Precision Grinding
The recently renamed Helitronic Vision 700 L from Walter specializes in long milling cutters, drills, step drills, woodworking
tools and profiling tools from 3 to 200 mm in diameter.
Grinding Toward
Perfection
Multiaxis grinding machines get creative
with their axes, moveable workholding
systems, software and measuring tools
Sarah A. Webster
Editor in Chief
P
recision grinding is evolving incrementally
to better handle old challenges and new.
These include manufacturing, regrinding and
finishing tools and eccentric parts—such as
nonround or nonpolygon shapes—made of a
wide range of materials.
To meet these challenges, a variety of machine builders
are offering faster, more accurate multiaxis precision grinding machines. Many come with other new enhancements
such as improved in-process gaging, systems that easily
or automatically dress, change and balance a growing
number of wheels—and even new mechanical approaches
that promise to reduce machine wear and maintenance or
move the workpiece in creative ways.
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Precision Grinding
And that doesn’t even include the changes in software,
Combining Grinding and Erosion
which are moving toward working (almost) automatically
One shift that has had a big impact on grinding is the in-
with accessories to deliver a near-perfect part with little
creasing use of new materials, such as carbon fiber reinforced
operator involvement.
plastics (CFRPs) and other composites, in industries such as
aerospace and automotive. That, in turn,
is driving an increase in demand for tools
W
NE
made out of super-hard materials.
Tools made out of polycrystalline
diamond (PCD), the hardest man-made
material in the world, are targeted for
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the machining of nonferrous materials,
such as CFRPs, aluminum, titanium
alloys, ceramics and carbides. Mean-
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while, polycrystalline cubic boron nitride
(PCBN), the second hardest material,
is targeted for cutting iron-based alloys,
such as cast irons, hard steels and ironbased composites. Making these superhard tools is a challenge that is leading
the development of new approaches.
Take the new Anca EDGe, launched
at EMO Hannover 2013 in September.
The EDGe machine features a doubleended wheel spindle that has the ability
to both erode PCD and grind carbide
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ideal for customers looking to reduce
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aren’t new in and of themselves, the
double-ended HSK wheel spindle in the
EDGe can erode and grind in one setup
and it has other new features as well.
Russell Riddiford, president, Anca
Inc. (Wixom, MI) said the proprietary
EDGe-Spark generator monitors and
controls the energy level of every spark
for the resistivity of the substrate, be it
tungsten carbide, diamond or cobalt
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Precision Grinding
distance for optimum surface finish, material removal and
The five-axis CNC Vision 700 L is based on the popular
cycle time. What’s more, it provides exceptional operator feed-
high-precision Helitronic Vision, which has linear or torque
back in real time. “We take the precision and high-accuracy
motors in all axes, and a unique kinematics concept. In the
demands of our customers very seriously,” Riddiford said.
Vision, a closed 3D gantry supports the grinding spindle and
Testing of tools eroded on the EDGe machine resulted in
a large rotary C axis supports the tool, which allows grinding
better figures for cutting force, exit burrs on CFRP and drill life
in all four quadrants. But the Vision 700 L features a much
than ground tools, Anca said. The process achieves surface
larger working envelope than the Vision.
finish on tools of less than 0.2 µm Ra.
Anca, an established grinding company that is well known
for its ToolRoom design software, also boasts that the EDGe
has a fast, easy-to-use interface for inputting tool geometry.
The Anca software, which includes integrated 3D graphics,
is used to adjust power generator settings and is designed to
create programs for a wide range of tool types.
In order to deliver the EDGe, Anca partnered with Precorp, a leading manufacturer of PCD cutting tools and a key
supplier to companies such as Boeing, as well as the Royal
Melbourne Institute of Technology, which assisted the project
with research and data analysis.
The EDGe, with a base made of polymer concrete, weighs
4500 kg and is 2160-mm wide, 1530-mm deep and 1990-mm
high. It accommodates wheel sizes up to 202 mm. The machine
offers programming resolution down to 0.001 mm in the X, Y
and Z axes, with programming down to 0.001° in the C and A
axes. The standard in-process probe system is from Renishaw.
A Solution for Very Long Tools
The GrindSmart 628XS is a six-axis CNC super precision tool
grinder for the manufacturing and regrinding of round & nonround cutting tools, from Ø 0.1 to 16 mm. Its features include
an automatic loading/unloading system, precision clamping
system, and innovative V-block and steadyrest support.
