KMT High Precision Grinding English 2012 - KMT Precision ...

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KMT High Precision Grinding English 2012 - KMT Precision ...

High Precision

Ranges up to 4 000 mm

Combination grinder replaces four machines

New control panel extends service life

World leader in

high precision grinding

by KMT


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Dear reader,

Here at KMT Precision Grinding, we are very proud of our long

history and the leading position in which we now find

ourselves. We have achieved this position thanks to our

committed, knowledgeable staff and our strong customer

base. We do not just sell grinding machines. We strive to

provide our customers total support from installation and

continuous aftermarket service, through the life of our

products with updates and renovations. This magazine

provides a few examples of our aftermarket and service

products. You can also find out how important precision is for

fuel injection components and what Hans-Erik Ångström,

internal combustion engine technology researcher, thinks

about the future.

KMT Precision Grinding is a company that is growing in

many ways, and we are constantly improving the service we

give to our customers. We are

increasing our workforce in

China in order to handle the

rapidly growing market in the

East. We are also focusing on the

American market, where we will

be taking part in the major IMTS

trade fair in the autumn.

Pleasant reading!

Thomas Karlsson,

President & CEO

www.kmtgrinding.com

KMT LIDKÖPING Tel: 0510-88 000, e-mail: infolidkoping@kmtgroup.com

KMT UVA Tel: 08-634 75 00, e-mail: infouva@kmtgroup.com

KMT USA Tel: +1 508 634 4301, e-mail: infoboston@kmtgroup.com

KMT China Tel: +86 10 652 20 515, e-mail: infouva_asia@kmtgroup.com

KMT Germany Tel: +49 7152 35 9390, e-mail: infouva_germany@kmtgroup.com

KMT India Tel: +91 981 082 4106, e-mail: infoindia@kmtgroup.com

Publisher: Ann-Christin Sandin Almén Project manager: Daniel Svensson Editor: Henrik Ekberg,

Håkan Hellström Photos: Stefan Svensson, Simon Johansson, Jennifer Nemie, Anders Nilsson, KMT

Layout: Örjan Folcke Ads: Malin Svensson Mediasales: Maud Svensson, Maria Sveed Production:

Roxx Communication Group, www.roxx.se Printing: Strokirk-Landströms, 2012

www.kmtgrinding.com High Precision Grinding | 3


4 | High Precision Grinding


Worldwide leader in the

field of precision grinding

KMT Precision Grinding has, today, subsidiaries all over the world. The

branches in Boston, Leonberg, Lidköping, Bromma, Gurgaon and Beijing

cover all time zones and provide a 24 hours support.

KMT’s subsidiaries in the US, China and Germany are

working with sales and aftermarket. The production sites

for new machines, rebuilds and repair work are located in

Sweden; rebuilds are also performed in Gurgaon, India.

KMT Precision Grinding, today’s world leader in the field

of precision grinding, is one of the oldest machine manufacturers

in Sweden. The company is a merger of UVA

International AB and KMT Lidköping, which were founded

in 1928 and 1875 respectively as Nomy AB as well as

Lidköpings Mekaniska Verkstad AB.

Lidköping started off with the production of exterior

lighting, park benches, ploughs and other agricultural

products. The engine construction started in 1902 and in

1908, we became one of the first suppliers to SKF, which

was established in 1907. UVA began production of

hydrodynamic bearings as well as gearboxes for, among

other things, railways. n

Some important dates

in KMT’s history:

1875 Lidköpings Mekaniska Verkstad (LMV) was founded

1928 Nomy, which became later UVA, was founded

in Stockholm

1929 LMV is incorporated in SKF

1979 LMV starts cooperation with partners in the US

1982 KMT Precision Grinding GmbH (today’s name) starts business

in Germany

1986 Lidköpings Mekaniska Verkstad AB (LMV) changes its name to

Lidköping Machine Tools AB (LMT)

1996 UVA is incorporated in Karolin Machine Tools (KMT)

2000 SKF sells LMT to KMT

2000 KMT opens office in China

2006 LMT changes its name to KMT Lidköping

2006 KMT Production Machinery India starts business Gurgaon, India

2007 UVA and KMT Lidköping merge and the company changes its

name to KMT Precision Grinding AB

2008 Nordstjernan takes over all shares of KMT

2008 KMT Beijing starts business in China

2009 KMT Precision Grinding Inc starts business in Boston, USA

2012 KMT has today approx. 180 employees around the world.

www.kmtgrinding.com High Precision Grinding | 5


Combination grinding machine

that replaces four single machines

A combination grinding machine from KMT can replace up to four machines on bearing

ring production lines. As well as saving on space, the ring never leaves the machine. All

operations are performed in one handling.

“This means that you can easily increase the production rate if you need to. We are world

leaders when it comes to these combination grinding machines,” says Jan Pettersson at

KMT in Lidköping.

The LIDKÖPING

SUUC 600

grinding machine

is used to

manufacture

bearings with

an inner

diameter of at

least 80 millimetres.

