Quality Means Getting the Right CNC Centerless Grinder

While Hank Matousek Sr. was perfectly content in his position as quality control manager at a bearing company during the late 1960s and early ‘70s, he had no idea that his employer’s growing financial woes and a pending layoff would become his surprise catalysts to found Grind All.

TGS-CL-6020

Not surprising, though, was that Matousek’s background as a quality leader would lead him to place value and excellence above all in his new enterprise. From Hank’s one-man shop with one used grinder in a central Ohio basement, to today’s 45-machine, 52-employee, Brunswick-based Grind All Inc., the Matousek family still places quality above all else. Hank’s “Do it right and make your product better” creed has been the cornerstone of Grind All’s operations since the company was founded in 1972. “Do the best you can and people will come back. Do jobs better than anyone,” says Grind All president Henry Matousek Jr., quoting his father.
That’s why, while other manufacturing companies are tossing around “quality” buzzwords, Grind All is busy applying real time and resources toward meeting its ongoing quality goals. As a result of that focus, Grind All has had ISO 9001:2008 certification since 2011.
Over the course of Grind All’s nearly 45 years, its customer base has grown to include many companies in the aerospace and defense industries. That’s why obtaining an additional certification to AS 9100C was the logical move for quality-obsessed Grind All. The AS 9100C certification, issued by SAI Global, is the highest of global standards for quality assurance in the aircraft, space and defense (AS&D) industries. The AS 9100C certification, along with its ISO 9001:2008 certification and ITAR registration, would make Grind All uniquely qualified to offer a complete range of services to even the most quality-conscious customers.
Obtaining AS 9100C certification is no easy task for any company—not even one like Grind All. Critical factors in the AS 9100C certification are the processes, characteristics, parts and software that have a significant effect on product realization and on the use of the product. As Grind All began the certification process by evaluating their inventory of production machine tools (centerless grinders, OD grinders, ID grinders, surface grinders, honing machines and flat lapping machines), it became clear that the company’s antiquated Cincinnati 220-8 centerless infeed grinder would not make the cut. Although it had been successfully rebuilt over the years and was working, it did not provide the reliability and precision required by AS 9100C regulations. Grind All saw two options: Either invest a significant amount of money to patch up the 220-8, or find an outside source for centerless grinding work. Neither option was acceptable. As the Cincinnati centerless became even more unreliable, Henry Matousek Jr. turned to Total Grinding Solutions for advice.
President Dan Geddes and company partner Joe Giacalone, founders of Total Grinding Solutions of Warren, Michigan, are the brains behind the development of the TGS machine. With a combined 75 years of grinding experience, Geddes and Giacalone made it their goal to design and build a robust centerless grinder that would be precise and would boast the technological innovations of the best machines on the market. The key was to engineer this machine with the latest state-of-the-art features, but to sell it at a very moderate cost. “We applied our hands-on grinding experience with our in-depth knowledge of grinders and set out to design a quality centerless grinder that could handle even highest-volume production runs with extreme accuracy and consistency,” says Giacalone. “We were looking to produce a more economical, more precision-based solution. We know what works, and we were determined to ‘build a better mousetrap,’” adds Geddes.
After several iterations, the TGS-CL-6020 CNC centerless grinder was launched at an open house in August 2014 at the company’s Warren, Michigan location. That’s where Matousek and his team saw the machine for the first time. While Matousek appreciated the grinder’s modern design, he was especially pleased to learn that the tooling from his ailing Cincinnati 220-8 centerless could cross over to the TGS-CL-6020. This meant that he wouldn’t have to spend precious resources on pricey tooling.
As Grind All compared offerings from TGS and several other suppliers, the TGS CNC centerless grinding machine stood out for several reasons. The TGS CL-6020’s flexibility would accommodate Grind All’s requirement that the machine be able to run a variety of parts and, most likely, two or three different parts and materials per day. The controls on the TGS-CL-6020 had to be user-friendly to minimize training time and shorten the learning curve. As a job shop, albeit a very successful one, Grind All did not have an unlimited budget, and price was a consideration. Luckily for Grind All, the TGS-CL-6020 had been priced to meet the needs of the middle market, whose options previously were low-cost basic machines or expensive high-end machines. After a series of test grinds, analyses and consultations, Grind All management selected the TGS-CL-6020 to replace its old Cincinnati.
To further accommodate the client’s needs, TGS modified the machine controls to mimic what was already in place at Grind All.
With its new TGS machine, Grind All met its AS 9100C criteria.
“The machine’s FANUC controls are great. They’ve always been great. It’s nice to be able to call TGS or FANUC for assistance rather than being tied in to some company’s proprietary software,” says Matousek. “The TGS is everything we would want in a machine. Once our new centerless got going, it’s proven itself as a solid machine that will carry us into the future. It will be around for a long time.”

