Responding to customers seeking solutions to optimise grinding cycles for their production needs, Anca has developed a tailored dressing solution in a software update with optimised dressing from solid through the removal of air passes.
This intelligent solution can help customers improve and streamline their production processes. Applications like tap, punch, keyhole punch and drill require a lot of in-process dressing on the machine, so customers will benefit significantly from this new software feature in terms of time and cost.
In the existing implementation of solid dressing, the final wheel profile is offset in the radial direction, such that the first pass only dresses the wheel by the specified infeed per pass. This method results in a significant amount of air dressing, where the dresser roll is not in contact with the grinding wheel. A particular customer request was to find a solution to reduce solid-dressing cycle time.
The solution was implemented by trimming sections of the dressing path that lie above the wheel radius, and increasing the feed rate of moves where the roll is not in contact with the grinding wheel.
This update is compatible with any machines offering wheel-dressing capability that are running the ToolRoom RN33.2 release onwards. The feature is available for all solid-dressing surface types, including form, periphery and segment dressing. Optimised dressing has replaced the existing implementation of dressing, which will no longer be available due to the longer cycle times. Optimisations will automatically be calculated for dressing a profile on to a new or flat-profile wheel, and only air dressing beyond the wheel radius will be optimised.
For further information www.anca.com
Oldham-based Constant Group recently took the decision to invest £1m in fibre-laser cutters and press brakes and, while these machines may have been the main focus, the arrival of a Timesavers 12-600-W deburring and finishing machine from Ellesco has also made a significant impact on efficiency when graining stainless-steel materials.
“Prior to the acquisition of the 12-series machine we were hand-graining all of these parts, which could take 20 minutes each; we now achieve that in seconds, with consistent quality,” reports Matthew Garlick, joint managing director at Constant Group.
The Timesavers 12 series is among the smallest machines in the range and can be specified with working widths of 225 or 600 mm, the latter being specified by Constant Group, which acquired the basic configuration with an abrasive belt for graining and removing vertical burrs.
A cylinder brush or rotating disc can be fitted to remove side burrs and for edge preparation. Sheet between 1 and 75 mm thickness can be processed with simple control that allows work to flow under the belt at between 3 and 9 m/min to achieve the finish required. The simplicity of the Timesavers 12 series is also playing another important role for Constant Group in that its ease-of-use allows anyone to set and operate it, releasing skilled employees to work on higher value operations.
“Since the arrival of the Timesavers machine it has been running eight hours a day minimum with no issues whatsoever,” says Garlick. “The ability to have anyone run it is a big advantage, especially during the COVID-19 pandemic, where if we had staff absent we knew we could continue operating.”
For further information www.ellesco.co.uk
DeburringEXPO, the fourth edition of the trade fair for deburring technology and precision surface finishing, will be held at the Karlsruhe Exhibition Centre on 12-14 October 2021.
The exhibition will be accompanied by an expert forum, which is in great demand as a source of knowledge, complete with simultaneously interpreted presentations (German <> English). Beyond this, examples based on actual practice and benchmark solutions will provide ideas and stimulation for the optimisation of processes.
The supplementary programme at DeburringEXPO will be geared towards increasing demands for efficiency in production and changing manufacturing technologies, such as in the areas of joining, coating and assembly. A new theme park ‘Automated Deburring with Industrial Robots’ will provide information concerning corresponding solutions, and address the integration of deburring and rounding processes in an interlinked/digitalised production environment. Elsewhere at the show, the ‘Cleaning after Deburring’ theme park will deal with growing demands for technical cleanliness.
DeburringEXPO has a very high proportion of participating visitors (94%) involved in operational investment decisions. These decision-makers are seeking out solutions in a targeted fashion at the show.
“The challenges faced by companies from virtually all manufacturing industries also have an impact on surface-finishing processes such as deburring, rounding, and the production of precision surfaces and cleaning,” explains Hartmut Herdin, managing director of promoter FairXperts GmbH & Co KG. “Beyond this, these process steps are becoming more and more important in the growing market for component conditioning.”
Key requirements in this regard include ongoing quality improvements, increased efficiency, optimisation, automation and the digitalisation of processes, as well as solutions for parts manufactured using new and modified production technologies, such as 3D-printed workpieces and components made from hybrid materials.
For further information
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