A new variable speed 2in (50mm) die grinder that greatly simplifies the procedure required to change accessories. Having a spindle lock only one wrench is needed on the collet.

A new variable speed 2in (50mm) die grinder that greatly simplifies the procedure required to change accessories has been introduced by Metabo. While other tools require two wrenches to change accessories, the GE700 has a spindle lock, so only one wrench is needed on the collet. The new grinder is extremely flexible, featuring an extended spindle ideal for operation in confined areas and Metabo's Vario-Constamatic (VC) full-wave electronic speed control.

The VC speed control allows users to vary speed to accommodate a variety of accessories, including flap wheels, carbide burs, abrasive cut-off wheels, and mounted points.

This makes the tool useful for grinding and cutting a wide range of materials, from hard to soft, including plastic.

The GE700 has a hardened and ground 1/4in collet for accurate balance of fitted attachments, and auto-stop carbon brushes that increase brush life while preventing motor damage that can be caused by worn brushes.

The power switch is ergonomically located on the top of the tool, making it easy to operate for both right- and left-handed users.

Offered with a 3-axis NC gantry loader as standard an angle-approach, cylindrical grinder has a 320mm swing and 125mm maximum centre distance for grinding small, high precision parts.

New from the grinding machine division of Toyoda will be theGW3A-12, an angle-approach, cylindrical grinder with a 320mmswing and 125 mm maximum centre distance. Available also with astraight approach wheel, the machine is Ideal for grindingrelatively small components such as fuel injector and electronicparts. The machine is the first Toyoda grinder to be offered witha 3-axis NC gantry loader as standard equipment, allowing longperiods of unattended running.

Further integration with otherproduction cells is achieved using pallets or conveyors.

Idealfor use with alumoxide wheels, or with CBN as will bedemonstrated at MACH 2002, the machine has a compact footprintmeasuring only 950mm wide without the loader.

It is also thefirst Toyoda grinder to be fitted with a Fanuc control - the 21iCNC - rather than the manufacturer's own.

This providecontrol of six axes, three for the machine and three for theloader.

A notable feature on this and all other Toyoda grindersis the STAT hydrostatic / hydrodynamic wheel spindle bearing.Absence of metal-to-metal contact and good vibration dampingcharacteristics assure high accuracy and long service life.Grinding speed is 45 m/s, although 60 or 80 m/s is available forCBN.

Other specifications include 219mm wheelhead infeed and20m/min rapid traverse rate; 32 - 1,000 rpm workhead spindlespeed; and 25mm tailstock quill stroke.

A single point, diamondwheel dresser is standard with the machine.

On show also will bethe Toyoda GU4x100 CNC, a universal grinder featuring automaticindexing of the wheelhead under computer control for deployingeither the internal grinding spindle or one of two externalgrinding wheels for straight- and angle-approach.

Poweredindexing of the wheelhead is in five degree or one degreeincrements using a Hirth coupling and hydraulic clamping toensure precise location.

A full B axis is a further option.Available in two versions with 1000mm or 1500mm between centres,the machine has maximum internal and external grinding diametersof 300 mm and 120 mm respectively, 320 mm swing over the tableand a wheel surface speed of 30m/s (optionally 45m/s).

An angle grinder, which maintains a constant speed while operating during both maximum load and no-load conditions, allows the user to achieve significantly greater productivity while grinding.

The WE14-150 Plus angle grinder, which maintains a constant speed while operating during both maximum load and no-load conditions, has been introduced by Metabo. The tool features Metabo's Vario-Constamatic (VC) full-wave electronic speed control, allowing the operator to achieve significantly greater productivity while grinding. The WE14-150 offers thermal overload protection to reduce motor burn out when used in heavy-duty applications.

A light signal flashes to give warning of impending overload to the operator if the temperature of the windings should approach the maximum permissible value.

The grinder includes several standard features for easy operation, including Metabo's unique 'Quick' system that enables the operator to change grinding wheels without the use of tools, significantly reducing downtime.

Metabo also offers a tool-less wheel guard adjustment that allows the operator to make adjustments rapidly and safely.

The WE14-150 incorporates Metabo's Marathon motor with epoxy resin powder-coated field coils, which make the motor extremely resistant to destructive grinding dust and help prevent overheating.

The grinder also includes a two-position side handle for additional comfort and control during operation, as well as Metabo's exclusive S-automatic safety clutch to prevent injury from kickback in the event of a wheel jam.

A winding protection grid deflects harmful airborne debris away from armature windings, increasing motor life by up to five times.

