The needle nozzle directs the coolant to the cutting site. The result is an extremely good cooling effect on the tool and the workpiece. The consumption of coolant is also reduced.
Instantaneous tool change speed, extremely short work assist time and changeover operation, all buttons need only to be pressed. The modern centerless grinding machine exploits a very competitive manufacturing process to uncover considerable productivity potential. According to different use cases, the advantage of production efficiency can reach 100%.
In a centerless grinding machine, the potential for improving the workpiece processing cycle is often not only reflected in the grinding process, but also reflected in the conveying of the workpiece. The new Kronos speed centerless plunging type grinding machine with high-speed centerless feeding device (HSCL) can be used to process slender workpieces with diameters up to 8 mm and lengths up to 80 mm. The workpiece replacement time is <1s (Fig. 1). As a result, Studer Mikrosa's traditional 3s workpiece change time can be reduced by more than 60%. This also has an impact on the overall machining cycle time of the centerless grinder: for the end user, its production efficiency can be greatly improved, and the cost per piece can be reduced significantly.
Fig. 1 Kronos speed plunge-cutting centerless grinding machine for workpieces with a diameter of less than 8mm and a length of less than 80mm can be finished in 1s
Studer Mikrosa and engineers at Wenger Automation & Engineering in Winterthur, Switzerland, have developed HSCL's new loading system, which uses coolant as the conveying medium for the workpiece: the coolant lifts the workpiece from the workpiece holder (applied Patented hydraulic lifting principle) and replacement of the workpiece within <1s. The easy-to-operate feeding device control system is integrated into the machine's control system, and the workpiece's forced transport guide ensures safe transport. Since the feeding device is pneumatically driven, there is no need to invest expensive auxiliary equipment.
Pneumatic components built into the machine
Pneumatic components are also integrated into the machine. In addition, the use of compressed air also ensures that the cooling lubricant is hardly carried away: in the case of conventional loading devices, the workpiece loses part of the cooling lubricant attached to its surface when the workpiece is blown, so there is only a small amount of cooling lubricant. The cooling lubricant is conveyed along with the workpiece. Mikorsa intends to abandon the expensive NC axes on Kronos speed equipment, but instead offers a new type of centerless grinding machine and a turnkey, fast, space-saving and maintenance-free engineering solution. The feeding device can use both thin oil and emulsified oil for transmission, so its applicability is very wide, such as for single and double shift production and continuous two-shift operation.
When investing in internal business accounting, it is necessary not only to take into account acquisition costs, but also to consider some related costs in the future, such as the repair and maintenance of energy and related components. Only in this way can all the costs be known before making an investment decision. In this way, a more cost-effective equipment can be found rather than an expensive one because process time, long-term quality assurance and other factors cannot be explicitly included in equipment costing.
The most important basis for understanding TCO is the difference between direct and indirect costs. There is a so-called "downtime" that belongs to indirect costs, that is, the system is not used to directly create value for workpiece grinding operations. Mikrosa aims to significantly shorten this time by improving the production efficiency of the centerless grinder.
It is the goal of all manufacturers to flexibly use mass production processes and minimize the time for reloading. In the process of centerless grinding of large batches of processes, it often takes a lot of adjustment time and replacement time. This process designer must first consider these factors of centerless grinding when designing the process flow. In addition, this concern about the so-called "uncontrollable complexity of the process" often leads to investments that tend to be less efficient, but seemingly simple.
Investment determines TCO utility
Since people cannot make a one-to-one technical comparison of the grinding process with respect to the grinding process, the unintentional grinding investment cannot be widely recognized, and its huge cost saving potential may not be tapped by the processing industry. Compared with other processes, centerless grinding has enormous economic potential. In different applications, its production efficiency advantage can even reach 100%. As reflected by the TCO, a cost audit should be conducted before investing in equipment at lower acquisition prices and higher TCOs.
The centerless grinding and the manual adjustment of the equipment usually require longer adjustment and up-loading times than during the two peak hours of processing, but by adopting such a process with great potential for production efficiency, the above-mentioned deficiencies can be remedied. In order to greatly reduce the ancillary time during processing, Mikrosa integrated a new, easy-to-use software module in the control system. In a conventional centerless grinding machine, both the calibration of the B-axis and the rotation of the regulating plate are performed mechanically. On the Kronos S-type device, these adjustment functions are automatically performed by independent calculation models and the control system of the device.
