Feature on Grinding and Surface Finishing

Tool manufacturing around the clock

Based in Lower Bavaria, Huber GmbH CNC-Präzisions-Werkzeugschleiferei is a user of sharpening machines from Vollmer, with a VGrind 360S grinding machine the most recent arrival. Huber is using the Vollmer machine and its 24/7 automation capability to boost the production of semi-standard milling tools for the machining industry.

Manufacturing standard and special tools, resharpening circular/bandsaw blades and supporting customers with reliable services – this is how Huber generates a profit of around €2.7m a year.

“Our latest VGrind 360S grinding machine with chain loader enables production around the clock, seven days a week, allowing us to fulfil our high order volume quickly and with high precision,” says Christoph Ziegler, production manager at Huber GmbH. “As such, the Vollmer machine is a perfect match for our guiding principle and self-imposed goal to deliver the best possible quality and precision ‘despite’ the high speed of our processes.”

Alongside automation, the decisive factor for Huber was that the VGrind 360S is suitable for ensuring consistently high-quality machining thanks to the wear-free linear induction motors in the X, Y and Z axes, as well as reducing maintenance costs. With two grinding spindles situated one above the other and the grinding wheel set positioned at the C-axis pivot point, the VGrind 360 tool grinding machine enables efficient multi-level machining. The company can reduce machining times thanks to the shorter travel distances of the linear axes, which is also beneficial in terms of the speed promised by Huber.

As a final point, a plate heat exchanger cools both the machine’s spindles and motors to increase thermal stability and improve both the precision and performance of the grinding process.

More information www.vollmer-group.com

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

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