Using a biomedical engineering micro-dosing technique, CBN and diamond coated honing tool lives can be increased up to 10 to 20 times, while grinding performance can be quadrupled.

Using a biomedical engineering micro-dosing technique, CBN anddiamond coated honing tool lives can be increased up to 10 to 20times, while grinding performance can be increased up to fourtimes. It is no surprise that the tool grinding time and costs -and quality of finish - is directly dependable on the quality ofthe grinding wheel. Distribution of CBN or diamond grains on awheel surface is random - which influences grindingcharacteristics.

Dr Gregor Burkhard of the Institute of MachineTools and Manufacturing, the Swiss Federal Institute ofTechnology, Zurich, has developed a precise grain-placing methodbased on medical practices.

The result is significant shorteningof tool grinding time and grinding wheel life.

Dr Burkhardpresented his results at the Fritz Studer Grinding Symposium,held in Thun, Switzerland, earlier in 2002.

With random spacingof CBN or diamond grains, the spaces in between the grains canclog, resulting in 'burning' of the tool or workpiecesurfaces, said Dr Burkhard.

Usually CBN and diamond coatedgrinding wheels consist of a steel or aluminium wheel body thecircumferential work surface of which is electroplated withnickel or nickel alloy to secure the abrasive grains.

Usually,the surface is coated with an adhesive, and the wheel rolled in alayer of abrasive grains.

The adhesive holds them in place duringthe electroplating process.

'The grains are randomlyarranged,' said Dr Burkhard, 'which means that thedistance between the individual grains - which serves totransport cooling lubricant into, and chips out of, the machiningzone, is also random.

This represents a major disadvantage ofsuch tools, as individual spaces can easily become clogged duringmachining, which then eventually leads to abrasive burning on thetool and, therefore, to spoilage.' Another point made by DrBurkhard was that with existing grinding wheel electro-platingmethods, the abrasive grains are only 'mechanicallyclamped' in place and grain projection is only 40 - 50% ofthe mean grain diameter.

With the new grain dispensing method, itis possible to determine the size and location of the vacantspaces.

Then, if an active brazing alloy bond is used, grainprojection can amount to 80-100% of the mean grain diameter.'This permits good supply of the cooling lubricant into, andgood removal of the chips from, the machining zone, ' saidDr Burkhard, 'thus enabling higher metal removal rates andcutting times.' Dr Burkhard's team has adapted the useof micro-dosing from biomedical engineering processes.

Normallyused for precision pipetting purposes, micro-dosing producesuniform drops with a maximum diameter of about 40 microns at anemission frequency of up to 2000Hz.

Such a dosing head consistsof a glass capillary tube connected to a reservoir via a feedpipe.

It forms a jet with its mid-section enclosed by apiezoactor.

The piezoactor contracts when a voltage pulse isapplied, so causing a drop to be emitted.

A heater is alsoincluded to set the optimum viscosity of the fluid.

So DrBurkhard's team built a prototype device to sequentiallydose the work surface of a grinding wheel body with liquidadhesive drops in specific patterns and distribution.

The wheelis then rolled through a thin layer of abrasive grains, the sizeof the drop determining whether a single, or clusters of, a CBNor diamond grain are picked up.

Brazing paste is then applied tothe wheel work surface.

In practice, the prototype'micro-dosed' structures were applied to mandrel-typehoning tools (or honing sleeves) to hone the interrupted bore ofa hardened gear wheel to the finished size of 12F7 diameter.Before, the process was carried out in three stages usingelectroplated honing sleeves with settings of 0.04, 0.04 and acalibrating pass of 0.01mm (on diameter).

The mean service lifeof the electroplated tools was 5000 strokes at the 0.04mmsetting.

In tests, with setting at 0.08mm on diameter, life ofthe electroplated honing sleeve was 1000 bores.

The micro-dosedand brazed honing sleeve lasted for 6000 bores.

Yet themicro-dosed tools had not yet been fully optimised in terms ofgrain size and grain spacing! Further development resulted in themicro-dosed honing sleeves producing a service life of 10 to 20times greater than the traditional electro-plated honing sleeves.Development went on to produce internal grinding CBN and diamondcoated pinwheels and a disc-type grinding wheel.

In tests withthe latter, a wheel of 300mm diameter and 20mm wide was used intests in hardened tool steel in a Maegerle surface grinder,producing a related time/machining volume of Qw = 20mm3/mms at acutting speed of Vc = 40m/s.