Edward Sinkora, senior product manager for United Grind-
Meanwhile, the Walter brand from United Grinding (Mi-
ing’s Tool Division, said that finite element analysis showed
amisburg, OH) has developed a unique approach to grinding
that “we could open up the back of the gantry” and reconfig-
long, rotationally symmetrical tools up to 700 mm in length
ure several parts, including the automated worktable, grinding
made of carbide, HSS, ceramic, cermet and cubic boron
head and wheel changer to accommodate longer tool lengths.
nitride (CBN). Walter sees a market in the automotive sector,
Sinkora said the Vision 700 L “does everything the regular
which is replacing many gundrill and deep-hole indexable ap-
Vision does” but “in order to grind very long tools, we moved
plications with very long solid-shank drills for engine blocks and
the rotary C axis to the grinding head. So in this approach the
crank housings. Spiral-flute tools offer faster feed rates, due to
tool is carried on a strictly linear axis while the grinding spindle
their higher chip removal rates.
swivels.” And by opening up the rear of the gantry, the machine
Originally introduced in 2012 as the Helitronic Vision Long,
is able to travel farther on the X axis during very long grinds.
the recently renamed Helitronic Vision 700 L from Walter spe-
Two independent carriages support the workpiece and
cializes in long milling cutters, drills, step drills, woodworking
allow it to be moved in a manner that allows for graceful grind-
tools and profiling tools from 3 to 200 mm in diameter.
ing down the length of the tool, as shown in a video at http://
tinyurl.com/visionlong.
Visit www.MfgEngMedia.com for a related article,
Precision Grinding Strengthens Its Bond with A&D.
Not only the cutting surface itself but also how it
adheres to a matrix have improved in recent years.
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ManufacturingEngineeringMedia.com
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November 2013
As with the Vision, the machine base of polymer or
mineral cast, with the patented gantry, promises extreme
rigidity. The maximum control resolution for the linear axes is
0.0001 mm (0.1 µm) and for the rotary axes, 0.0001º. The
QVI® SNAP™
Simple, one-button
measurement lets you
measure entire parts
instantly - with no fixturing.
Precision Grinding
spindle power is 35 kW with 10,000
rpm. Grinding wheels up to a maximum
diamater of 254 mm can be changed
by means of a 6-, 12- or 24-station
wheel changer, with the latter two being
options. A Fanuc six-axis CNC robot
is used for the automatic loading and
unloading of the tools.
Two independent carriages
support the workpiece and
allow it to be moved in
a manner that allows for
graceful grinding down the
length of the tool.
The Vision 700 L uses Helitronic Tool
www.ramoptical.com
Measurements Made Simple.
Studio, Version 2.0, grinding software
with complete 3D simulation for secure
off-line setup. Tool accuracy can be even
Custom Engineered
To Your Needs
Designers & Manufacturers of Drilling & Tapping Solutions
New Slant Bed Precision Tapper offers:
• High speed - High volume
• Versatile tapping, drilling and reaming
• Wide range of standard options . . .
• Horizontal or vertical
configurations also available
• Flexible parameters
(feed & speed)
• Single or multiple head
applications
• Custom bowl with track &
feed fixturing
• Servo precision control
• Ball screw drive
See this machine and others
in action in our new video
www.rockford-ettco.com
Proven solutions from the brands you trust.
UNIVERSAL - AUTOMATIC
3445 Lonergan Drive,
Rockford, IL 61125
815/874-9421 Fax: 815/874-9425
addition of a Helicheck Pro measuring machine, which uses several CCD
cameras and segmented LED lights to
measure virtually all geometries. Repeatability is under a micron. An optional
1000× magnification camera measures
the edge prep (hone) down to a 5-µm
radius. For form tools, the software can
compare the measured tool profile to
the nominal profile and calculate the
necessary offsets for the grinder to make
the tool, as Sinkora said, “more or less
perfect.” At least under 2 µm.
Increasing Flexibility
In making continual improvements
to its GrindSmart lineup (528XS6000XL), Rollomatic (Mundelein, IL)
has redesigned its GrindSmart 620XS to
Made in USA
Always was and Always will be!
further enhanced and certified with the
304 Winston Creek Parkway,
Lakeland, FL 33810
863/688-0071 Fax: 863/682-6233
make it even more flexible and reliable.
The resulting GrindSmart 628XS
is a six-axis CNC super-precision tool
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Precision Grinding
grinder for the manufacturing and regrinding of round and
Previously, the machine featured a belt drive, with a
nonround cutting tools, from Ø 0.1 to 16 mm. Its features
servomotor controlled by a rotary encoder. “On the 628XS,
include an automatic loading/unloading system, precision
we have fitted a rotary glass scale that is directly coupled to
clamping system, and innovative V-block and steadyrest
the workhead spindle, thereby taking the belt drive out of the
support. The machine can grind specialty tools, including
equation. This allows us to control the rotary tool axis move-
form tools, indexable and nonindexable inserts, replaceable-
ment much tighter. Its benefits include better flute finish and
tip tools, reamers, taps, step tools, torx drivers, surgical and
higher feed rates.”
dental tools, among others.