6 | High Precision Grinding www.kmtgrinding.com


KMT Precision Grinding has supplied the

market with combination grinding machines

via the two brands, LIDKÖPING and UVA, for

more than 20 years. There are many advantages

to being able to rough and finish grind both

internally and externally in a single operation.

All using one and the same machine

Instead of using four different single-use

machines for the various work elements,

everything is done by one and the same

machine. At the same time, you do not have to

load and unload the rings the way you have to

for single machines. Single machines require

more space and staff to run them, too. When

a ring is ground in a machine that only

executes one operation, there is also a risk of

the piece warping and becoming oval.

“The stresses in the ring after hardening,

among other things, are gradually released

when you grind internally and externally at

the same time. This means that we can grind

round rings that do not warp by clamping

them just once,” explains Jan Pettersson.

For the automotive, paper

and wind power industries

The rings manufactured in these machines are

normally for larger bearings, such as the ones

used in the automotive and paper industries

and in wind turbines. The LIDKÖPING SUUC

240 is used to manufacture bearings with an

inner diameter of at least 80 millimetres.

The biggest machine, the LIDKÖPING SUUC

800, is able to handle bearings with an

external diameter of up to 820 millimetres.

Tony Gustavsen, machine engineer, and Jan Pettersson, process engineer, at KMT in Lidköping.

The work side can be rotated by 90° for easy changing of the workpiece.

The rings are fed vertically into the machine

using a robot, thereby keeping the loading

time short. The total cycle time for the

smallest rings is just 40 seconds, and 15

minutes for the biggest.

“It is also easier to maintain high quality as

you are using the same tools in a combination

machine. Maintaining the tolerances in one

and the same batch is also simpler,” reckons

Tony Gustavsen, machine engineer at KMT in

Lidköping.

Customised to suit customer requirements

The company in Bromma manufactures UVAie,

which performs both internal and external

grinding of smaller products, simultaneously or

in sequence. This machine, which is part of the

UVA Nomyline series, is a modular product

which allows the machine to be fully customised

to suit customers’ requirements. n

www.kmtgrinding.com High Precision Grinding | 7


Robot based automation solutions

for the manufacturing industry

From single robot installations to

complete production systems

Artech Automation AB Laxå - Sweden

www.artechautomation.se Tel. +46 (0)584 44 44 80

Turn-key deliveries with full responsibility

from idea to production start

More than 800 robot applications

on the market since 1995

a company within the Artech Group”

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The Specialists …

Accessories

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…for frequency converters for grinding, dressing,

…for frequency converters for grinding, dressing,

milling and other high speed applications

milling and other high speed applications

We have a long tradition as a proud supplier of dressing

We have a long tradition as a proud supplier of dressing

and grinding systems to KMT Precision Grinding.

and grinding systems to KMT Precision Grinding.

If you need a special drive, we will have an adequate

If you need a special drive, we will have an adequate

premium solution for you, too.

premium solution for you, too.

Walpersdorfer Str. 38 Tel: ++49 (0)9122 63148 0

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Str.

/

38

Germany email:

Tel: ++49

info@bmr-gmbh.de

(0)9122 63148 0

Germany

91126 Schwabach / Germany

web:

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info@bmr-gmbh.de

Germany web: www.bmr-gmbh.de

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IMTS, International Manufacturing Technology Show, is the US largest manufacturing exhibition and gathers more than 85,000 visitors.

Focus on technology and productivity at

the US largest manufacturing exhibition

A superior service offer is what makes KMT stand out on the very competitive US

market.

KMT has found that a proactive approach to keeping machines well maintained leads

to better productivity,” says Brad Klar, President of KMT Precision Grinding Inc. USA.

“We also realize that costs associated with downtime are far greater when it is not

predicted. In preparation, KMT matches service programs with customer challenges.”

“We have a strong

focus on service, and

our service engineers

play an important

part in helping our

customers to make

money with their KMT

brand machines”, says

Brad Klar.

KMT Precision Grinding, Inc. is located

outside of Boston, Massachusetts. The

company consists of nine full time team

members, including sales specialists for

UVA, Lidköping, and Aftermarket Parts

and Service. Three of the employees

work at the Boston facility.

”We also have service engineers

strategically placed across the country

to be as close to the market and our

customers as possible,” says Brad Klar.

“While this only addresses part of all

the demand, the company also relies

on a network of first class independent

service specialists, all of whom have

had training and/or prior knowledge of

KMT brand machines.”

KMT machines are found in many

different manufacturing industries in

the US, but the two largest segments

are ball bearings and fuel injection.

A full service program

The US subsidiary provides a full

service programme to its customers,

including sales, installation, and service

of new Lidköping and UVA internal

and external grinding machines.

“We have a strong focus on service,

and our service engineers play an

important part in helping our customers

to make money with their KMT brand

machines”, says Brad Klar. “The service

engineers are often assigned to specific

plants so that they in turn become part

of our customers’ production team. In

doing so, our service engineers can

recommend common sense solutions

to optimize machine performance and

assure uptime.”

With programs such as these in

place, plant management can schedule

downtime for maintenance on their

own terms, and avoid the costs and

headaches of unplanned interruptions.

