Manufacturing Machinery World November 2019

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FINISHING ON A HIGH NOTE With so much added value already invested in a component, the last thing any engineer needs is to scrap parts due to poorly performed grinding operations. One of the most popular ways of avoiding this undesirable situation is to invest in the latest grinding machine technologies, which is exactly the case at Huddersfield-based Meltham Carbide Precision. The company has become one of the latest to install a Rollomatic CNC peel-grinding machine, which is available in the UK from Advanced Grinding Solutions. Meltham, which was founded in 1976, and is owned and managed by Eric Charlesworth, is a specialist manufacturer of plug gauges and components such as punches, mould and core pins, and blank carbide rods for the cutting-tool industry. Eric Charlesworth had been aware of Rollomatic tool grinders for some time, and had identified a need for grinding his parts to a higher precision and reducing manufacturing times. Having received a demonstration of a Rollomatic machine, Meltham was attracted to its pinch and peel method, which ensures that the grinding operation is always performed immediately adjacent to where the component is supported. This capability allows parts featuring very large length-to-diameter ratios to be machined easily, with component lengths up to 400 times diameter being ground without deflection issues and with diameters controlled to under 0.002mm. Just one example of how the machine has improved efficiency is in manufacturing a set of 10 carbide punches of 6.35mm diameter by 110mm long with a point, radius and three different diameters, to 5µm tolerances. “This would have taken us a full day to manufacture previously, but now, on the Rollomatic we need just 15 minutes to set up and around 2 hours to grind,” says Eric Charlesworth. “The surface finish is also much better, while the lengths and diameters are all well within tolerance.” Elsewhere, a leading European producer of helical and spur-tooth pinion gears, has selected a GTG2 gear-grinding centre from Holroyd Precision to test-grind a range of specialised gears and tooth forms. Developed purposely for grinding precision spur and helical gears, worms, screws, and rotors of up to 350mm diameter and 160mm gear face width, Holroyd GTG2 grinding centres use what is described as a unique machining system to achieve accuracy to DIN 2 levels and beyond. Steven Benn, Holroyd’s regional sales director, says: “The GTG2 was selected for its versatility, reliability and accuracy – the latter achieved through high levels of on-board machine intelligence and a machining process developed to compensate for helical twist.” Helical twist occurs when helical gears are ‘lead crowned’ to improve meshing and reduce noise and wear. Lead crowning varies the GRINDING & FINISHING amount of material removed from the flank of a tooth, across the face width, by causing the tool motion to deviate from a true helix. The problem is that ‘in-form’ grinding has the undesirable effect of causing the profile of the tooth flank to vary across the face. Particularly in high precision and low-noise applications, this variation affects gear-wheel performance by concentrating loads on particular areas of teeth during meshing. GTG2 machines correct this problem by calculating and controlling additional motions of the wheel during the grinding operation. Dedicated surface finishing solutions are also proving popular across industry, as evidenced by a new stream-finishing machine featuring OTEC patented pulse-drive technology ‘Pulsfinish’ at Bury-based Fintek. Fintek operations manager Jamie Phillips says: “The difference Pulsfinish makes to mass finishing is substantial. Pulse finishing produces rapid relative motion between the media and workpiece by quickly changing the rotational direction of the workholding heads in a programmed and controlled way. High acceleration and deceleration increase the finishing forces exerted on the workpiece, making it possible to accurately and evenly deburr round and smooth surfaces from Rpk 0.2µm to 0.1µm, in under a minute.” Demand also remains high for tool and cutter grinding solutions. A case in point can be seen at Industrial Tooling Corporation (ITC), which recently took delivery of an MX7 Linear grinding centre from Anca. The MX7 Linear is the fourth Anca grinding centre acquired by ITC and the fifth such machine to arrive since the company extended its manufacturing facility by over 50% in 2016. Able to process tools up to 300 mm long, with diameters up to 200 mm, the MX7 Linear uses Anca LinX linear motors and scales. With respect to productivity, the latest arrival at ITC incorporates Anca’s FastLoad-MX automation system. The FastLoad-MX uses existing machine axes to ensure a compact design with a small footprint. Loader movements are kept simple, allowing ITC to undertake the grinding of tools in small batch sizes. New innovations in the tool grinder segment include the Vollmer VHybrid 360 grinding and erosion machine, which can be used to produce solid carbide and PCD cutting tools in a single set up. VHybrid 360 is based on multi-layer machining, which is implemented through two vertically arranged spindles. The bottom spindle can be used for both grinding and eroding, while the top spindle is reserved exclusively for grinding. From a blasting perspective, Guyson International has created a universal automated blast system that is based on the company’s existing Multiblast RSB. The latest system incorporates roof-mounted servo drives to provide saturation coverage from the attached blast guns across the entire rotating table, thus delivering full blast coverage to all components. An interesting honing development has seen Applied Nano Surfaces (ANS) of Sweden enter into a joint development programme with Sunnen that is focused on the patented ANS ‘Triboconditioning’ process, which is designed to reduce friction and wear on a variety of honed parts and components. Triboconditioning is a combined mechanical/chemical surface-treatment process that uses a machining procedure to level off surface peaks and apply a friction and wearreducing compound to the component surface. Unlike spray coatings, the compound becomes an integrated part of the component structure at a nano level. The process is mechanically simple and, in most cases, can be performed with Sunnen honing equipment. As a final aside, Jones & Shipman Hardinge says it now offers a rebuilding and upgrading service for its grinding machines, including those by sister companies in the Hardinge Group – Kellenberger, Hauser, Voumard, Tschudin and Usach. “It’s a service designed to maximise the lifespan of a machine which, while perfectly sound in structure and capability, could benefit from upgrading,” explains Jones & Shipman Hardinge UK managing director Mike Duignan. “If you take a universal Kellenberger Varia for example, a refurbishment and upgrade to include the latest Fanuc 0i control with the new Kellenberger menu-based programming software, could be as much as 25% cheaper than buying a new machine.” 20 Manufacturing Machinery World, November 2019
A. J. Baker (Grinding) Ltd Specialists in the supply and rebuild of CINCINNATI CENTRELESS GRINDING MACHINES Providing high quality , high precision grinding services since 1995. • CNC grinding • Surface grinding • Thread grinding • Centreless grinding • Honing • All materials Te el: 0116 271 8188 Email: nfo@centralgrinding.co.uk www.centralgrindingservices.co.uk Additional Service Include: • Manual / CNC Controls • Machines can be supplied Rebuilt, Reconditioned or Overhauled. • Cincinnati spare parts MIDDLEMORE LANE WEST, REDHOUSE INDUSTRIAL ESTATE, ALDRIDGE, WALSALL, WEST MIDLANDS WS9 8BG, UK Tel: +44 (0)1922 745075 Fax: +44 (0)121 378 3291 Email: enquiries@ajbaker.com Web: www.centrelessgrinders.com For all your vibratory finishing equipment and materials Manufacturing Machinery World, November 2019 21
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