Kellenberger K100 released

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.
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Laser roughening and honing machines

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.
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Grinding experts combine resources

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.
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Rotor grinding machine on order

The latest company to order a Holroyd TG350E rotor grinder is Jaguar Compressors, a division of the Xiamen East Asia Machinery Industry Company. Currently in build, and costing some £1.3m, the machine will be shipped to Jaguar’s Xiamen, China-based manufacturing facility in mid-2020.

Holroyd reports the TG350E rotor grinding machine is rapidly making a name for itself as the preferred choice among industrial refrigeration specialists. There are currently around 70 TG series machines in use around the world and, each year, Holroyd typically receives orders to build several new TG models.
“The team at Jaguar Compressors continually strives to enhance the performance and energy efficiency of its screw air compressor products,” says Holroyd regional sales director Steven Benn. “With the ability to grind medium-to-large capacity rotors of up to 350 mm in diameter and 1795 mm in length, the TG350E model offers a versatile, high-quality solution to Jaguar’s varied production requirements in producing screw compressors for a variety of applications, including precision filters, gas storage tanks and refrigerated dryers.”
A further benefit for users of Holroyd TG series models is that a significant amount of production time can be saved as each machine’s diamond dressing discs are able to continuously dress during semi-finishing cycles. By contrast, cutting tools typically require periodic regrinding, the frequency of which is determined by the materials and volumes being cut.
Developed primarily for the finish-grinding of helical screw components after they have been milled to a rough or semi-finished state, Holroyd TG series machines are just as suited to prototyping and batch manufacture as they are to volume production. Fully automated on-machine probing provides closed-loop feedback of corrections to the dresser disc.
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Automated filter units introduced

The Autofiltrex range of automated filters, which is suitable for most ferrous metal-finishing processes, including grinding, honing and lapping, has been introduced by Eclipse Magnetics.

Described as the latest generation in cost-effective, high-performance filtration, the Autofiltrex was exhibited at the recent EMO 2019 exhibition in Hanover, where Eclipse Magnetics says it received high levels of interest and positive feedback.
Sales and marketing director Steve McAllorum says: “We were delighted to see that the Autofiltrex was a popular product on the Eclipse Magnetics stand at EMO. The Autofiltrex is a great example of how an investment in magnetic technologies can improve efficiency in metal-finishing operations.”
Eclipse Autofiltrex units can be fitted in-line or off-line, ensuring 24/7 “ultra-polished” fluids and delivering advantages over traditional filter media. The modular design allows the addition of further units to accommodate increased flow rates, depending on application needs. Offering sub-micron filtration performance, the Autofiltrex range delivers cleaner fluid to the machine, thus improving surface finish and accuracy, as well as reducing expenditure on filter media.
Designed as a ‘plug and play’ device, minimal set up is required, and the system can be fully integrated with CNC units for ease of use and to provide 24/7 uninterrupted filtration. In addition, the option of an additional waste reclaim unit is available to enable a fully automated system with waste disposal.
Three sizes are available – the AF1 (no reclaim unit), the AF3 and the AF5 – each occupying minimal floor space with the capacity to increase fluid life by up to 10 times.
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