Product category:
Abrasive machining - manual and CNC machines
News Release from: Emag UK | Subject: Emag Karstens HG 204 S CNC cylindrical grinder
Edited by the Manufacturingtalk Editorial
Team on 04 November 2003
Production grinders feature configurable
platforms
For external cylindrical, out-of-round, face and internal grinding operations a new design platform allows for a number of machine variants to be configured in accordance with individual wishes.
The amalgamation of Reinecker, Karstens and Kopp combines the grinding know-how of the Emag Group under a single roof Each of the three companies can tap into many decades of in-depth experience in the manufacture of grinding machines and the application of its technology
This article was originally published on Manufacturingtalk on 12 Nov 2001 at 8.00am (UK)
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EMAG is a market leader in vertical machining
EMAG has literally turned machining on its head.
The pick-up-principle simplifies automatic loading and unloading of workpieces at almost no extra cost.
This collective experience has left its distinguishing mark on the new design platform, which allows for a number of machine variants to be configured strictly in accordance with individual customer requirements.
The machines provided by the Emag Grinding Group cover everything from the grinding of prototypes to the production grinding of large batches of small or large, long or short shaft-type components externally (know-how Karstens), and from the internal and external grinding of high-precision chucked components (know-how Reinecker) to the grinding of cams and camshafts (know-how Kopp).
To a large extent, the basic machines - even for very different manufacturing tasks - are identical, with all the advantages this brings the user: standardised operation, programming and maintenance, resulting in a shorter learning curve and lower maintenance costs.
Further reading
EMAG UK - a company profile
Since its foundation in 1984, EMAG UK has established a strong position in the UK automotive market supplying CNC multi-functional production centres.
Turrets feed vertical shaft turning centre
Following on from its earlier horizontal shaft turning machine, Emag has developed a vertical shaft turning machine using two turrets to exchange workpieces as well as perform machining.
Grinding and automation expertise extended
With the integration of Ingersoll Naxos crankshaft grinding machine company into the Emag Group, systems can be developed in conjunction with Karstens, Reinecker, Kopp and Heilig Automation.
It makes the use of available personnel more flexible and easier to plan, and allows for multiple-machine operation.
At EMO 2003 we shall be showing the smaller size 2 version, the Emag Karstens HG 204 S for the external cylindrical grinding of medium sized shafts of max.
400mm length.
The machine is based on the new design platform (Figs.
4061, 4054) for grinding lengths of max.
3000mm and grinding wheel diameters of max.
610mm (standard version).
The type 204 F is designed for the grinding of chucked components of max.
400mm dia.
Grinding as finish machining process - today and tomorrow - quality requirements, for ground components in particular, are increasing steadily.
At the same time, the integrity of the process capability is becoming the main criterion in volume production grinding.
Values of Cpk 1.67 / Cpk 2.0 are a reality.
Other important objectives of production planning today are short, flexible production sequences.
Short retooling times must be achieved, to ensure that component manufacturing costs do not rise despite a steadily increasing workpiece diversity and the shrinking of batch sizes.
In addition to that, different batch sizes and workpiece contours require different automation concepts.
The machining result depends, to a large extent, on choosing the correct grinding tool.
Modern machine designs have to take into account the demands made by different grinding wheel abrasives.
This applies to coolants too, which are of equally fundamental importance to the machining results.
Although, in the past, machine manufacturers (and frequently also the machine user) have paid little attention to these matters, it is imperative that all future machine designs thoroughly address them.
The new modular design for cylindrical grinding - in the HG series of machines from Reinecker Karstens Kopp the new generation of horizontal grinding machines from the Emag Grinding Group takes account of all the demands made on modern cylindrical grinders.
The basic assemblies, such as spindles, measuring devices and drives are manufactured in large numbers within the Group and assembled into working entities of modular design.
This includes, in particular, a variety of work headstocks, grinding units, tailstocks, measuring and dressing attachments for CBN and corundum grinding wheels, as well as interfaces for loading and unloading equipment.
The thermo-stable machine base, which carries the slides, is of high static and dynamic rigidity.
The sturdy compound table design reduces the footprint and saves on expensive production floor space.
It also makes the changeover of grinding wheels easier.
NC tailstocks and flexible drivers ensure that a variety of workpiece sizes can be quickly accommodated.
The machining area allows generous axis movement.
The energy supply circuitry is maintenance-friendly.
High-precision, play-free, preloaded linear roller guide rails in all linear axes allow for smallest infeeds, with optimal continuity of movement.
These stick-slip-free and well-dampened infeeds and axes tracks lead to contour integrity and an exceptional surface finish.
The machines are prepared to accept cutting oils as well as emulsions and allow high-pressure and high-volume deliveries that also facilitate CBN technology.
The demands for operator comfort and ease of service are fulfilled by a standardised control system that covers all applications.
The Emag on/off-line operating and programming system takes care of the varied demands made on this modular machine design by the different machining challenges.
All process-specific functions, including loading, gauging, etc., can be called up with standardised commands and are dialogue-based - a very operator-friendly feature.
Other demands from production companies have also been taken into account.
Energy supply lines are located outside the machining area.
This prevents contamination and downtimes, makes for an uncluttered machining area and increases maintenance-friendliness.
The machine enclosure is separate from the machine base, so that outside influences can have no adverse effect on machining results.
A modular design for a wide range of applications - the various grinding lengths and the different sizes of grinding spindles, work headstocks, tailstocks and back rests allow for the machining - between centers - of a large variety of workpieces from many branches of industry and weighing up to 1000kg (size 3 machines) / 250kg (size 2 machines), using a tailor-made machine and the most appropriate grinding method.
Such workpieces include gear shafts, shafts for differential gears and electric motors, pinions for pumps and steering systems, slide valves, steering gearboxes, turbine and compressor wheels, axles, main spindles, components for textile machinery, for wind power generators and for other high-precision devices.
HG platform for the machining of chucked and shaft-type components and for out-of-round machining - the basic idea behind the development of a size 2 machine in this series is to be able to offer a universal production grinder with the emphasis on external cylindrical and out-of-round grinding of batches of shaft-type components as well as chucked components.
The individual machine units are of modular design and the machines can also be used for angle head plunge grinding as well as face and internal grinding.
The combination of external, internal and face grinding processes in a single set-up on a single machine clearly illustrates the high degree of flexibility of this machine series.
Typically, the HG series allows you to complete-machine rota-symmetrical workpieces in one set-up.
The proper automation components for (almost) every application - depending on their intended use, the machines of the HG series can be manually loaded and unloaded, or alternatively automatically loaded by one of a selection of workhandling systems.
At EMO 2003 Emag showed a smart solution: an integrated loader in conjunction with an Emag Heilig palletising unit.
The integral loader handles the direct loading and unloading of the workpieces and comprises a compact design with minimum traverse distances, to ensure the shortest load and unload times.
In order to remove the need for synchronised workpiece flow interlinked machines are designed to include an in-process storage facility in the form of a palletising system.
The workpieces are deposited in stackable baskets or pallets and then transferred to the palletising unit.
The stacker units are accessible individually and can thus be loaded, unloaded or exchanged independently, thus providing the machine operator with a large time slot during which to exchange pallet stacks containing finish-machined components and raw parts.
Moreover, the system also allows a single machine operator to service several machines with components. Request a free brochure from Emag UK ...
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