“There are KMT machines in the US

that have been in operation for 50

years, so there is definitely a strong

tradition to take very good care of

your equipment here,” says Brad Klar.

KMT offers machine upgrading,

rebuilding and refurbishing, thus

extending the life span of older

machines.

“Upgrades improve reliability and

productivity of the machines,” says

Brad Klar. “Another way to meet

changes in demand is retooling and

re-engineering.”

The service offer also includes repair

service, preventive maintenance

programs specifically tailored for

Dick Seiss is Service Manager at KMT Precision

Grinding Inc.

customer operations, and field service

support for mechanical, electrical, and

applications for all brands.

KMT at IMTS

KMT will be present at the IMTS

exhibition in Chicago on September

10–15. IMTS, International Manufacturing

Technology Show, is the US

largest manufacturing exhibition and

gathers more than 42,000 visitors.

“The IMTS is a great opportunity to

meet both existing and presumptive

customers,” says Brad Klar. “KMT will

focus on the technology as well as the

productivity of our machines. Welcome

to visit us in our booth N-6970!” n

www.kmtgrinding.com High Precision Grinding | 9


Photo: Anders Nilsson

WIND POWER IN THE WORLD

Wind power started to be expanded in the

early 1980s. In Germany, wind power accounts

for around 6 percent of the country’s electricity

production, and no less than 20 percent in

Denmark. Denmark was also where the

expansion of commercial wind power began.

Wind power is one of Denmark’s biggest

export industries nowadays. India, Spain,

China, the USA and Canada are other major

wind power countries.

10 | High Precision Grinding www.kmtgrinding.com


KMT’s contribution to a more

sustainable society is spelled V-T-G,

and its importance in the manufacture

of wind turbines cannot be

underestimated.

“Our biggest model, the VTG 4000,

can machine wind turbine components

more than four metres in size.

These bearings require a kind of hard

turning and grinding – which is

extremely demanding – in order to

produce the best possible end

product,” says Eive Johansson, chief

designer at KMT Precision Grinding

in Lidköping.

New technology and long tradition

meet in VTG machines

There is no doubt that wind turbines

will have an important role to play in

the future. And as the need constantly

grows, the wind turbines surrounding

us become bigger and bigger. At the

same time, demands for wind turbine

technology to be as efficient as

possible are becoming more stringent.

In this regard, the bearings in these

devices have a significant part to play

in reducing friction and permitting

stable rotation.

With all its experience of grinding

bearings, KMT was the first grinding

company in the world to invest in

machines that both grind and turn

components for industries that require

larger diameters, such as wind turbines,

offshore, and paper. The result: VTG

1 500 and VTG 4 000. The former

handles bearings with an external

diameter of between 500 and 1500

millimetres for the aircraft-, marine-,

offshore- and paper industries, while

the larger machine handles bearings of

between 1300 and 4000 millimetres

for the wind turbine industry.

Extremely large precision bearings

“The major advantage of these machines

is that they allow us to manufacture

extremely large precision bearings. We

have the same resolution for positioning

in these large machines as we have

in our smallest ones. The linear motors

are the same, it is just that they are

longer,” says Per Junskog, comparing

with a classic ball screw machine:

“The sliders are relatively slow and

lose precision as you increase in size,

but this is not the case with the linear

motors. We maintain the same high

precision even though we are

manufacturing bearings four metres

in diameter.”

The linear motors in the vertical

grindingmachines used for the

positioning of grinding wheels and

turning tools move incredibly fast

when a tool is changed. This is

important to a machine that handles

both grinding and turning where a

number of elements are included in

production. This speed, combined with

a carousel in a hydrostatic bearing and

hydrostatic sliders, resultsin minimal

friction, and makes KMT’s machines

unique.

“The latest technology in the form

of linear motors and our long tradition

of hydrostatics means that the linear

and rotary movements are more

accurate. Hence it is possible to

achieve an optimum profile on the

surface,” explains Eive Johansson.

Stringent demands on every part

There are bearings in several locations

in a wind turbine. For instance, they

can be found in the support for the

rotor blades, in the turbine shaft and

in the transmission. The more efficient

the beaings, ,the more easily the turbine

rotates and therefore less energy is

lost. The rotating rotor blades drive

the turbine shaft, and the bearings for

the turbine shaft can be up to four

metres in diameter. These bearings are

subject to major stresses. Stringent

demands are also made of certain

smaller bearings, even though these

are not subject to any major rigours.

“For example, the bearings located

at the blades are locked in a certain

position and therefore does not require

any high precision. But enormously

stringent demands are made of every

part in the device as the insurance

sums involved are huge,” says Per

Junskog.

The wind power industry has been

in a depression for a couple of years,

but Per Junskog believes that this is

changing because requests for KMT’s

vertical grinding machines are now

more common.

