Manufacturers can now achieve faster processing times thanks to the hybrid milling and grinding capabilities available on the new Mikron MILL S/X (U) series from GF Machining Solutions. The new series combines milling and jig grinding in a compact footprint.

According to GFMS, these three- and five-axis machines deliver accuracy, precision, speed and best-in-class ergonomics. The various models can operate as stand-alone machines or, to improve productivity, can be integrated with automation systems to create flexible manufacturing cells.

Featuring Automated Machine Calibration (AMC) from GFMS and an advanced cooling system that cools the machine’s structure and spindle, changes in ambient temperatures or heat generated within the work environment during machining operations do not affect the machine’s ability to deliver high accuracy, even during long machining runs or extended periods of operation.

The AMC package allows operators to recalibrate the machine and recover its original precision, at the press of a button.

In MILL S and X machines, GFMS accommodates the grinding set-up within the standard footprint, while the laser measuring system and dressing spindle (boasting an increased spindle speed from 3000 to 20,000 rpm) are located close to the working area to ensure quick and fast grinding. In addition, the dressing spindle sits at a slight inclination in order to dress any type of grinding tool.

GFMS can equip the machine with an additional AE sensor to track grinding operations. Additional AE sensors are located on the machine table, allowing operators to adapt the process using the automatic tool detection cycle. This cycle, developed by GF Machining Solutions, avoids air grinding by detecting exactly when the grinding tool touches the part – thereby optimising the process.
For further information www.gfms.com

Stock removal taking longer than expected and product wearing out too quickly? Tyrolit says that its Cerabond X brings a new dynamic to the process by maximising stock removal through enhanced abrasiveness, reducing working times and prolonging product lifetime in combination with a uniform finish.

Widely used in the market, ceramic grain is one of the most common forms of abrasives, known for being sharp, tough and strong. However, despite the advantages that ceramic abrasive grains have regarding stock removal, the best grain in the world can only be utilised for a limited time should it not be combined with a quality vulcanised backing and bond structure.

Tyrolit’s new self-sharpening ceramic grain, combined with a bespoke bonding system, is said to enable optimal bonding of the ceramic grain. New to the market, the Cerabond X product range not only includes fibre discs, but also a full range of metal removal products, including cut-off wheels, rough grinding wheels, flap discs and belts, which are suitable for all steel and stainless steel stock removal.

The structure of the ceramic grain in the new Cerabond X products not only provides extremely fast stock removal, but also shorter cutting time, reports Tyrolit. With the added benefit of flap discs featuring a trimmable core, the products deliver 30% higher stock removal rates. Furthermore, the entire disc can be utilised, maximising lifetime through the need of fewer discs.

Due to the durability of ceramic grain, combined with the bonding structure, Tyrolit says that the products perform better than others when used at high pressure, making the new Cerabond X system suitable for heavy-duty applications.
For further information www.tyrolit.co.uk

Today, centrifuges are the most commonly used systems for cleaning and recycling the process water required in mass finishing operations. A case in point is Wegmann Automotive, a specialist supplier of balancing weights, which is today utilising a fully automatic Rösler Z1000 centrifuge.

As a pilot customer, Wegmann expanded the software for its centrifuge with the ‘advanced version’ of the digital process water management system from Rösler Smart Solutions.

Wegmann makes its balancing weights as stampings from steel and galvanised steel, as well as die-castings from zinc or zinc alloys. Eugen Weizel, department manager for mass finishing and coating, says: “After the stamping or die-casting process, the weights undergo a part-on-part mass finishing operation in a rotary vibrator. The goal is to remove the residual oil left over from the stamping process and the water-based mould release agent that remains from the die-casting operation. At the same time, the compound provides corrosion protection for the steel parts, while the zinc die-castings require a certain surface tension for the subsequent coating step. The surface tension is carefully monitored and controlled.”

Since the process water is recycled, the process water cleaning operation – with a fully automatic Z1000 centrifuge from Rösler – and control of the compound concentration are key factors that determine the quality of the balancing weights.

Says Wegmann’s Manuel Salomon: “When the mass finishing machine and the centrifuge were commissioned, we quickly recognised that there is a close correlation between the process water quality and the quality of our products. Therefore, we carefully measured the compound concentration once per week and recorded the measured results. This allowed us to define the compound concentration for our finishing process and correct it as needed.”
For further information www.rosler.com

Glendower Cutting Tools has purchased a Rollomatic 630 XW six-axis CNC tool grinding machine that is now busy boosting the company’s production of cutting tool inserts. The ethos at Leicester-based Glendower, which is very much a specialist insert manufacturer, is to have complete in-house control over all manufacturing processes, as evidenced by the arrival of the Rollomatic 630 XW.

Dave Chattaway, Glendower’s chief engineer, welcomes the ability to program all special insert geometry from his office, with the machine currently busy producing special inserts in small batches of 10s, 20s and 30s. However, with production rising to over 40,000 inserts per month, it will not be long before the Rollomatic’s automatic part loader is used on larger batches of 1000 inserts or more.

Chattaway states that the 6th axis on the Rollomatic allows him to create very special forms that are not possible on machines with fewer axes, thus facilitating ‘one-hit’ production in a single set up, which saves a lot of time and brings higher accuracy than is possible when grinding special forms on two or three separate machines. The ability to program quickly and then manufacture small batch work has shortened lead times across the shop floor.

The Rollomatic 630XW can grind many kinds of cutting tools with a more complex geometry whereby its additional 6th A-axis, which is said to be unique within the industry, provides improved accuracy on ball-nose end mills or corner radii with a possibility to incline the grinding wheels by up to 45°. This capability avoids collisions, allows for easier programming, and makes it possible to machine demanding and highly precise geometric forms in a single operation. The UK and Ireland agent for Rollomatic is Advanced Grinding Solutions.
For further information www.advancedgrindingsolutions.co.uk