'This is four times the valuefor conventional tools,' said Dr Burkhard.

Bear in mind thatthe increased metal removal rate was achieved without optimisingcoolant to suit the new wheel.

In many industrial fields, including the automobile industry, product platforms have been used successfully for several years, it has now been applied to cylindrical grinders.

The modular platform concept is to the customer's advantageIn many industrial fields, including the automobile industry,product platforms have been used successfully for several years.A standardisation of systems, sub-assemblies and components, evenover different makes and models, are of central importance, themain target being a reduction of engineering time and costs.Although the above cannot be directly applied to machine tolls,the following explanations should show that similarities existand a platform concept also provides considerable advantages withregard to the universal and external cylindrical grindingmachines of Studer. The Studer product range is characterised bya large variety of machine types and versions with the intentionof satisfying the different requirements of a large number ofinternational customers. Due to this multitude of types andvariations, there are additional expenses for engineering,production and logistics.

In this field, a modular platformconcept, combined with a consequent 'same partstrategy', provides economical and technical advantages forthe manufacturer as well as for the customer.

All the newdevelopments of recent years in the field of universal andcylindrical external grinding machines are based on two basicplatform types with standardised sub-assemblies, components andinterfaces.

The product platforms for the respective machinetypes derive from this: Platform basis A for the machines S21,S31 and eco, Platform basis B for machines S32 and S41 Furtherproduct platforms can be built from the above, and realised withminimal technical risks.

Characteristics of the basic types ofplatforms A and B - common characteristics * Machine bed inGranitan S103 with 3-point support.

* Circulating balls screwswith directly coupled servo motors.

* Linear measuring systems.

* Well dimensioned slides.

* Coolanttray.

* Protected guideways.

Varying characteristics: Platformtype A: * Distance between centres max: 1000mm.*Centre height max: 175mm.

* workpiece weight, max: 120kg.

*Guideways, X and Z axis: linear roller ways.

* Distance betweenthe guideways: 200 mm.

* Workpiece table: 140 mm for centreheight 175mm and 200mm for centre height 225mm.

Platform type B:* Distance between centres, max: 1600mm.

* Centre heightmax: 225mm.

* Workpiece weight max: 180kg.

* Guideways: X axis:Pre-loaded hydrostatic guideways and Z axis, linear rollerbearings.

* Distance between the guideways: 250mm.

* Workpiecetable: 140mm.

Platform concept combined with modularsub-assemblies - the combination of product platforms and modularsub-assemblies, such as wheelheads, workheads, tailstocks, etc,form the basis for a versatile and clear product structure.However, the possibilities of combining are limited by physicaland economical restrictions.

These are due to the machine sizes,the drive power of the wheelhead and the type of machine, i e,universal or cylindrical external grinding machine.

Product andstrategic marketing considerations are further criteria which caninfluence and restrict the combination possibilities.

The basicversions of wheelheads are firmly allocated to the differentproduct platforms.

We distinguish between wheelheads withintegrated B axis for the universal cylindrical grinding machinesand the fixed or limited swivelling wheelheads for thecylindrical external grinding machines.

The layout of grindingwheels can be adapted to the customer's requirements withinthe possibilities of the respective modular concept.

For furtherinformation with regard to the grinding wheel layout, pleaserefer to the respective documents.

Depending on the main use, theproduct platforms can be equipped with workheads for universal orchuck applications.

One of the main differences, apart from theadmissible load, is the tool clamping interface.

For automaticprocessing, for instance of highly accurate components in largeseries for the Diesel injection industry, special workheads canbe installed.

On all the product platforms there is the samebasic tailstock type.

This unit is conceived for the differentcentre heights and table loads.

For automatic processing, specialversions are available.

Summary - the modular platform conceptfor the universal and external cylindrical grinding machines ofStuder brings various advantages: * Reduced engineering time andcosts for realising similar machine types or versions.

* Savingsfor the manufacturer and the customer by using compatible systemsand components.

* Versatile product structures by combining theproduct platforms with modular sub-assemblies and standardisedinterfaces.

* High reliability of the products thanks to ampleexperience gained with the product platforms under differentworking conditions.

* High and stable quality thanks toproduction in series and standardised quality checks.

*Accessories can be used for different product platforms.

*Identical service and maintenance thanks to similar systems andcomponents.

* Short-term availability of spare parts.

*Simplified retrofitting of functions and sub-assemblies..

Facing and internal grinding machine can concentrate and combine serveral operations - including profile grinding - into one set-up under CNC.