“This means that people’s interest is

on its way back. And we believe that

their quality demands will be more

crucial and that manufacturers of wind

turbines will also choose to invest in

quality products and bearings in their

devices. They stand to gain from doing

so in the long run.” n

Per Junskog, machine

salesman, and Eive

Johansson, chief

designer, at KMT

Precision Grinding in

Lidköping.

www.kmtgrinding.com High Precision Grinding | 11


High Precision Grinding

liDKÖPiNG

VtG1500/4000

Machine type Workholding Principle Work Piece Dimension

iD oD

VtG1500

VtG4000

internal /

external /

Hard

turning

Magnetic

chucking

UVA

NoMyliNe iNterNAl/

FAce/exterNAl

Inner Ring SRB

Windmill, radar Station

Hard turning/grinding

external or internal

Inner Ring

Gearbox,

large crane

Hard turning/

grinding

external or

internal

min Ø 440

max Ø 1 450

min Ø 1 000

max Ø 3 800

Slewing

Bearing

Windmill

Hard turning/

grinding

Valve Lifter Pump Head

Nozzle Grinding Pump Body

min Ø 500

max Ø 1 500

min Ø 1 300

max Ø 4 000

Machine type Workholding Principle Work Piece Dimension

UVAi internal chucking

oD Width

ø 0,5-100 max 200

UVAitwin internal chucking ø 0,5-36 max 120

UVAe external

UVAie

external/

internal

Chucking/

between centers

Download catalouge

on your mobile device

Download catalouge

on your mobile device

ø 1,0-80 max 160

chucking ø 1,0-36 max 160

Uvaiindex internal chucking ø 0,5-36 max 80

liDKÖPiNG

DG300/400/500/700/800

Machine Grinding Wheel Principle Work Piece Dimension

DG300 300 mm

iD

ø 5-160

oD

max 80

DG400 500 mm ø 15-240 max 120

DG500 500 mm ø 20-250 max 80

DG700 700 mm ø 190-610 max 250

DG800 800 mm ø 300-820 max 250

liDKÖPiNG

SUU240/320/600

Download catalouge

on your mobile device

Inner Ring DGBB

Bearing - Face

Outer Ring DGBB

Bearing - Face

Download catalouge

on your mobile device

Gear Part

Automotive -

internal

Outer Ring Flange

Bearing - internal

Inner RIng DGBB

Bearing - Face

Joints

Bearing - Face

Machine type Workholding Principle Work Piece Dimension

oD Width

SUU240

ø 20-240 max 120

internal/ Shoe

SUU320

external/

Flange

centerless/

centric

ø 100- 320 max 140

(rib Face) chucking

SUU600 ø 150-600 max 200

Inner Ring Spindle

Bearing - external

Inner Ring Truck HUB

Bearing - external or

internal or rib Face

12 | High Precision Grinding www.kmtgrinding.com


Machines

liDKÖPiNG

cl630/660

Machine Principle

liDKÖPiNG

SSB 110/200

Camshaft

Automotive -

external

Download catalouge

on your mobile device

Work Piece

oD

Outer Ring

Bearing -

external

Wheel Width

Inner Ring DGBB

Bearing - internal

Inner Ring DGBB

Bearing - internal

Wheel Ø

(WorN)

cl630 ≤125 300 (400) 610/630 (380)

cl660 ≤250 610 (700) 610/630 (380)

Download catalouge

on your mobile device

Joints

Automotive -

external

Machine type Workholding Principle Work Piece Dimension

oD width

SSB110

Ø 19-150 max 65

internal

Shoe

centerless

SSB200 Ø 20-160 max 100

Outer Ring HUB

Bearing - internal

liDKÖPiNG

SUUc240/600/800

Machine type Workholding Principle Work Piece Dimension

SUUc240

SUUc600

SUUc800

external/

internal/

Flange

(rib Face)

liDKÖPiNG

SGP62B

Shoe

centerless

liDKÖPiNG/UVA

NANo iD

Outer Ring Truck HUB

Bearing - external and internal

Outer Ring

Railway

Bearing - external

and internal

Outer Ring DGBB

Bearing - external

Inner Ring DGBB

Bearing - external

iD/oD Width

iD min ø 80

oD max ø 250

iD min ø 130

oD max ø 600

iD min ø 370

oD max ø 820

max 130

max 180

max 250

Inner Ring SRB

Bearing - external

and internal

Machine type Workholding Principle Work Piece Dimension

SGP628 external

Inner Ring DGBB

Bearing - external

Machine type Workholding Principle Work Piece Dimension

Nano internal

Shoe

centerless

Shoe centerless/centric

Download catalouge

on your mobile device

Download catalouge

on your mobile device

Download catalouge

on your mobile device

oD Width

ø 7-62 max 40

oD Width

min ø 8

max ø 72

www.kmtgrinding.com High Precision Grinding | 13

max 52


”What is driving

development is the

competition between

manufacturers, the

new emissions requirements

being specified

and customers’ desire

and also authorities’

demands for reduced

emissions,” says Hans-

Erik Ångström.

14 | High Precision Grinding www.kmtgrinding.com

Photos: Simon Johansson


Researcher Hans-Erik Ångström on KMT:

“It is wonderful that Sweden

has a company that can do

such precision work”

As emission requirements become more stringent, more stringent demands

are also made of the parts that control fuel injection in diesel engines; that

is to say, products manufactured by KMT’s Nomyline machines.

