A compact portable sander allows for better control when sanding over curves and convex surfaces, and its small pad size enables the easy sanding of concave surfaces a well.

Metabo Corporation, a leading international manufacturer of professional grade portable electric power tools and abrasives for industrial, construction and welding applications, has introduced a new 3-1/8in random orbital disc sander that provides increased additional flexibility for use in all types of sanding applications. The SXE400's Variospeed full-wave electronic speed control makes the sander suitable for several types of applications, including woodworking, automotive bodywork, fine metalworking, and polishing. Weighing only 3.3 lb., the SXE400 is easily maneuverable and its low 4-1/8in profile makes the sander compact enough to get into confined spaces difficult to reach with larger sanders.

Dust extraction is conducted through the sanding pad itself, so there is no bulky shroud to obscure the work surface.

The small 3-1/8in sanding disc diameter enables even pressure to be exerted over the entire sanding surface, resulting in clean sanding on narrow surfaces such as door and window frames.

- The small size of the SXE400 allows for better control when sanding over curves, making the sander well suited for convex surfaces, and its small pad size enables the easy sanding of concave surfaces a well.

The SXE400's Power Control System, featuring an integrated backing pad brake, helps eliminate sanding scratches, which significantly reduces the time needed to smooth sanded surfaces, resulting in increased productivity.

The SXE400 provides 5,000 to 10,000 orbits per minute with a 2.0A motor and features an orbit size of 1/8in.

Triple dust-sealed bearings help increase the life of the sander.

Standard equipment includes a hexagon key for changing the backing pad and 5 cling-fit sanding discs.

An optional carrying case as well as a variety of sanding discs for different applications are also available.

Best described as a distillation of the classic features of previous Swiss-built grinders this universal type comes with a wide range of hardware and software options at competitive prices.

Best described as a distillation of the classic features ofseveral previous Kellenberger models, the Swiss designed andbuilt Kel-Viva has an R type wheelhead for straight approachexternal grinding, and UR versions with a high resolution B-axisas standard for the multi-wheel universal internal / externalmachines.

Normal Kellenberger features such as true hydrostaticslideways and 0.0001mm resolution on diameter are included alongwith a complete range of hardware and software options to producethe highest quality ground parts with round cylindrical profiles,non-round parts using C-axis workhead option and even groundthreads.

The above Hardinge produced machines are pricedcompetitively and reflect the forward looking corporateobjectives of expansion through geographic markets and products.

It was the need to maintain high levels of flatness and parallelism within a few microns for its in-house press tooling that led Datum to buy a machine tool package including precision grinders.

It was the need to maintain high levels of flatness andparallelism within a few microns for its in-house developedUniCut press tooling that led Hampshire based Datum PrecisionTooling to the purchase of a machine package including twoOkamoto surface grinders, a Bridgeport Series 1 turret mill and aHarrison Model 390 centre lathe from 600 Centre of Shepshed nearLoughborough. Since the installation of the two grindingmachines, which also coincided with the purchase of a wire EDMand five-axis vertical machining centre, the company has beenable to diversify from being a very successful printed circuitboard tooling and press tool manufacturer into the automotive,medical, telecoms and plastic injection mould tooling business.And, due to the capacity of the larger Okamoto 105 DX-V is nowable to provide a sub contract grinding service to localindustry. Datum Precision was set up in 1990 and now employs 24people in two 7,000 (square feet) factory units in Finchdean justoutside Waterlooville, with sales of over GBP 850,000.

With anown product in UniCut, which is a new concept for producinghighly accurate shaped holes and profiles in acetates, polyester,polycarbonate, plastics, paper and flexible circuit boardmaterials, the business is building.

It is now supplying toolingfor producing the likes of mobile phone lenses, automotivedashboard instruments, panels and fascias, labels, gaskets andapplications where overlays are required.

In order that theshaped parts can be punched using the UniCut press tool design,the relevant materials are fed in strip format which is mountedon a backing strip which allows the components to be simplypeeled off at the point of assembly.