The flexibility of the 628XS lies in several areas. The
Aside from improved ergonomics, such as a larger
workhead is configured so one can switch from round tools
control monitor, the 628XS features a new Fanuc control
to inserts simply by swapping two plates. “The switch over
30iB. The workhead has been redesigned to accommo-
is remarkably rapid,” Schwarzenbach said. The other is the
date quick-change features to switch from round tools to
proprietary software, VirtualGrindPro, which features a large
inserts. The guiderails of the three major linear axes have
library of different types of cutting tools and inserts ready for
also been reinforced.
grinding. The machine also has an optional wheel and nozzle
“The linear scales are not glass scales anymore, but magnetic, which increases the life of the scales,” said Eric Schwar-
changer, which includes six wheel packs with the coolant
nozzles prepared and ready for production grinding.
zenbach, president of Rollomatic. “The design of the guiderails
and other moving parts has been deliberately focused on
Unique Hydrostatic Guideways
While it is marketed as a universal, high-precision
longevity with minimal maintenance intervention.”
grinder, the recently updated Kellenberger Kel-Varia from
OMG, EXPANDING
MACHINE VERSATILITY
FOR OVER 50 YEARS
Hardinge (Elmira, NY) is targeted at low-volume, highvalue, large and heavy parts, especially those that are
nonround, such as polygons, free contours, and eccentric
shapes—a consequence of the C-axis option of interpolating the X and C axes.
This spring, Hardinge began offering a new direct-drive
We can avail ourselves of the technical
know-how and human resources required to design and manufacture cutting
edge products. We have a strong focus
on providing quality customer service,
with the goal of maximizing customer
satisfaction.
Series MO
workhead and hydrostatic B axis on the Kel-Varia. The precision hydrostatic guideways in combination with the directdrive workhead technology provide extreme accuracy in
Series TA
concentricity and radial run-out: Part roundness of <0.2 μm;
nonround contour accuracy of <6 μm; internal eccentric bore
of <4 μm; straightness (slots) of <2 μm.
Series HT
Jeff Hilliard, North American sales manager for Grinding,
Hardinge, said the hydrostatic guideway system is unique.
Series VH
Tilting
angle
head
Hydrostatic guideways, combined with a strict separation of
the machine base from the assemblies that generate heat or
vibration, provide superb precision and productivity.
Series TSI/TSX
The hydrostatic guides for the longitudinal slide movement (Z axis) and for wheelslide infeed (X axis) provide
Series BAH
the basis for the machine’s extreme accuracy. The X- and
Series T
Z-axes movements are practically frictionless at all speeds.
There is no stick slip; even the smallest increments of 0.1
μm can be traveled without a problem. Because there’s
OMG NORTH AMERICA
802 Clearwater Loop, Post Falls, ID
83854 Phone: 866-440-8519
e-mail: [email protected]
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no metal-to-metal contact, there are also no wear characSeries MT-TC-TC3
|
November 2013
teristics compared to the traditional Vee and Flat system.
“There’s a film of oil for shock absorption,” Hillard explains.
kg). Previously, these bigger molds would have endured “days
“You don’t have to worry about bearings and guideways
upon days of finish polishing,” Hillard said. But now, “We can
being damaged.”
eliminate a lot of steps and tons of man hours of hand-polish-
The direct-drive workhead has an infinitely variable spindle
ing the mating parts.” ME
speed from 1 to 500 rpm (with Heidenhain control) with a maximum weight
capacity of 750 Nm / 300 kg (660 lbs)
with an option of ±60 second micro-correction for easy adjustment of cylindricity.
The new workhead allows heavy
parts to be quickly and precisely
THE HOT RODS OF CUTOFF LATHES
accelerated and braked with zero
backlash during bidirectional move-
Follow us on
ments for increased productivity. A
large spectrum of parts and a wide
range of geometries can be processed
using combinations of cylindrical
Type in MMTco
grinding, OD and ID out-of-round
grinding, thread grinding and jig
grinding all in one setup. Advanced
C-axis (ultra-high resolution) operation
allows precise grinding of grooves and
satellite and centering bores.
Hardinge finds many of the end
users of the Kellenberger Kel-Varia are
in the container mold business. The
Kel-Varia can now deliver parts up to
FEATURES:
•
•
•
•
•
Two Axis Slide
High Torque Digital Drive
Menu Prompted Touch Screen
Digital Read Out or Servo Positioned
Heavy Duty Stock Stops
24" (610 mm) in diameter. Previously,
18" (457 mm) was the limit. The weight
limit also has doubled to 550 lb (250
Want More Information?
Anca Inc.
Ph: 248-926-4466
Web site: www.anca.com
Hardinge Inc.
Ph: 800-843-8801
Web site: www.hardingeus.com
Rollomatic
Ph: 847-281-8550
Web site: www.rollomaticsa.com
United Grinding Technologies
Ph: 937-859-1975
Web site: www.grinding.com
Cut to the Finish
Modern Machine Tool has been building
cutoff lathe machines for almost a century.
Our lathes have evolved over the years into a
completely automatic operation—from feeding to cutting to finishing. Our compact cast
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