“It is wonderful that Sweden has a company that can do such precision

work,” says Hans-Erik Ångström, Professor of Internal Combustion Engine

Technology at the Royal Institute of Technology in Stockholm.

Machines which grind parts with

tolerances measured in thousandths

of a millimetre are manufactured at

the KMT plant in Bromma.

The amount of fuel injected in a

diesel engine has to be exact in terms

of both quantity and structure. Injector

nozzles control this fuel volume, and

KMT’s UVA Nomyline machines are

used to manufacture them. The major

challenge faced by the automotive

industry nowadays involves reducing

fuel consumption in order to reduce

emissions of carbon dioxide, for

example.

“Nowadays, system pressures are

being increased in order to reduce

emissions. But at the same time, this

increases the demands on our

products, and we are working hard to

keep up with developments to be able

to offer our automotive customers the

things they demand,” says Urban

Myrefors, site manager at the KMT

plant in Bromma.

0.3 micrometres in diameter

Pressures can be increased without

sacrificing strength by reducing the

diameter of the holes in component

parts. This makes even more stringent

demands of the grinding machine in

that the holes are slimmer. The

increase in pressure also means that

the shape tolerances of all the sealing

surfaces are tighter so as to reduce

leakage. According to Urban Myrefors,

Hans-Erik Ångström, together with Royal Institute of Technology students Hans-Christian Vinners and Bengt Aronsson.

there is currently extreme expansion in

the field and new systems are turning

up all the time.

“It is becoming harder and harder

to grind these components. For instance,

we are down to around 0.3 micrometres

in diameter, but our machines can

handle this because of the technology

in our designs, including hydrostatics

and linear motors,” says Urban

Myrefors.

Enormous stresses

Researcher Hans-Erik Ångström at the

Royal Institute of Technology, who

Urban Myrefors, plant

manager at KMT

Bromma.

used to work for Cummins in the USA

and as head of design at Scania, says

that there are no signs to indicate that

work on increasing injection pressure

in diesel engines is diminishing.

“There are enormous stresses on the

systems. And the actual pump that

generates the pressure cannot be too

big. What is driving development is the

competition between manufacturers,

the new emissions requirements being

specified and customers’ desire and

also authorities’ demands for reduced

emissions.”

>>>

www.kmtgrinding.com High Precision Grinding | 15


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cDD Dressing tools –

focus on the detail

Dressing-spindle systems

Dressing-spindle systems


What manufacturers are currently

working towards is the new EU

legislation on emissions, Euro 6, which

will come into force as of 31 December

2013. Essentially, this involves reducing

particulate emissions by half, and

reducing emissions of nitrogen oxides

by 77 per cent in all new trucks.

Hans-Erik Ångström feels that

finding a fast fuel mix to meet these

emission requirements would be a very

significant step.

“We have to find the right mix of

fuel to air which really gets into the

combustion chamber and has time to

mix before being ignited. But it is hard

to find the right mixture that operates

broadly; with different fuel volumes,

speeds and air densities. I think this is

what attempts are being made to

achieve, but I cannot claim that a

solution is particularly close at hand.

A type of combustion like this can be

achieved at low partial load at present,

but this is not possible for truck engines

that operate at maximum output.”

Research into biofuel

Hans-Erik Ångström and his colleagues

“We have to find the right mix of fuel to air which really gets into the combustion chamber and has time to mix before being ignited,”

says Hans-Erik Ångström.

at the Royal Institute of Technology are

currently working to see how biofuel

affects injection systems. But it is too

early as yet to say anything about that

research.

Ångström has worked together with

KMT previously on a project relating to

Hans-Erik Ångström and his colleagues at the Royal Institute of Technology are working to see how biofuel affects injection systems.

At GMN, clocks aren’t ticking faster than elsewhere in the world.

Considering the fact however, that we develop high frequency spindles reaching

highest rpm per second, it might be assumed that our seconds last longer than usual.

By now, we are developing materials and technologies that enable even higher

frequencies. And maybe one day, we can even steer the rotating speed of the sweep hand.

GMN Paul Müller Industrie GmbH & Co. KG

Äußere Bayreuther Str. 230 · D-90411 Nürnberg

a rotary injector. For this, KMT helped

to produce components for the research.

“It is fantastic that we have a

company in Sweden that can do such

precision work.

These are advanced components,

and KMT is a prominent player.” n

Phone: +49 911-5691-0

vertrieb.spi@gmn.de

UVA’s BAsIC MACHINEs

UVA in Bromma - part of KMT since 1996 – has

been manufacturing grinding machines for internal

combustion engine parts since 1965. Its production

line is made up of the tried and tested basic

machines:

• UVAi – for internal grinding

• UVAe – for external grinding

• UVAie – for both external and internal grinding

• UVAi Twin – offers two parallel grinding

processes

• UVA MC – simultaneous grinding from two

directions

These machines are modular and customised to

suit customers’ specific requirements concerning

the input and outfeed of parts, for example. The

machines can be configured for up to five internal

grinding operations or any combination of internal

grinding and flat grinding

www.kmtgrinding.com High Precision Grinding | 17

.de


The grinding machine

that never falls silent

The only thing that can really silence a centreless

machine is its electronics. But we have found an

effective solution to this at KMT Precision Grinding.