However, the critical natureof maintaining the depth of cut of the tool so the resulting edgeis clean, the razor sharp tool is not blunted and the backingmaterial is not pierced, is where the investment in newproduction machining was key to Datum.

Says Sales and MarketingManager Gary Gibbs: 'We are now supplying most UK and agrowing export market with UniCut tooling for producing productssuch as telephone lenses, labels and fascias and have recentlybroken into the Far East with a major producer which means thetooling concept is proving to be a real winner.' The UniCutpunch tool concept can produce up to nine components at a time.It can be supplied as a bolster with a tool cassette whichenables different profile shapes to be quickly and easily changedover or as a compound pierce and blank tool in order tocombination punch holes and the profile of the part in the samepressing cycle.

When the tool is produced from design to finalpass-off it is championed by one of Datum's six highlyskilled toolmakers.

Each toolmaker will operate any of thecompany's machines, to produce the relevant parts, thenassemble the finished tool, perform the try-out and finallysign-off the project.

Because of the accuracy required from thepress tool, the machining datums initiated by grinding the platesflat and parallel is critical to all the following operations andthe ultimate tool performance.

The larger of the two Okamotos,the ACC 105 DX profile and surface grinder has a table size of1050mm by 500mm and a load capacity of 700kg, while the smallerACC 450 DXA profile grinding machine has a 410mm by 150mm table.Each machine was chosen due to simplicity of setting and thecapability to be set up on a task in automatic cycle and left torun unattended allowing the tool maker to get on with somethingelse.

Maintains Technical Director, Robin Lovett: 'This madethe machine purchases excellent value for money and gave us acapability we never had before.

Also, because of the accuracy wecan obtain, this ensures that when following milling operationsare performed the tool blade can be maintained to a consistentsharp edge around the profile and we can therefore preciselycontrol the quality of cut the tool makes and ensure a longservice life.'

Automatic wheel balancers enable CNC valve seat grinders to maintain dimensional tolerances of under 5 microns, while producing up to 15 components a minute, 24 hours a day.

Designing and manufacturing special purpose CNC machines capableof maintaining dimensional tolerances of better than 5 microns,while producing up to 15 components a minute, 24 hours a day, isundeniably a tough task. But when these same machines are likelyto be installed in plants located anywhere from Argentina orIndia to China or South Africa, then the need for precision mustalso go hand-in-hand with reliability, durability and excellentproduct support. The same is just as true for any 3rd partyequipment incorporated in the design.

That's certainly theview taken by Earlsdon Technology; which is why the specialistmachine tool builder has specified automatic wheel balancingtechnology from Schmitt Europe for its latest generation ofpurpose-designed valve seat grinding machines.

Custom-engineeredequipment and automation solutions for high speed or massproduction applications are at the heart of EarlsdonTechnology's business.

The Coventry-based company isparticularly strong in the fields of high volume engine componentmanufacture, high performance fastener production and automatedcentreless grinding machinery.

Not surprisingly, its customersinclude many familiar names in the aerospace sector, as well asautomotive component suppliers such as TRW, Federal Mogul andEaton.

'As a relatively small, but experienced player, wehave focused our activities on niche market requirements,'says Managing Director Simon West.

'Our latest VSG-X1grinders are a typical example, being designed specifically forengine valve production.

The machines incorporate fully automaticcomponent loading and unloading and will achieve cycle times ofless than 5 seconds on components up to 160mm long and 50mm headdiameter.' 'Maximum manufacturing tolerances willnormally be less than 20 microns on seat-to-face length, 15microns TIR (total indicated run out) on seat run out, 3 micronson seat roundness and less than 0.25 microns on surfacefinish,' he adds.

Precise control - meeting these sorts ofrequirements calls for precise control of the grinding process.

Akey element in this is ensuring the dynamic balance of thegrinding wheel itself.