Press the button to reduce the auxiliary time and realize the replacement
So far, if you want to ensure the safety of unmotivated processing (Figure 2), you need to have a lot of work experience. This perception of the process can sometimes make potential users feel unsure. Of course, the regulation of a centerless grinder is itself a more complex task. For the roundness of centerless grinding, the decisive factor is the angle relationship between the selected workpiece and the grinding wheel, the workpiece and the workpiece support, and the contact point between the workpiece and the adjusting grinding wheel. When the "Grind Gap Geometry" is erroneously adjusted, a circular appearance is not produced, and the workpiece forms a corresponding polygon in the μm range. In order to repeat this complex adjustment process and allow many different equipment operators to master the adjustment process, Mikrosa developed the Heureka control integration software. This software helps the operator to master the complex process (Figure 3) by which the optimum workpiece support height and angle adjustment values ​​can be measured for a variety of different machining tasks, thereby enabling the grinding process to be The stable operation of the entire effective diameter range of the cutting plate and the adjusting plate also ensures the required workpiece roundness.
Figure 2 Quality results of paired nozzle pin grinding (rated size deviation ± 0.0005mm)
Expert system integrated into the control system
In the past, not only was this so-called “geometric roundness effect†causing headaches for many equipment operators, but also the dynamic performance of the equipment was not satisfactory. In this regard, Mikrosa integrated an expert system in the control system of the Kronos equipment, which can match the speed relationship of the equipment with the mechanical frequency characteristics of the moving mechanical components, thereby avoiding the limitation of dynamic characteristics. Caused roundness errors.
Fig. 3 Heureka software can be used to measure the optimal workpiece support height and angle adjustment values ​​for a variety of different machining tasks. This enables a stable grinding process.
In order to be able to take full advantage of this grinding process, the machine tool needs to fully demonstrate its compliant static and dynamic stiffness and good "thermal stability" characteristics. For nearly a decade, Mikrosa has been using a mineral cast iron body (Granitan) for its equipment. This material has excellent thermal stability and damping properties. The basic conditions of good system rigidity have already passed through the extensive dimensioning and FEM thermal symmetry optimization design of the equipment components as early as the development stage. When the important surface in the centerless cylindrical grinder not only need to be polished, but also when the artificial scraping grinding, the equipment also showed a very stable. The surface is hand-finished by experts (Figure 4). As a result, the load-bearing portion is greatly improved, and this processing quality cannot be achieved by the processing equipment. The scraped parts are all surfaces that are important for the quality of the equipment, such as the bearing holes of the grinding shaft and the adjustment shaft, or the bearing surfaces of the spindle box and the workpiece holder. Customers can produce with stable processing accuracy and achieve long-term quality assurance. Before each new device is mass-produced, it must be analyzed and evaluated, and optimized according to the customer's production conditions.
Figure 4 When the important surface in the centerless cylindrical grinder not only need to be polished, but also when the artificial scraping grinding, the equipment also showed a very stable
Effect of cooling on grinding results
Cooling plays an important role in grinding, especially high-speed grinding. The heat load of the workpiece and the grinding tool must be as low as possible to avoid thermal damage to the corner area and increase the service life of the tool. In addition, for different centerless grinding tasks, 400 l of cooling lubricant (KSS) can be poured into the grinding gap every minute. This is also a non-negligible cost factor, especially the required KSS purification treatment costs.
Mikrosa therefore asked itself how to save coolant without affecting the quality of the workpiece. The solution to the problem is the use of new needle nozzles for fixed cooling of workpieces and tools. In the new cooling system, the layered coolant is accelerated to the peripheral speed of the grinding wheel, and the needle nozzle brings the coolant directly to the cutting position. The high pulse effect of KSS can cause the generated air cushion to crash toward the grinding wheel. As a result, excellent cooling of the workpiece and the tool is achieved, and the consumption of coolant is significantly reduced.
Good equipment maintenance can extend the life of the equipment. Mikrosa has introduced state-of-the-art maintenance and maintenance through online surveillance. This is a solution that integrates mechanical, systems theory, electronics, and information technology. Sensors at key points selected on the device provide data to the device control system on a regular basis. The control system can perform real-time analysis of the data information and can send the operator an alarm that the limit value has been exceeded, and at the same time prompt the operator to perform more accurate expert diagnosis. By measuring eigenvalues ​​and sensory data, the online monitoring function can reveal the operating status of the device and selected components.
The Mikrosa device saves the data shown in the database. The database can identify technical process time and downtime due to maintenance, and measure utilization, performance, and outage probability of analyzed system components. Condition monitoring contributes to cost savings, because the life of important equipment components can be fully utilized, and maintenance and maintenance measures can be highly coordinated with production plans. In addition, monitoring data can be used for the analysis of weak links, the strengthening of process safety, and early detection of component wear conditions.
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