Rapid grinding in the smallest of spaces

In many applications it is uneconomical to use oversize universal cylindrical grinding machines for the external machining of smaller components. With the new WPG 7 CNC external grinder, Emag Weiss demonstrates another way of grinding workpieces with a maximum length of 250 mm. This very small machine requires only a minimal footprint, but at the same time features a whole range of high-tech components for flexibility and productivity.

The WPG 7 fits on two Euro pallets for easy transportation by crane as an easy to set-up machine. It is then possible to start grinding immediately without compromising on quality or process reliability as the WPG 7 has negligible heat build-up thanks to its rigid design. In addition, in-process measurement with Marposs technology, which works independently of the cycle time during the machining process, is available as an option.

The machine uses straight or angled external grinding wheels (with or without profile) featuring a maximum diameter of 500 mm. It is not possible to integrate an internal grinding wheel and there is no B-axis for swivelling the headstock.

Included in the WPG 7 are features such as highly dynamic axes, a powerful and controllable grinding wheel drive, and a work-head with stationary or live centre (MK4/MK5 or W20/W25). The graphical dialogue interface of the control panel is also important for productivity. It is based on a FANUC control system and considerably simplifies the input of technology parameters for certain cycles. The basic version of the control already includes all common grinding cycles.

Last but not least, Emag Weiss offers the WPG 7 CNC solution with automatic or manual loading.

More information www.emag.com

Nissei showcases indexable insert grinder

Nissei Industry from Japan has been developing vertical and horizontal double-disc grinding machines for more than 40 years. Among other things, these machine concepts are for grinding hard materials, one of the company’s core applications in the Asian market. One specific application is the surface grinding of indexable inserts made of carbide, cermet or ceramic. Nissei presented a machine optimised for this purpose, the VP3-400RW, at the recent GrindingHub exhibition in Stuttgart, Germany.

When grinding indexable inserts, the demands on the mechanical and thermal stability of the processing machine are particularly high. The unit from Nissei has the corresponding rigidity, and this with a comparatively compact design. Thickness variations of the ground indexable inserts with capability values of Cp/Cpk of well over 4 are achievable with dimensions of 6.33 ±0.13 mm, for example.

As the main drives for the two 400 mm diameter diamond grinding wheels, the VP3-400RW contains two AC spindle motors delivering 15 kW each. The internal workpiece feeder, which has a 180° swivel function and linear oscillation, features AC servomotors for high dynamics and fast set-up.

The control of the VP3-400RW is by FANUC, allowing various machining modes such as simultaneous grinding of both sides of the workpiece or grinding of the sides one after the other, as well as grinding of only one side. It is possible to store and automatically call-up the respective machining parameters for different types of indexable inserts. Another important feature is the fully automatic dressing device, which can correct the shape on both grinding wheel surfaces simultaneously if necessary.

Nissei presented the VP3-400RW at GrindingHub as a co-operation partner of Nagel.

More information www.nagel.com

Polishing machine manufacturer wins awards

Coalville-based polishing machine manufacturer Zeeko is one of only five companies this year to win two King’s Awards for Enterprise, one for international trade and the other for innovation.

Zeeko develops and produces seven-axis CNC optics polishing machines for complex, ultra-high-precision freeform applications. The 2024 award for international trade is a result of a sharp upturn in these activities, plus additional sales in the past three years of both new machine platforms and tools for mainstream industrial use.

Exports account for about 98% of production. Order intake is currently between £10m and £12m per year, compared with well below £2m during the pandemic. The King’s Award for Enterprise in the category of international trade was based on this performance.

The 2024 award for innovation stems from the chance discovery of a new process that was easy to overlook, but which turned out to be extremely effective for the polishing and finishing of metal, ceramic and carbide items such as turbine blades, orthopaedic implants, precision moulds and ball valve components. Called Shape Adaptive Grinding (SAG), the technique utilises a low-cost, robotic machining platform together with associated tools and software. It is also deployable on any CNC machine, such as a milling centre or multi-tasking lathe. Housed in a separate factory in Coalville, Zeeko Industrial is a new division that builds and markets these robotic polishing cells worldwide.

Richard Freeman, MD of Zeeko, says: “We are delighted to receive two King’s Awards this year. Our highly skilled and innovative team deserves this recognition. A high-technology manufacturing business rarely leads its competition by more than 18 months, so we are continually researching and innovating, both to grow and to protect our lead.”
More information www.zeeko.co.uk

Telsonic generator boost ultrasonic cleaning

As a company with a heritage of ongoing product development and innovation, Telsonic has recently launched its new DCG cleaning generator, which the company says delivers powerful ultrasonic energy for industrial cleaning applications.

The new DCG is a high-power cleaning generator that is compact in design and suited to use in harsh operating environments. Telsonic designed the generator’s inputs and outputs especially for system integration, offering all possible external control options. A further important feature of the DCG generator is high compatibility with its ECO predecessor. The new DCG does, however, benefit from new functions, such as analogue inputs and outputs. These I/O are compatible with popular industry standards, which allow the cleaning process to provide important feedback.

A number of generator variants are available with options for 25 or 40 kHz frequency, and maximum power levels between 800 and 2400 W, together with a supporting range of tube resonators from 340 to 1180 mm depending upon the variant selected.

Application areas for the DCG ultrasonic generator include cleaning production level or finished components, and as part of maintenance procedures. The range of industries that can tap into the advantages of the technology includes automotive, aerospace, medical, electroplating, precision engineering, power stations, metal and aviation, to name but a few.

Telsonic UK offers a comprehensive range of ultrasonic modules and systems for a variety of plastic and metal welding, cutting, sealing, cut and seal, sieving and cleaning applications.

More information www.telsonic.com

Coatings firm achieves 25% turnover increase

Burscough-based IRS Surfacing Technologies has achieved 25% year-on-year growth in turnover from 2021 to 2023. Despite a challenging period for the manufacturing sector, current projections for 2024 are estimated to outstrip those of 2023 for IRS.

For the six months leading up to the end of November 2023, the specialist coatings business accelerated growth by achieving a 44% increase in turnover compared with the same period last year. This lays the foundations for a strong financial future, forecast at £1.4m for 2024.

Specialising in ceramic, stainless steel, thermal and bronze coatings, as well as overlay technology, the family-run business reports that demand for its services continued to grow during the pandemic. The business was able to make a £30,000 investment in improving its welfare facilities for staff, as well as installing a new office in February 2022 to bolster its customer-facing relations and attract more business. 

Since 2021, IRS has increased its monthly revenue through organic growth and is currently on-boarding an average of four new customers a month. The coatings company also recently launched a new website, which forms part of a wider marketing plan to expand its regional platform to a larger customer base.

IRS was founded in 1989 by John Berry, the late father of the current owner, Rob Berry, who says: “At IRS, we pride ourselves on quality, and I truly believe that’s why the business continues to do so well. It’s not just quality in our products, but in everything from our staff to service, through to after service. As a business owner, seeing an uptick in financial performance is always good news, and it’s a trajectory we want to retain.”

More information www.irsltd.co.uk