 mm swing over table, and 500 mm, 750 mm, 1,000 mm or 1,500 mm distance between centers. The GSU-40B features a ø 410 mm swing over table, and 470 mm, 720 mm, 970 mm or 1,470 mm distance between centers. A model with distance between centers of up to two meters is available to allow for the grinding of long parts such as aircraft landing gear. Wheel sizes for both GSU models are ø 510 mm OD x 50 mm W x 127 mm ID. www.shigiya.com

DIAMOND COMPOSITE HUB WHEEL BRUSHES
In Booth N-7163, Brush Research Manufacturing Co., Inc. (Los Angeles, CA) is pleased to announce an expansion in their abrasive nylon product line to include diamond impregnated composite hub wheel brushes. The introduction of the new diamond filament wheels extends the range of their finishing and deburring tools to now finish harder materials like glass, ceramic, carbide and hardened tool steels.

These new brushes are composite hub construction which yields a much denser and more uniform fill pattern putting more cutting points at the point of attack. The new black diamond filled composite wheel brushes come in three diameters: 100 mm, 150 mm and 200 mm.  The 150 mm and 200 mm diameters come in either 10 mm or 15 mm face thickness to accommodate a variety of flute relief requirements. The 100 mm diameter brush is manufactured in a 5 mm face width to allow finishing smaller sizes.

The black diamond filament comes standard in 600 grit which has proven to have the perfect combination of cutting power and ultra smooth final finish. Other grits are available on special order. These wheels are extremely long lasting and priced well below other diamond wheels on the market. www.brushresearch.com

ADVANCED GRINDING TECHNOLOGIES
In Booth N-6800, United Grinding North America, Inc. (Miamisburg, OH) will showcase 19 grinding machines, including two historic machines – the largest number of products the company has ever had at the show. Booth highlights will include the global introduction of a Studer ID cylindrical grinder, the North American debut of a Mägerle surface and profile grinder and the 20th anniversary of Walter’s best-selling CNC tool and cutter grinder. Applications experts will also be available to help attendees determine the right grinding solution for their manufacturing needs.

With its new ID cylindrical grinding machine series, the Studer brand is entering a new market segment of long workpiece production, such as spindle housings and rotor shafts. One of the machines in this series that will be on display can process short work pieces via an overhung grinding spindle as well as grind parts up to 51.2 in (1,300 mm) long with an additional steady rest. The maximum internal and external grinding length for this machine is 9.8 in (250 mm) and 5.9 in (150 mm), respectively. With linear motors and a StuderGuide precision guideway system, the series is equipped with the latest drive technology in order to meet today’s customer demands.

A demonstration of a Mägerle MFP 100 5/6-Axes Grinding Center with Toolchanger.

Its original version was introduced at IMTS 20 years ago. Now the latest Walter Helitronic Power CNC tool grinding machine brings precision, productivity and flexibility to the production and re-sharpening of rotationally symmetrical tools and parts with complex geometries. In honor of its two decades of success, which includes more than 3,800 units sold worldwide, the machine on display will feature a custom-painted design.

During IMTS, United Grinding North America, through its comprehensive grinding machine selection on display, will be prepared to present manufacturing solutions as they specifically pertain to productivity enhancing factory automation, optimizing total cost of ownership, minimizing production costs per part, and providing total turnkey installations. Additionally, the company encourages attendees to bring their part drawings to its booth so applications engineers can discuss the most appropriate grinding solution for their needs, including complementary workholding, fixturing, tooling, robotics and machine monitoring.

Customer care will also be an important focus inside the booth. To keep up with its unprecedented growth over the past couple of years, the company continues to invest in customer-centric business processes to ensure its products and services remain aligned with customer requirements. In fact, the company recently implemented an internal cross-function initiative, known as PuLs®, to help make its customers more successful than ever. This initiative focuses on applying best practices in every aspect of the company’s business, from sales to applications support to training to preventive maintenance. And, as part of the PuLs initiative, the company regularly sends out surveys to effectively gauge customer satisfaction levels using the Net Promoter Score® measuring method.

United Grinding North America is the subsidiary for the North American market, with two production plants of 16,732 sq ft space in Miamisburg and 16,732 sq ft in Fredericksburg, VA, and over 155 employees around North America. Apart from its production plants in the U.S., the company runs an additional sales and service office in Queretaro, Mexico, and occupies a leading position in the North American grinding machine tool market by offering innovative products in the technology areas of surface and profile grinding, cylindrical grinding and tool grinding. www.grinding.com

UNIVERSAL 6-AXIS PRODUCTION TOOL GRINDER
In Booth N-7200, Rollomatic Inc. (Mundelein, IL), a leading machine tool manufacturer based in Le Landeron, Switzerland, will announce a 6-axis CNC tool grinder for production grinding of a large variety of diverse cutting tools that enables shops to achieve sustained competitive advantage. With new software developments, larger hp and higher rigidity of the machine base, in-field use of the modified GrindSmart 628XW® with SmartChanger® has demonstrated that this machine tool is ideal for increased productivity on an extended range of different high-performance cutting tools, including:

  • Carbide endmills up to 20 mm (3/4 in) = 11 min
  • Carbide drills up to 12 mm (1/2 in) = 8 min
  • Razor-sharp cutting edge with polish wheel
  • Sticking of wheel with max. spindle load of 30 percent
  • Step drills
  • Form tools/drills
  • Stepped endmills
  • Miniature tools
  • Porting tools
  • Thread endmills
  • Indexable inserts
  • Reamers
  • Enlarged coolant supply 30 gal/min

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