GRINDSTAR

Highlights

Grinding Process

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Technical data

Equipment and Options

Workpieces

GRINDSTAR

GRINDSTAR - Profile and cutoff grinding machines

Replace turning with grinding

The GRINDSTAR machine concept replaces turning through the use of dressing-free high-speed plunge-cut grinding. This can open up enormous potential for savings, in particular when working with large production volumes.

Highlights

Customer-specific process and technology configuration
Grinding of difficult-to-machine and hardened materials possible
No chip removal problems, as small chips are transported away by the cooling medium
Machine availability greater than 96 %
Low-manned production and cost benefits due to grinding directly from bar stock
No burr formation

Grinding process descriptions

Minimal grinding times can be achieved with GRINDSTAR. This new kind of grinding method can be used both with CBN and diamond as an abrasive. Especially when dealing with large production volumes, this opens up scope for enormous savings. The machine is fitted with innovative coolant technology which helps to extend tool life. Machine availability is more than 96 %. Two different grinding methods are used in the machine: Firstly plunge-cut grinding/profile grinding, and secondly cut-off grinding. The essential synergy effect is achieved by combining the two methods in a single clamping set-up. It is also possible to collate similar parts, known as part families, to allow economical grinding to be achieved when working with smaller batch sizes.

: Grinding

: Turning

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GRINDSTAR

Technical data: GRINDSTAR

Grinding Length: 400 mm
Grinding Wheel Diameter: 520 mm
WxDxH mm (without peripherals): 2400 x 1800 x 2100
Weight: 4500 kg

Equipment and Options

TORSION-RESISTANT MACHINE STAND: The machine base has a torsion-resistant, low-tension design which ensures a high level of rigidity for the grinding process. The inclined bed ensures the optimum discharge of chips and minimal tension due to ultra-low thermal expansion.
METICULOUSLY DESIGNED MATERIAL AND WORKPIECE HANDLING: The bar feeder – with a capacity of up to 4 meters in the standard version and optionally up to 6 meters – takes care of the storage and infeed of bar stock. The bar feeder also removes bar material remnants. A pneumatically controlled pressure valve is used for reliable monitoring of the workpiece end position. It is integrated in the right-hand secondary spindle. Automated removal of finish ground workpieces from the machine is performed using a part catcher and conveyor belt.
EASY-TO-PROGRAM CONTROL SYSTEM: The machine is equipped with CNC path control. Its modular hardware and software makes programming tangibly simpler by simulating the familiar operation of a lathe. This ensures efficient and flexible application while cutting down on time required for familiarization.
VARIABILITY OF ABRASIVE: Depending on the application, galvanically bonded CBN or diamond is used as an abrasive. Once the grinding wheels come to the end of their long service life, the steel base body can be recoated.
SAFETY THROUGH FULL PROTECTIVE COVER: The full protective cover ensures complete encapsulation of the work area and complies with general safety regulations. A pressure relief valve is integrated in the cover.
SPECIFIC MEASUREMENT SYSTEMS: The measurement systems are also individually adjusted to the various workpieces and customer specifications. The measurement methods used allow captured measured values to be evaluated and used for measurement correction in line with the prepared measurement strategy.
SIMULTANEOUSLY SWITCHED WORKPIECE SPINDLES: The two synchronized workpiece spindles ensure optimum workpiece transfer for profile grinding and cutting off. Their speed can be steplessly adjusted depending on the application from 1 - 6,000 rpm. A hydraulically actuated collet chuck provides impressive ultra-precise concentricity.
STEADIES FOR GREATER GRINDING PRECISION: The two steadies arranged right and left ensure reliable support.
AUTOMATIC GRINDING WHEEL BALANCING SYSTEM: To ensure optimum grinding results, the grinding wheels are balanced using a balancing system integrated in the grinding spindle.
FIRE PROTECTION AND LTA AIR FILTERS: In case of an fire, the machine interior is automatically hermetically sealed, suffocating a fire before it has a chance to spread. If required, extinguishers (CO² or water mist systems) and exhaust air purification systems can be additionally installed. A competent partner for fire protection and filtration solution solutions is LTA Lufttechnik GmbH, which also belongs to the JUNKER Group and which researches, develops and produces filtration systems for industrial air purification.

The Filtration systems