Leader balances the benefits

Leader Chuck International provided demonstrations of Balance Systems’ range of solutions at the recent Advanced Engineering 2019 exhibition in Birmingham, UK.

In the spotlight was grinding-wheel balancing, in-line dynamic gauging, touch detection and spindle monitoring with the B-Safe machine tool monitoring system.
Mark Jones, managing director at Leader Chuck International, says: “Balance Systems’ knowledge and experience of grinding process systems helps to improve the quality of the workpiece. They offer the capability to reduce grinding-wheel wear and speed-up cycle-time, while extending machine lifetime and increasing operator safety.”
Spindle and grinding wheel balancing is an essential operation in order to achieve workpiece surface quality and ensure long life for the rotary components.
Says Jones: “We offer a range of systems based on balancing heads that can be installed externally or built into the spindle. Control units are equipped with cable and contactless solutions, and provide constant vibration monitoring. The newly designed ‘Absolute Balancer’ technology is characterised by high performance levels in terms of execution speed and balancing precision for single and two-plane applications.”
In-process measuring systems offered by Balance Systems allow manufacturers the opportunity to produce components that conform to specification even under the most severe environmental conditions, such as warm-up, thermal shifts, chemical coolant, local or induced vibrations, and so on, and to operate using high-speed cycles.
The close control of grinding wheel balancing and its dresser helps attain a near perfect profile, while also optimising the removal of the grinding wheel surface, as evidenced by longer tool life.Identification of the instant when the tool touches the workpiece is essential to minimise cycle time, reduce ‘air grinding’ and optimise axis infeed.
For further information www.leaderchuck.com

Laser roughening and honing machines

The EA211 evo engine from VW has been manufactured using the latest technologies to increase efficiency, such as coating of the cylinder liner. Set to install new production lines in China, Gehring has received an order to supply the laser roughening and honing machines for this purpose.

Dr Sebastian Schöning, CEO of the Gehring Group, who oversees the firm’s development strategy, says: “We are happy that we were able to achieve concrete environmental improvements together with our customer.”
The thermal coating of cylinder bores is a highly sought-after technology for increasing the efficiency of internal combustion engines. Gehring is focusing on optimising the process chain of: laser roughening – coating – honing. In order to produce a strong bond between the coating and engine block, efficient roughening processes are required to ensure overall functionality.
Gehring’s laser roughening technology is said to bring about operative advantages. For instance, apart from cost savings and an improved working environment, there is also a positive effect on overall engine design. In addition to high adhesive tensile strengths with low roughness, economic advantages take effect in mass production, since no wearing tools are needed and coating material is saved. Both aluminium and cast iron can be pre-machined with the laser-refining process.
Gehring laser-roughening machines have two spindles with novel rotation optics for the simultaneous machining of two cylinder liners. The co-ordinated process steps (roughening – coating – honing) lead to low friction and wear-resistant cylinder liners, which contribute to more compact and efficient internal combustion engines, says the company.
For further information www.gehring-group.com

Advanced Grinding Solutions at EMO

Advanced Grinding Solutions (AGS) had no less than 10 of its machine manufacturing partners exhibiting at the recent EMO 2019 exhibition in Hanover: Rollomatic (tool grinders); Bahmuller and Tschudin (internal/external and centreless grinders); HandlingTech (automatic loading systems); Gerber and Magnetfinish (deburring machines); FLP (lapping and fine-grinding machines); Nova (external/internal grinders); Platit (coating machines); and Comat (filtration systems).

Rollomatic showed many tool grinders, including its six-axis 830XW for manufacturing large diameter cutting tools that has a novel combination of hydrostatic guides and linear motors for high levels of surface finish. Also of major interest was the Rollomatic LaserSmart 501 machine for machining PCD, CVD, and natural diamond tools. The 501’s machining speed is stated as being up to four times faster for processing multiple features such as cutting edges, chip breakers, and cylindrical lands in one operation. The machine has four cameras for complete and easy viewing of all laser operations. Rollomatic also used the show to debut its NP50 machine for the grinding of cutting-tool blanks.
Tschudin was exhibiting its latest ‘Cube’ grinder, which is stated as being the world’s smallest CNC centreless grinding machine, while HandlingTech displayed various loaders for machines, including its advanced palletZ and ecoZ models.
Platit exhibited its most flexible coating machine, the Pi 411 Plus, while Gerber focused on three brushing machines for deburring components, including the new Eco-Innovation, which received its worldwide debut.
For further information www.advancedgrindingsolutions.co.uk

Grinding experts combine resources

Okuma, which is represented in the UK by NCMT, and German grinding expert Dr Kaiser Diamantwerkzeuge GmbH, have jointly developed a grinding system that is said to offer a number of advanced wheel dressing functions. Dr Kaiser and Okuma can look back on a successful co-operation having previously created a special app to determine optimal dressing parameters. Now, Dr Kaiser has developed a vitrified CBN grinding wheel, a dressing spindle system and the related dressing tools for an Okuma GP25W x65 CNC grinding machine.

Once installed, the Dr Kaiser C72FCA2 dressing spindle is connected to the OSP-P300G Okuma control via Profinet. With its output of 1.3 kW, the dressing spindle achieves a steady circumferential spindle speed during synchronous dressing, as well as during counter-rotation dressing.
During the dressing cycle, the control receives process data from the dressing spindle. The spindle is equipped with integrated acoustic emission sensors that detect when the dresser and grinding wheel come into contact. As the sensors can determine contact in the micrometre range, the system allows for correct alignment of the axes. This capability reduces air-grinding time, minimises wear on the diamond dressing tool and ensures defined abrasion of the grinding wheel.
Operating the system is simple because the Okuma control visualises all dressing process data and allows for the optimal adjustment of all parameters. Changes made by the operator, or variables recorded in real time, are automatically translated by the control into an NC program.
For further information www.ncmt.co.uk

£100,000 facility

A historic building converted into a £100,000 training facility at Tees Components has been officially opened by the leader of Redcar & Cleveland Council, Mary Lanigan.

In total, the investment has created seven training stations, which feature manual and CNC turning, manual and CNC milling, surface grinding and bench work. The development includes the introduction of two new machine tools – an XYZ CNC and DRO manual mode milling machine, and a Colchester Harrison M300 manual lathe. In addition, the centre includes a workshop classroom area complete with IT facilities.
For further information https://teescomponents.co.uk/