“We replace the control systems on site at customers’

premises. It takes no more than two weeks,” says Otto

Jernström, head of sales at KMT Precision Grinding.

“We have customers

who have handed

in machines that

have been operating

extensively for 30

years. Following a well

defined inspection and

subsequent servicing,

these machines are

like new,” explains

Otto Jernström.

The quality features of Lidköping

centreless machines are renowned. That

is why there is such enormous demand

for both old and new centreless

machines. The actual basic structure,

like all other KMT machines, is based

on hydrostatics in order to reduce

friction and eliminate wear in the most

susceptible locations. As a result,

hydrostatic slides, ball screws, and

grinding spindles retain the same good

qualities from year to year.

“We have customers who have

handed in machines that have been

operating extensively for 30 years.

Following a well defined inspection

and subsequent servicing, these

machines are like new,” explains Otto

Jernström.

Replacing customers’ control

systems

One problem that may be encountered

with centreless machines that have

been operating for maybe 20 or 30

years is that it is difficult to find spare

parts for the electronics, particularly

for the control systems. Quite simply,

this is because some parts are not made

any more. At KMT, this problem has

been resolved by offering customers

new control systems. The exchange

takes place at the customer’s premises

and does not take more than a couple

of weeks.

“The customer does not have to

send off the machine for a number of

months; the stoppage can be planned

well in advance. They have the

opportunity to run up production and

be ready when we arrive,” says Otto

Jernström.

High precision

First, all electronics are stripped from

the machine. Then we install a

completely new electrical cabinet, a

new control panel, new servo motors

and any other equipment required.

When everything has been installed

and all the cables have been placed,

the engineers at KMT test the function

of the updated centreless machine and

then restart it so that it can continue

production for many years to come.

Otto Jernström points out that KMT

still carries out complete renovations of

centreless machines at its plant in

Lidköping.

Over the years, KMT Precision

Grinding has supplied more than 4 000

centreless machines, predominantly

high precision machines. Rods,

Rebuilt CL630,

manufactured in 1983.

hydraulic pistons, piston pins, shafts,

pipes and rings for bearings are subject

to continuous grinding, giving a

throughput rate of up to several

meters per minute. A centreless

machines can supply six internal

grinding machines with parts.

“Our product development is very

much involved with fine-tuning the

technology and the process, as well as

with the software (PLC/CNC). We are

making progress on improving our

products every year,” says Otto

Jernström.

First machine in 1922

The first machine for grinding using

the centreless principle was supplied

by Lidköpings Mekaniska Verkstad in

1922. Many customers nowadays use

this kind of machine to grind various

components for cars, such as camshafts,

racks for power steering, universal

joint crosses or piston pins.

Of the 120 or so moving parts that

can be found in a four-cylinder engine,

more than half are normally ground

using the centreless principle. However,

these machines are also suitable for

grinding bearing rings and rollers for a

range of different bearing types, pistons

for hydraulic cylinders with extremely

stringent demands in terms of roundness

and diameter accuracy, strong steel

rods and shafts for electric motors. n

18 | High Precision Grinding www.kmtgrinding.com


KMT from a customer’s perspective

Antoine Hilaire works at the method

and development department at

Ascometal in France, and he answered

a number of questions we asked him

about KMT. Ascometal has more than

2 250 employees and manufactures

special steels for the automotive

industry, among others, with functions

for engines, injection, steering, transmission

and gearbox components.

Ascometal currently buys their shaft

grinding machines from KMT.

Are you happy with your grinding machines?

We certainly are. These machines are highly

productive and dimensioned correctly for our

production. They are incredibly robust, which

is evident from our products: high quality and

robust production. This means we have to do

very little maintenance. All mechanical and

KMT’s trademarks:

Everything in

Everything pneumaticsin

pneumatics

SMC Pneumatics Sweden AB

SMC Pneumatics Sweden AB

Ekhagsvägen 29–31, 141 71 HUDDINGE

Tel: 08-603 12 00 Fax: 08-603 12 90

E-post : post@smc.nu Ekhagsvägen Webbplats 29–31, 141 : 71 www.smc.nu

HUDDINGE

Tel: 08-603 12 00 Fax: 08-603 12 90

E-post : post@smc.nu Webbplats : www.smc.nu

n Linear Encoders

n Rotary Encoders

n Angle Encoders

n TNC Controls

n Touch Probes

electrical equipment is reliable and of very

good quality.

What types of product do you manufacture?

We produce small diameter metal shafts for

the automotive industry using a throughfeed

grinding process.

How would you describe your cooperation

with KMT?

KMT are receptive to our needs, and as part

of a joint project between Ascometal and

KMT we have produced the ultimate grinding

process for our products in terms of quality

and productivity.

What are the most important advantages

of KMT in its role as a supplier?

Experience, knowhow and the fact that KMT

know their grinding processes.

n Digital Readouts

n Length Gauges

www.heidenhain.de

What do you think of servicing and

aftermarket services at KMT?

