Within the UK abrasive machining segment, tool grinding retains a major presence. A case in point can be seen at tooling specialist Gandtrack and sister company GT Grinding, which have been mirrored by their regular investment in Walter tool grinders and automatic measuring machines.

Housing 28 employees between them, Gandtrack and GT Grinding have installed a total of 12 Walter machines (10 Helitronic tool grinders and two Helicheck inspection machines) since 2000. And while in each successive case, the new machine has resulted in a higher level of production efficiency, it is Gandtrack’s latest investment – a Helitronic Power with robot loader – that catches the eye.
“We found that machining batches of initially 20-60 each month of comparatively long [up to 280 mm] reamers in 15 different sizes, and with long flute lengths of 70 to 90 mm, wasn’t proving ideal when using the machine steady,” says director Adrian Jones. “So, we investigated the use of the Helitronic Power’s automatic tailstock in conjunction with the machine chuck. We liaised with Walter AG in Germany – whose engineers prepared the program and, with carbide rods in hand, we spent a full day there producing the reamers. The demonstrations showed that we could halve machining times and, importantly, avoid scrap.”
Explaining that the process allows the tailstock to be removed from the reamers for the completion of end work, Jones also highlights how the use of probing in conjunction with the tailstock/chuck “means the exact position of the flutes can be determined”.
The choice of a robot loader instead of Walter’s Eco loader, which Gandtrack/GT already have on four machines, was also determined by practicality, as well as by the potential for increased production, says Jones.
For further information www.walter-machines.com

The definition of quality has been described as an ongoing process of building and sustaining relationships by assessing, anticipating and fulfilling stated and/or implied needs.

Never has this definition been more appropriate than when applied to Aldershot-based FT Gearing Systems Ltd. In addition to establishing long-term relationships with its customers, this manufacturer of gear technology and high-precision components also enjoys enduring associations with a small number of carefully chosen machine-tool suppliers. At the top of the list is Studer, and the company’s UK agent, Advanced Grinding Supplies.
Continuous expansion at FT Gearing in recent years has led to regular investment in the Swiss-built machines, resulting in the company now operating 16 Studer CNC grinders – the largest collection owned by a single UK company.
Explaining the company’s loyalty to the Studer brand, managing director Graham Fitzgerald says: “Studer machines are able to consistently deliver levels of accuracy and repeatability that conventional grinding machines are unable to achieve. For instance, through the use of Studer technology we are able to accomplish sub-micron cylindricity results on 35mm diameter gear journals. We can also achieve surface finish of 0.08 µm and gear flatness to three light bands. To enable grinding to sub-micron tolerances, we recently installed our Studer CNC machines in a new temperature-controlled facility.
“To guarantee the highest possible levels of quality and productivity, we also use the best available grinding consumables and accessories,” he adds. “Therefore, as well as purchasing our Studer grinders from Advanced Grinding Supplies, we also rely on the company for items such as diamond dressing tools, precision centres, abrasives/grinding wheels, coolant filter media and air filtration systems.”
For further information www.adgrind.co.uk

Hardinge Group company Kellenberger has released its K100 for medium and high-technology grinding operations. The K100, which was on show at the recent EMO exhibition in Hanover, was equipped with a WeFlex automatic loader to demonstrate the flexibility of the modular concept and its suitability for operating in automated, high-volume factory environments.

In terms of functionality the K100 platform delivers a diverse range of configuration options for a wide range of grinding operations. Thanks to the modular solution on one common platform – and the new assembly concept designed to reduce throughput time – it is possible to optimise production costs for the machine and ensure an attractive price-to-performance ratio.
The user-friendly and ergonomic design of the machine is based on a new, simple operator guidance system with an intuitive 19” touchscreen panel. K100 machines are equipped with the latest Fanuc 31i CNC controls, optionally available with newly designed cycle programming or workpiece-related graphic programming.
Three important features distinguish the K100 machine series: the collision-free compact wheel-head solution; an enhancement of its performance parameters; and the service-friendly machine design concept.
The new tandem wheel-head is a compact construction featuring a motor spindle. A reinforced casing accommodates larger grinding wheel diameters for internal grinding, while a choice of 10 wheel-head variations allows the optimum layout of the machine based on the components to be processed.
Enhancement of performance parameters include higher grinding wheel drive power for increased productivity, a newly designed Z guideway for precision profiling and a C axis with direct drive for greater precision when performing non-circular grinding.
For further information www.kellenberger.com

The EA211 evo engine from VW has been manufactured using the latest technologies to increase efficiency, such as coating of the cylinder liner. Set to install new production lines in China, Gehring has received an order to supply the laser roughening and honing machines for this purpose.

Dr Sebastian Schöning, CEO of the Gehring Group, who oversees the firm’s development strategy, says: “We are happy that we were able to achieve concrete environmental improvements together with our customer.”
The thermal coating of cylinder bores is a highly sought-after technology for increasing the efficiency of internal combustion engines. Gehring is focusing on optimising the process chain of: laser roughening – coating – honing. In order to produce a strong bond between the coating and engine block, efficient roughening processes are required to ensure overall functionality.
Gehring’s laser roughening technology is said to bring about operative advantages. For instance, apart from cost savings and an improved working environment, there is also a positive effect on overall engine design. In addition to high adhesive tensile strengths with low roughness, economic advantages take effect in mass production, since no wearing tools are needed and coating material is saved. Both aluminium and cast iron can be pre-machined with the laser-refining process.
Gehring laser-roughening machines have two spindles with novel rotation optics for the simultaneous machining of two cylinder liners. The co-ordinated process steps (roughening – coating – honing) lead to low friction and wear-resistant cylinder liners, which contribute to more compact and efficient internal combustion engines, says the company.
For further information www.gehring-group.com

Okuma, which is represented in the UK by NCMT, and German grinding expert Dr Kaiser Diamantwerkzeuge GmbH, have jointly developed a grinding system that is said to offer a number of advanced wheel dressing functions. Dr Kaiser and Okuma can look back on a successful co-operation having previously created a special app to determine optimal dressing parameters. Now, Dr Kaiser has developed a vitrified CBN grinding wheel, a dressing spindle system and the related dressing tools for an Okuma GP25W x65 CNC grinding machine.

Once installed, the Dr Kaiser C72FCA2 dressing spindle is connected to the OSP-P300G Okuma control via Profinet. With its output of 1.3 kW, the dressing spindle achieves a steady circumferential spindle speed during synchronous dressing, as well as during counter-rotation dressing.
During the dressing cycle, the control receives process data from the dressing spindle. The spindle is equipped with integrated acoustic emission sensors that detect when the dresser and grinding wheel come into contact. As the sensors can determine contact in the micrometre range, the system allows for correct alignment of the axes. This capability reduces air-grinding time, minimises wear on the diamond dressing tool and ensures defined abrasion of the grinding wheel.
Operating the system is simple because the Okuma control visualises all dressing process data and allows for the optimal adjustment of all parameters. Changes made by the operator, or variables recorded in real time, are automatically translated by the control into an NC program.
For further information www.ncmt.co.uk