New software from NUM provides manufacturers of CNC cylindrical grinding machines with a means of adding non-circular grinding capabilities to their products, without incurring significant development time and cost.

Non-circular grinding is used in a variety of automated manufacturing applications, such as the production of camshafts, crankshafts, cams and eccentric shafts. However, the process is extremely complex because the non-circular contour leads to constantly changing engagement and movement conditions between the grinding wheel and the workpiece.

NUM has now added non-circular grinding functionality to its NUMgrind cylindrical grinding software, which forms an application-specific element of the company’s Flexium+ CNC platform. The new function is fully compatible with other Flexium software, from release 4.1.20.00 onwards.
NUMgrind is specifically designed to simplify the creation of G-code programs for CNC grinding machines through the use of an intuitive graphical HMI, conversational-style ‘fill in the blanks’ type dialogues, or a combination of the two.

Unlike conventional CADCAM workstation tools for generating CNC machine-tool programs, NUMgrind is intended for use in the production environment. The software enables shop-floor personnel to handle every-day machining tasks quickly and efficiently – and the work can be easily shared among several employees and machines.

Operators simply determine the sequence of the grinding process via the HMI and enter the necessary data for the grinding operations, grinding wheels and dressing in the dialogue pages. Programming is further simplified by the fact that the HMI is supported by a library of predefined shapes, which includes eccentric circles, hexagons, pentagons, polygons, Reuleaux triangles and rhombi. A CNC program is then created completely automatically and stored in an executable form.

For further information www.num.com

At ZSO Zerspanungs und Systemtechnik GmbH in Oberstaufen, Kadia has implemented three ‘Deburr-Automation-Cells’. The function of these systems includes not only deburring workpieces, but complete automated handling of parts. European Precision Machines Ltd is the UK agent for Kadia solutions.

For ZSO managing director Carsten Binder, the project was particularly important as it involved the handling and deburring of grey cast iron housings for mobile hydraulic pumps weighing up to 26 kg – heavier than parts usually processed by the company.
“Our plan was to have a robot carry out all the recurring processes,” he says. “Deburring would also be possible on the machine tool, but a robot is a far more cost-effective solution.”

The Kadia proposal was based on a six-axis robot with a payload of 120 kg and a reach of 2.5 m, supplied completely from a single source. Kadia’s scope of supply included process development, the robot, cell, gripper, deburring stations and tools. Not to forget, of course, the sequence programming with all safety-relevant designs. Kadia delivered the first automation cell in April 2019, a second in September 2019 and a third in January 2020.

Notably, the automation cells had to be connected to three identical Heller H5000 machining centres. ZSO had gradually purchased several of these four-axis machines (already equipped with robot interfaces) especially for the pump housings. The robots had to carry out loading and unloading of the machine tools, as well as the deburring, within the machining cycle time (around 20 minutes).

“It’s important for our customers that we were able to increase process reliability and thus produce quality deburring results,” says Binder. “All edges are now deburred absolutely evenly and according to customer requirements; there are no variations in the execution. In addition, the robot never forgets an edge or thread, so reworking is a thing of the past.”

For further information www.kadia.com

Just 25 km lies between Ehingen-based tool manufacturer Schrode CNC-Werkzeugschleiftechnik and Biberach-based sharpening machine specialist Vollmer.

Both companies have had sharpening in their blood for generations: Vollmer develops grinding and erosion machines, while Schrode manufactures cutting tools for metals, composites or wood. Schrode’s list of customers includes companies from the automotive, tool manufacturing, mechanical engineering and medical technology sectors. To machine its carbide tools, the toolmaker uses two Vollmer VGrind 360 grinding machines with automation solutions, making true 24/7 unmanned production possible.
“At the core of our company today is a highly motivated team of 10 employees, combined with my father’s experience and my youthful enthusiasm,” says Christian Schrode, CEO at Schrode CNC-Werkzeugschleiftechnik. “Sharpening has been in our blood for five generations, and it has made us a reliable and flexible partner in the fiercely competitive tool-sharpening technology market.”
Schrode develops carbide-tipped tools such as milling cutters, drills, step drills and special tools with diameters of 0.2 to 100 mm. Batch sizes range from 1 to 5000-off.
“One of our strengths is the production of individual special tools that we develop in collaboration with our customers,” says Schrode. “We believe that it is important to cover the entire value-added chain when it comes to CNC tool grinding, from designing the tools and manufacturing, right through to aftersales services, such as regrinding.”
To manufacture its carbide cutters, two years ago Schrode opted to invest in two Vollmer VGrind 360 tool-grinding machines. With the HP 160 automation solution, Schrode can produce its tools around the clock in an unmanned operation. Thanks to the two vertically arranged spindles, the VGrind 360 enables efficient machining to be carried out on multiple levels, which can reduce non-productive times.
For further information www.vollmer-group.com

As part of its growth plans, ActOn Finishing is launching a new partnership with Spanish industrial company, Gpainnova. The partnership will enable ActOn to supply DLyte surface finishing technology to the manufacturing sector, including the healthcare, aerospace, automotive, 3D printing and motorsport industries.

The DLyte machine combines grinding and polishing in a one-step process to produce smooth and shiny finished parts. Applications include metal components which require high performance or superior finishes, made from materials such as steel and stainless-steel, cobalt chrome, titanium, nickel, and other common metal alloys.
DLyte technology is the first dry electropolishing system of its kind, and the collaboration is set to have a huge impact on the British manufacturing sector by reducing polishing times by around 75%. The new polishing concept will also improve the corrosion/oxidation resistance, lifespan and friction of a part.
Sid Gulati, operations director at ActOn Finishing, says the DLyte fits perfectly with the firm’s existing range of mass finishing products: “We presently manufacture all surface finishing machines in the UK, so distributing the DLyte will complement our current offering as we look to grow the business. We’re confident that through this collaboration we can offer an advanced process solution and help our customers overcome challenges in finishing their components. Already we have added the DLyte 100I to our test lab so our clients can try out the new technology.”
For further information www.acton-finishing.co.uk

Lach Diamant has produced a grinding wheel for the tooth-face grinding of circular saw blades that is said to be more cost-efficient while maintaining high precision. The novel carrier system with 3D geometry and extended grinding layer surface is said to allow for effortless grinding of even the smallest tooth gaps.

Until now, the grinding of rake surfaces on carbide-tipped saws frequently fell short of requirements, especially regarding stability and efficiency. According to Lach Diamant, the new DragonFly grinding wheel offers higher in-feeds and feed rates to reduce grinding times, while producing high-quality, even rake surfaces without any ‘buckling’. Indeed, the vibration-absorbing and stable base body presents another innovation.
The DragonFly grinding wheel provides steady and secure grinding of carbide-tipped saws, as one user confirms: “The DragonFly wheel grinds without any problems, is very precise and has a significantly higher lifetime than all previous wheels.”
The DragonFly wheel (for tooth-face grinding) is accompanied by the DragonFly Back Cruiser for back grinding as well as the DragonFly Flank Cruiser for side grinding (from left to right).
DragonFly wheels are based on diamond abrasive technology. For many years, diamonds – preferably polycrystalline synthetic diamonds (PCD) – have been proven superior to carbide in machining. PCD offers high levels of wear protection, allowing users to profit from its elevated hardness.
For further information www.lach-diamant.de