It is not only central to maintainingdimensional accuracy and surface finish, but also contributes toother benefits, such as extended component runs between dressingcycles, increased wheel and dresser life, minimised vibration andreduced spindle bearing wear.

These in turn, result in greaterproductivity and lower machine maintenance costs.

'Ineffect, the wheel balancing equipment plays a crucial role in theperformance of the whole machine,' continues West.'That's why we went to significant lengths to assessthe capabilities of a number of suppliers' products beforespecifying any equipment for our new valve grinder models.'During our evaluation, we were impressed by the range ofgrinding wheel balancing solutions offered by Schmitt.

Detaileddiscussions with the company led to a series of trials, and thesubsequent adoption of their SBS dynamic balancers.'Comprising a sensor, spindle mounting adapter, balance head andelectronic control unit, the SBS system provides continuousmonitoring of the grinding process; eliminating the need forpre-balanced wheels and greatly reducing set-up times.

Theequipment uses the principle of mass compensation to correctimbalance.

SBS balance heads incorporate two eccentric weights,each of which is driven independently by electric motors througha precision gear train.

In operation, vibration or imbalancedetected by the sensor is relayed to the controller at the heartof the system.

The unit processes the signal and sends commandsto the balance head to advance each weight in the correctdirection to reduce the amplitude of the input.

When the minimumvibration level is achieved, the balance cycle is complete.

Thesystem continuously monitors the machine to provide a fullyautomatic system that maintains balance even if the wheel isstopped and re-started.

Balance accuracy - SBS equipmenttypically achieves balance accuracy of 0.1 micron peak-to-peakvibration displacement, which compares to 5 microns for normalunbalanced grinding operations and a figure of around 3 micronsusing statically balanced wheels.

'Not only did the Schmittsolution provide the high balance accuracy we were looking for,but the system's components are small and neat, enablingthem to be mounted more easily in restricted accessapplications,' says West.

'The SBS control unit isequally compact and proved easier than many of its competitors tointerface with the machine control system we had designed for thenew machines.

'A further important factor in our decisionwas that, as part of a large international organisation, SchmittEurope could provide us with first class, world-widesupport.' 'Indeed, we have already taken advantage ofthis facility,' he adds.

'Through the response ofSchmitt's US-based engineers, we have quickly resolved arecent problem at one of our customers' manufacturing plantsin Mexico, where 20 of our machines are installed.' So whatare the prospects for the future?

'Part of our reputationrides on the balancing equipment's performance,' notesWest.

'Since partnering with Schmitt, we have developed aclose relationship, where both companies work together to addressany issues that arise.

'Not surprisingly, we intend tocontinue incorporating Schmitt balancing and process controltechnology on our machines; and not just on valve seat grinders,but on other equipment - such as special purpose grinderswe've developed to produce critical components for aninnovative new medical device.' About Schmitt Europe - basedat the University of Warwick Science Park, Schmitt Europe offersbalancing and vibration control solutions that harness precisionas the key to manufacturing productivity.

The company'swheel-mounted, in-spindle, ring or hydro type automatic grindingwheel balancing systems dramatically improve surface finish andwheel life, while its acoustic emission monitoring equipmentprovides precise monitoring and control of grinding and wheeldressing operations.

Schmitt also offers high accuracy, verticalor horizontal axis component balancing machines, as well asnumerous laser measuring, alignment and surface textureinspection systems..

Why higher production rates using plated CBN abrasive grinding wheels cannot be achieved may be the spindles are not fast enough and the machine requires fast set-ups and high rigidity.

Enterprises that are willing to pay up to ten times more for CBN grinding wheels expect a large payback in terms of faster material removal, or more parts per wheel, or better form consistency, and usually all three. However, although it might seem easy to add a high speed spindle to an existing machine to take a CBN wheel, the user might then find that his parts have surface finish problems caused by the machine vibrations and chatter, which can occur at these high speeds. This is not usually a problem with the abrasives; rather it is with the machines onto which the CBN wheels are applied.