KMT always have staff available to talk to us,

and they speak French. This is an advantage

for us. These are just a few reasons as to why

we think KMT provides a very good aftermarket

service. n

Serviceföretaget för induStri, handel och Sjöfart

Box 730, 531 17 LIDKÖPING, Besöksadress: Plastgatan 6 A, Tel. 0510-270 85,

Fax. 0510-293 65, www.vanermek.se, e-mail. info@vanermek.se

LANGED Industrial washers

and advanced lego production.

EFFICIENT

ECONOMICAL

ENVIRONMENT FRIENDLY

® Långeds Mekaniska AB

Tel. +46 (0)531 410 25 • Fax +46 (0)531 400 46

www.langed.com • info@langed.com

www.kmtgrinding.com High Precision Grinding | 19


Oliver Heidisch, service technician at KMT in Germany:

“We provide knowledge in how to improve

the productivity of the machines”

The service technicians are no doubt

the part of KMT that has the closest

relationship to the customer.

“In a way, it is our job that really

gives our company a competitive edge

over other machine manufacturers,”

says Oliver Heidisch, service technician

at KMT in Germany.

“We don’t just make the machines

work, we also provide knowledge in

how to improve the productivity of the

machines.”

Oliver Heidisch was employed by KMT in 2008.

Before that he worked at one of the largest

maintenance outsourcing companies in

Germany.

“I have trained for 3,5 years in industrial

mechanics,” says Oliver Heidisch. “The service

technicians at KMT have a very varied

background, but most of them have some

sort of higher technical education. Even

though they have different training, they are

all very experienced in maintenance and field

service support.”

Oliver developed his big interest in this

profession while in an industrial placement

during school. After the secondary school,

he decided to start his industrial training in

machine mechanics in a local company.

Close relationship

Oliver and the other technicians often visit the

same customers, and the service projects can

last for more than a year.

“It will certainly lead to a close contact

between the technician and the other work

crew, for instance at a production plant,” says

Oliver Heidisch. “We get a good insight in the

production reality of the customer, and a

good picture of the different situations than

can occur and affect the machines. We are a

great resource for the customer.”

Service technicians perform field service

support for mechanical, electrical and

applications, as well as machine rebuilding

and refurbishments, either on or off-site,

depending on the clients needs and wishes.

Common sense

The KMT grinding machines are high precision

tools, known for their longevity.

“And there is a lot that can be done to

extend the life of the machines, for instance

upgrade to new CNC controls, dressing

systems and sensors, or perform software

enhancements,” says Oliver Heidisch. “A lot

of the time, it is a matter of common sense,

like preventive maintenance. It is an easy step

to take, that will avoid the costs and inconvenience

of unplanned productions stops.”

“And there is a lot that can be done to extend the life of the

machines, for instance upgrade to new CNC controls, dressing

systems and sensors, or perform software enhancements,”

says Oliver Heidisch.

The customer always comes first for Oliver.

“In a way, we take a pride in our job to

provide service to our customers,” he says.

“Not just to meet their expectation, but also

to exceed them.” n

FACTs ABOUT OLIVER HEIDIsCH

Where he lives: In a small village in the

southern part of Thueringia in Germany

Age: 37

Family: not married, since 8 years a girlfriend,

17years old daughter

Education: 3,5 years, machine technician, after

that working in various companies as technician

for maintenance, rebuilding and repair

Hobbies: motorsport, sailing, cycling

20 | High Precision Grinding www.kmtgrinding.com


Control panel breathes new

life into older control systems

A new control panel in a Uvatronic 2

not only extends its service life. Its

communication is also considerably

more efficient.

“The new control panel has functions

to use a computer in the panel to connect

directly to the machine via Ethernet and

then we can solve the program changes,

etc. says Ronny Strandberg, software

developer at KMT in Bromma. “This saves

time and money for the customer.”

Although KMT Precision Grinding machines

are renowned for their long service life,

customers’ needs are constantly changing.

This is why KMT offers a range of different

upgrade packages to extend the service lives

of its grinding machines and increase their

productivity. One update that has improved

grinding results and reduced scrap for the

customer involves switching from a belt driven

chuck head to a directly driven one.

“This means that the motor drives the shaft

directly, leading to less disruption and better

results in the long run,” says Urban Myrefors,

plant manager at KMT’s plant in Bromma.

Faster Loading

He also mentions the introduction of a vacuum

gripping system produced in order to speed

siemens.com/sinumerik

up loading and unloading of work pieces. .

There are also various upgrade packages available

for updating older control systems and

offering optimisation of processes and the

software that controls the machine so as to

achieve shorter cycle times and better quality.

KMT is currently working on a new control

panel for machines fitted with the Uvatronic 2

control system. It looks much the same as the

control panel found on the latest control

system, Uvatronic 3.

“This control panel is being fitted with a

Windows PC, which this control system did

not have previously. Communication is routed

via Ethernet into a small PLC which converts

the format so that it is suitable for the

Uvatronic 2 control system. This means that

you can get a new panel to work on an older

machine,” explains Ronny Strandberg.

