grinding
Grinding is still big business for UK manufacturing, and
nowhere was this fact more evident than at MACH 2008.
Steed Webzell reports
Grinding shows true grit
ACCORDING to the MTA the value of imported and
exported grinding and finishing machines in 2007 totalled
£96.5 million. With innovation a huge factor in attracting
new buyers, designers of grinding technology have
been industrious, hoping to capture a significant
slice of the potential rewards.
Beginning with universal grinding
centres, one new model to catch the eye at
MACH was the Toyoda Select G-100 from
600 Centre. This flexible machine can be
changed from straight to 30 o angle
approach by rotating the wheelhead.
Capable of accommodating parts up to
300mm diameter by 1000mm between
centres, it employs the latest STAT hybrid
spindle bearing. This combines the
benefits of hydrostatic and hydrodynamic
technology, providing higher spindle
stability than conventional bearings. When at
rest, the hydrostatic pressure maintains the wheel
spindle in the centre of the bearing eliminating any metalto-metal
contact during rotation. This configuration
improves damping and rigidity, and absorbs vibration.
Another new universal, on the Hardinge stand, the
Kellenberger Kel-Vita, is suitable for cylindrical, jig, face,
and ID/OD grinding technology requirements. A compact
machine suitable for production environments
(medium/large batch series production), it features the
GRINDplus IT control. For visitors seeking innovative
surface grinding solutions, Dorman Machinery offered the
new ABA Ecoline, which features linear guideways preloaded
for fast movements on all CNC axes, avoiding the
stick-slip effects that are familiar on some grinding
machines. Heavy loads can be handled easily and the linear
motor drive runs at a velocity of 60m/min. Visitors also had
the chance to see the latest in centreless grinding
technology via the Tschudin Granitline, a machine that
offers a configuration boasting six numerical axes.
Latest tool and cutter grinding machines from Anca
included the TX7 + Xchanger
which sees wheel packs increased
from two to 16, with coolant pipes
changed with the wheel arbours
taking the machine to new heights
of productivity. The machine also
features a ‘P-axis’ NC steady support
for grinding long drills. For wheel
technology, the new VIPER Ultra on the
Tyrolit stand extends grinding
performance on normally difficult to
machine nickel alloys. VIPER Ultra wheels
Tool and cutter
grinding developments
included the TX7 +
Xchanger
ABA Ecoline delivers an
innovative surface grinding
solution
48 MWP july 2008
have a new matrix and are made using a sintering process
that controls wetting and coating of the grain surface,
which improves bonding of the grain. The highly porous
bond system can absorb high dynamic
loads without damaging the bond
bridges, optimising use of the abrasive grain.
Lower grinding forces result in reduced
stress on the component and workholding
system. Power consumption is less and the
lower heat input to the workpiece
minimises the risk of burning. Cool
cutting is particularly important when
grinding nickel-based aerospace
components such as turbine blades, rotor
blades and nozzle guide vanes, primary
applications for VIPER grinding. Two sets of
comparative, non-CD grinding results on nickel
aerospace components using VIPER Ultra wheels and
their predecessors highlighted productivity improvements .
A Makino iGrinder G5 was used to grind the dovetail
form on a rotor blade in two operations. The machine was
fitted with a VIPER Ultra wheel, 220mm diameter by
25mm wide, running at 40m/s. Table speed was 2m/min
and infeed was between 0.1 and 2.0mm, depending on the
operation. A 30% increase in the number of components
ground per wheel from 200 to 260 was achieved as well as a
35% increase in productivity. The result was an annual cost
saving of ¤42,000 based on 35,000 blades per year.
In a second application, the fir tree root form of a
turbine blade was ground on a Bridgeport FGC 2 in four
operations using a 250mm diameter by 25mm wide VIPER
Ultra wheel running at 40m/s. Table speed was 1.5m/min
and infeed varied from 0.1 to 1.5mm. Production per wheel
jumped from 150 to 250 parts per wheel - a 67% increase -
and productivity was 30% higher. An annual cost saving of
¤20,000 was achieved based on 20,000 components per year.
Other innovations to draw attention at MACH included
the VM20, a multi-function and modular process
measurement and control system for use on
grinding machines. The VM20,
from Balance Systems UK, is
capable of wheel balancing,
touch sensing and in-process
gauging functions.
www.600centre.com
www.hardinge.co.uk
www.dormanmachinery.co.uk
www.anca.com
www.tyrolit.co.uk
www.balancesystemsuk.com
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