Fitting new high technology wheels onto old or existing machines is almost certain to result in the wheels not achieving their production potential, leading to disappointment for the user.

The most obvious reason why higher production rates cannot be achieved on conventional machine tools is that the spindles simply don't go that fast; but there is also another reason: the machine must be designed for fast set-ups and with the accuracy and stiffness that anticipates such elevated process speeds.

The same problems do not apply to machines designed specifically to employ the latest plated CRB wheels.

Holroyd's Edgetek range is a good example: the machines are produced with high power/high speed spindles that optimise the use of plated CBN wheels at surface speeds of up to 9000m/min.

This enables them to achieve high depths of cut and optimised metal removal rates far exceeding those of more conventional machines, such as CNC lathes, milling and machining centres and grinders.

In addition, the Holroyd Edgetek machines are manufactured with a polymer granite base, which has been shown to have strong damping properties.

These have been proven in dynamic response tests carried out by AMTRI.

Developed to satisfy the need for extreme rigidity and enhanced vibration damping, the polymer base typically weighs 3 tonnes and has no resonant frequency.

As a result, it enables higher precision machining to be achieved.

Combining this stiffness and damping capability with the Edgetek's ultra high speed machining capabilities and plated CBN wheels, is drastically reducing cycle times in many crucial industry sectors.

In one example, the cycle times for producing automotive parts manufactured from sintered metals were reduced from 70s per component to just 22s.

At the same time, the Edgetek's plated CBN technology is cutting consumable parts costs, achieving a reduction from US$1 to just 3.3 cents per component.

This is the result of the Edgetek machine producing a much larger number of components between tool changes: 15,000 as opposed to the 50 achieved with conventional milling and turning machines.

In another UK application, a single 5-axis Edgetek machine is slashing process times with single lift and set-up.

The Edgetek is replacing seven conventional milling and grinding machines, providing a reduction in the throughput time for a complex finished part from 8h to just 12min.

'This application epitomises lean manufacturing technology,' said Holroyd sales director, Neil English.

'It provides the opportunity to begin with a hardened blank, and then produce a part complete in a single set-up, using plated CBN wheels.

It is not the cost that is driving the trend toward plated CBN but the productivity,' said English.

'Smaller production runs and more set-ups, means that many companies no longer have the luxury to amortize the cost of bonded wheels, and the long non-productive set-up times associated with them, over extended production runs.

Plated technology fills the need for high metal removal rates with short set-up times and eliminates the need for dressing.

The plated CBN form wheels we use on our Edgetek machines have several advantages over bonded conventional or superabrasive wheels: they have higher material removal rate capabilities, and are freer cutting, which reduces thermal metallurgical damage to the work's surface.

Equipped with steel cores they are also safer, providing safety at high operating speeds in excess of 20,000 sfm.' He said: 'In addition, plated wheels offer the highest levels of consistency: they grind virtually the same profile, from the first cut to the last, across hundreds or thousands of workpieces.

As a result, the times associated with set ups, wheel changing, and wheel dressing are significantly reduced or eliminated.

Also greatly reduced is the average wheel cost.

This is because the wheels can be stripped of worn CBN and re-plated several times.' * Unequalled levels of precision and productivity across almost all part types - the flexibility of the Holroyd Edgetek design, and the huge variety of machine types and multi-axis configurations available, enables the machines to provide unparalleled levels of precision and productivity in the manufacture of almost any type of parts - gears and sprockets, rotors and impellers, medical instruments, hand tools, air foils and nozzle guides, airframe actuation components, ducting supports, mechanical seals - and many, many, more.

The machines serve a broad spectrum of industry types, including power generation, automotive, aerospace, medicals, tools and general engineering.

They can be tailored to suit specific applications and supplied as complete turnkey solutions as part of a manufacturing cell.

A worldwide service network provides support for the machines, and they also benefit from manufacturer- developed preventative maintenance plans.