Easier to use

Instead of traditional buttons, the new panel

comes with pushbuttons on the screen; it is

also equipped with a detachable pendant

which allows the operator to work a short

distance away from the machine. But

according to Ronny Strandberg, the biggest

advantage is the built-in computer which

allows the customer to get help easily and

quickly if anything goes wrong.

Urban Myrefors, plant manager at the KMT plant in Bromma.

“Quite simply, the customer establishes a

connection with us so that we can perform

actions from the office instead of having to

travel out to the customer’s premises. This

saves a lot of time and money as there is less

travelling involved and no need to explain a

problem over the phone, a task which can

sometimes be quite difficult.” n

Increase productivity using SINUMERIK

The innovative CNC platform to meet all requirements

www.kmtgrinding.com High Precision Grinding | 21

90886_E20001-F600-P610_AZ_SINUMERIK_Solution_Dachmotiv_186x65.indd 1 21.06.12 13:49


SlipNaxos shows 100 years of company history with 185

employees and a turnover of 320 MSEK in 2010.

Our activity consists in development, production and sales

of grinding wheels to worldwide industries.

The company is part of the Swiss group Winterthur Technology

Group, which is owned by 3M with more than 7500

employees within Research and Development and a total of

approx. 80.000 employees.

The largest part of our production consists of custom-made

grinding wheels, which have been developed to serve a

specific grinding operation or machine. The company’s large

resources and flexibility enables us to provide our customers

with the best possible service and the lowest possible

total costs.

Together we

make industry

more efficient

As cooperation partner

of KMT, TOOLS supplies

overall solutions for

products and services for

process, maintenance,

repair and operations

– we call that MRO

www.tools.se

22 | High Precision Grinding www.kmtgrinding.com


Aftermarket service for KMT Trademarks

LIDKÖPING and UVA

KMT Precision Grinding offers a large number of products and services, which

provides the customer with a maximum use of his investments. Training,

upgrades and optimization present one part of the services provided.

1. FIELD SERVICE

• Emergency support

• Production support

• Preventive maintenance

• Inspection and analysis

2. SPARE PARTS

Original parts for UVA and LIDKÖPING

3. TOOLING

• New design

• Tool spares

4. REPAIRS

• Spindles, slides, circuit boards etc

5. UPGRADES

LIDKÖPING

• UPS Power Backup Solution

• Ballscrew & Harmonic Drive (Centerless)

• Control System

• Acoustic Emission

UVA

• Upgrade to CMP-70

• Vacuum Loading

• Cycle Time Reduction

• Direct Driven Workhead

• Servo Optimization

• New control panel UVATRONIC

6. REBUILDS

• Complete rebuild of old

generation grinding machines

7. TRAINING

Grinding

• Mechanics

• Electrical and electronic

• Maintenance and preventive maintenance

8. SERVICE HOTLINE

SERVICE HOTLINE UVA

GMT 06.00–16.00

Phone: +46-8-634 75 33

Fax: +46 8-634 75 75

E-mail: infouva@kmtgroup.com

SERVICE HOTLINE USA

GMT 13.00–22.00

Office: +1 508 634 43 01

Cell: +1 617 335 4800

E-mail: serviceboston@kmtgroup.com

SERVICE HOTLINE ASIA

GMT 00.00–08.00

Phone: +86-1065 2205 15

Fax: +86-1065 22 06 63

E-mail: infouva_asia@kmtgroup.com

SERVICE HOTLINE LIDKÖPING

GMT 06.00–16:00

Phone: +46 510 88 112

Fax: +46 510 880 42

E-mail: servicelidkoping@kmtgroup.com

www.kmtgrinding.com High Precision Grinding | 23


CNC CONTROLS DRIVE SYSTEMS LASER SYSTEMS SERVICE

Ett väl beprövat CNC.

Nu på en ny nivå!

NYTT: gemensam fi berbuss

för spindlar och axlar

NYTT: Auto-korrigering och

Auto-diagnos

NYTT: utökade NC-cykler

NYTT: Automatisk back up.

Direkt i styrningen

FANUC Series 30i-B – den nya högeffektiva

styrningen för avancerade maskiner

Nu ännu bättre: Den nya serien 30i/31i/32i-MODEL B med en snabbare modulär PMC

med upp till fem kanaler. Perfekt för styrning av avancerade maskiner med upp till

32 servoaxklar, 24 simultant interpolerade axklar och åtta spindlar. Med extremt korta

bearbetningstider vid högsta precision ned till nanometer. För krävande svarvning, fräsning

och slipning och avancerade 5-axliga tillämpningar. Mycket användar- och underhållsvänlig.

Och alltid med världens högsta tillförlitlighet.

Det är bara en av våra starka sidor.

FANUC FA Nordic AB

Hammarbacken 4B / SE-19149 Sollentuna / Tel.: (+46) 8 505 80 700 / Fax: (+46) 8 505 80 701

info@fanuc.se / www.fanuc.se

NYTT: Tre gånger snabbare

PMC

NYTT: fl era funktioner för

5-axliga maskiner

NYTT: Energimätningsfunktion

för optimerad energianvändning

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