For additional information on Total Grinding Solutions, visit www.totalgrindingsolutions.com,
call 586-541-5300 or write to promotions@totalgrindingsolutions.com

WIN event set for AMRC in January

The launch event for the new Northern branch of the Women’s Infrastructure Network (WIN) is being held at the University of Sheffield’s AMRC. Founded by women at key regional businesses, the Northern WIN brings together women working in infrastructure sectors across the north of England.

The event, which is being hosted by the Nuclear AMRC, aims to link together like-minded women who want to expand their professional networks across industries and share best practice.
There will be presentations from women working in senior roles in the UK’s nuclear power sector. The half-day event on 24 January is free to attend.
For further information https://is.gd/wujafo

Lapping the field on productivity

Sunnen’s SVL-2115 bore finisher is a multi-stage automated lapping machine that laps and air-gauges bores in a single set up.

The machine is aimed at aerospace part manufacturers seeking a cost-saving solution for bores with large length-to-diameter ratios and tight tolerance requirements. Such parts include hydraulic valves, sleeves, fuel system components and other parts that are prone to distortion when honed.
Bringing increased productivity and part consistency to what is traditionally a manual process, the SVL-2115 is based on Sunnen’s existing SV-2115 honing system. The patented system control is designed for unattended operation and automatically laps and air-gauges bores throughout the cycle. Gauge readings are fed back to the control and the cycle is repeated until the parts are within specification.
Says Phil Hanna, Sunnen’s product manager: “For very expensive parts, an automatic lapping process reduces the possibility of scrap components due to human error. Since lapping is usually the last process during the machining of a workpiece, if the lapping is not correct, all the work to get the part produced up to that point is wasted.”
Patented Sunnen lapping tools are available for workpiece diameters from 6.3 to 45 mm, and lengths up to 12 times the bore diameter (not to exceed 200 mm). Additional diameter ranges are in development. The spindle speed range is 100-2000 rpm during lapping, but the machine is capable of slow speeds for non-powered steps, such as lapping paste application or slow-rotation bore entry. Stroking speed is 0-350 SPM, with stroke length optimised to achieve a high degree of cylindricity.
For further information www.sunnen.com

Tool grinding shop cuts production costs by 50%

Swiss tool maker Fraisa has achieved efficiency gains through automation to reduce production costs by 50%.

The collaboration with Anca required a customised solution to run unattended for 50 hours and grind multiple tap types. Anca says that its TapXcell can increase productive grinding hours from an average of 105 to 150 hours per machine, per week.
Fraisa is a family-owned business that offers its customers a complete range of solid round tools with end mills, drills and taps.
Amelinda Ilardi, engineering project manager at Anca, facilitated the collaboration with Fraisa: “To enable the machine to run unmanned we needed an in-process measurement capability to ensure grinding stability, so we designed a new application where the thread pitch diameter is measured by a Renishaw MP250 touch probe. Measuring to ±0.002 mm accuracy, this feature is crucial as it ensures every batch of taps are of consistently high quality.
“Not only can the machine run unmanned for 50 hours, it is fully connected, being linked to Fraisa’s factory ERP system for further efficiency and production data gains,” continues Ilardi. “The machine can be remotely monitored using our RedaX product and automatically sends notifications to keep Fraisa’s remote staff aware of the machine’s progress, and any issues or faults that need to be addressed. In addition, RedaX can be used to track the productivity and up-time of multiple Anca machines.”
TapXcell is a complete production package for tap manufacturers. The grinder itself includes a 37 kW grinding spindle that enables the grinding even of taps above M32, as well us dual wheel dressers and between-centre work holding. Grinding capability is complemented by the TXcell’s robot loader that manages automatically changing of up to 24-wheel packs and tools.
For further information www.anca.com

Turning the dream into reality

Everyone has dreams and Thomas Karpasitis is no different, except he turned his dream into reality with the creation of Karpas Engineering in the summer of 2018. Taking a leap of faith, Karpasitis, along with his wife Sophie, invested their savings and committed to making their new venture a success. This bold move is already starting to pay dividends, as customers recognise the all-round capability of the start-up business.

At just 30 years of age, Karpasitis has had a varied career within the CCTV, electromagnetic compatibility testing and 3D printing environments, but making things was always a passion.
“I got to that stage where I was fed up of working for other people and needed a new challenge,” he says. “The result is Karpas Engineering, a business that allows me to use my experience in design, project management and 3D development, and combine it with machining capability and machine assembly services. I knew that to do the job well I had to invest wisely, hence the decision to work with XYZ Machine Tools.”
With no business track record, financing any machine purchase may have posed additional challenges. However, working with XYZ Machine Tools, along with Mike Hankin of Capital Funding Solutions, the right machine and finance package was created, which saw the arrival three months ago of an XYZ 2-OP machining centre and an SMX 2500 ProtoTrak bed mill.
“After detailed discussions with XYZ’s area sales manager, we identified the machines that would be right for the business and began our journey,” says Karpasitis. “The partnership between XYZ and Hankin made the process go smoothly with a deal that was built around our personal credit history and a commitment to back it up with our own equity. The positives of the deal will see the machines being ours within a few years, and they will form the foundations of our machining capability.
My vision is to have several XYZ 2-OPs side-by-side to create a highly flexible machining cell.”

The combination of the XYZ 2-OP with its eight-position tool changer and the XYZ SMX 2500 ProtoTrak bed mill suits the mix of work that Karpas Engineering is targeting. The focus is on one-off prototype/development work, along with small-to-medium sized batch production and, with both machines sharing the ProtoTrak control system, transferring work from one to the other is straightforward when required.
“The compatibility of the ProtoTrak controls on the two machines makes it simple to scale up from prototype one-off work to production quantities,” says Karpasitis. “Programming is also quick and easy, which is what you need in order to maximise machine time and, more crucially, deliver accurate and on-time components to customers – from day one I was programming at the controls. I also have the option of importing programs directly from our CADCAM system when customers have provided drawing data.”
Within the first three months of the XYZ machines arriving, Karpas has gone from having no customers to a growing portfolio of regular business, even winning work that had previously been offshored to China.
“It is great to see that customers are buying into our commitment to them through our investment in machining capability,” states Karpasitis. “We will continue to develop our offering and gradually build up our capacity, including additional employees as the workload demands it.
“What we have achieved so far, we couldn’t have done without the XYZ 2-OP and SMX 2500 machines,” he adds. “They have provided the flexibility and efficiency that a small business needs, while at the same time making the transition to becoming a subcontract machinist straightforward due to their ease of use. If we can compete with China when it comes to machining, we are obviously doing something right.”
The XYZ 2-OP vertical machining centre, while compact in size, measuring just 775 mm wide by 1380 mm deep, provides a machining envelope with axis travels of 355 x 305 x 455 mm in the X, Y and Z axes, with up to 525 mm between the table and spindle nose. The spindle is a 6000 rpm, 2.24 kW BT30 unit, making it suitable for general machining or, as its name implies, second operation work. Components weighing up to 250 kg can be accommodated on the machine’s 457 x 381 mm table. Although designed as a portable machining centre that could be moved anywhere in the workshop to provide back-up to more expensive machinery, it has found a niche for itself as a stand-alone vertical machining centre.

XYZ’s SMX 2500 is the smallest of the ProtoTrak controlled bed mills with axis travels of 762 x 381 x 560 mm in X, Y and Z, with an additional 127 mm of quill travel. The spindle has two speed ranges covering 50 to 3600 rpm, and has an R8 taper as standard or, as in the case of Karpas Engineering, an ISO 30 spindle can be specified. The table measures 1245 x 228 mm and can carry up to 600 kg, making it highly versatile.
For further information www.xyzmachinetools.com