Danobat offers maximum flexibility in internal and face grinding with the new Overbeck IG 400 CNC internal and face grinding machine. Increase productivity and efficiency of the processes, reduce the space in the plant and guarantee the finishing of parts are the results of the new Overbeck IG 400 in the demanding internal grinding sector. * Danobat: Overbeck IG 400 - the IG 400 offers the possibility of concentrating and combining several operations coordinated by numerical control.

This model performs form grinding, and also has up to four workstations combining internal and face grinders and measuring devices.

The main advantage offered by the IG400 is the capacity to carry out all the part internal and face grinding operations in one clamping, regardless of the size of the batch.

The software designed for this machine allows for easily carrying out simple cycles by means of the introduction of basic parameters or more complex combinations that enable a greater degree of automation of the process.

More flexibility in programming with variable graphics simulation for grinding and wheel dressing feature the latest Chevalier CNC surface grinding machines.

Expansion of the Chevalier range of CNC surface grinding machines, represented in the UK by C Dugard of Hove, UK, brings new levels of programming flexibility with variable graphics simulation for grinding and wheel dressing where the speed of review sequences can be varied by the operator. The Smart II - Series of multi-function, 3-axis machines has been developed for surface, form, step, slicing and profile grinding parts as diverse as turbine blades, punches, graphite electrodes and ceramics and production batch work such as automotive cam followers and valve stems. With the new control and software, the machines can also be programmed to produce different slots with varying depths and pitches on the same part.

In addition, with the inclusion of a CNC rotary table giving speeds up to 33 rev/min, the machines can be used to create cylindrical grinding cycles as well.

Key to the flexibility of the Smart-II Series is the simple graphics-based conversational control that incorporates a wide range of macros for grinding and wheel dressing including compensation with full grinding and wheel dressing simulation.

The simulation cycles utilise the electronic handwheels for manual axis movements to provide the facility whereby forward or reverse display of the program paths can be viewed.

The faster the handwheels are rotated in either direction, governs the speed of the execution of the simulation cycle.

There are four automatic graphic modes for dressing: table type with single point diamond or diamond roller, overhead diamond roller or full profile dressing.

Further advantages of the Chevalier system is the automatic wheel compensation that can even be executed in profile dressing mode, while pre-set dressing cycles can be initiated at anytime during the grinding cycle.

Once the dressing cycle is complete, additional finish or 'patch' passes can be made without having to repeat the complete cycle.

The new machine range spans the Smart II-818, 1224 and 1640 providing table sizes of 200mm by 460mm, 300mm by 600mm and 400mm by 1000mm and table loadings up to 670kg.

The maximum distance from table surface to spindle centre 406mm on the smallest machine, 630mm on the 1224 and 630mm on the larger machine.

Grinding wheel sizes are 203mm by 12.7mm by 31.75mm, 355mm by 50mm by 127mm and 355mm by 50mm by 127mm.

The machine is built on a single T-shaped base casting giving maximum rigidity with hardened and ground double 'Vee' ways and Turcite-B coated longitudinal and crossfeed guideways between base, saddle and table.

There is a range of options for the spindle specification from 1.5kW to 11.25kW depending on the machine size with further options for oil or air cooling.

Additional options include: linear scales, automatic wheel balancing, single disc dresser and a paper filter coolant system.

The highly productive S-series of cnc cylindrical internal and external grinding machines offer a wide range of options, fast setting-up and high precision.

Grinding Technology for Tool Production The highly productiveS31cnc cylindrical internal and external grinding machine has awheelhead with two external grinding wheels for rough and finishgrinding left/left. Range of applications includes any type ofcylindrical internal and external machining for automaticproduction of individual components and series. The modularmachine structures, the modern control and programming technique,as well as the grinding technologies, guarantee a highproductivity and excellent machining quality.

The S31cnc isavailable with a distance between centres of 650/1000mm and acentre height of 175mm.

The machine has now been completed withan additional wheelhead version.

This allows the installation oftwo motor spindles.

Consequently, two diagonally installedgrinding wheels, with diameters up to 500mm, can be used.

Thanksto the independently programmable drives, these wheels can beadapted optimally for the respective grinding task, guaranteeinga large speed and perfor- mance range.

The B-axis swivelsautomatically with a resolution of 0.0001deg so that even thesmallest taper angles can be processed with cylindrical grindingwheels to extreme accuracy.

The Studer S32cnc is a fast, accurateand reliable external, cylindrical CNC grinding machine.

TheS32cnc has chameleon-like properties.

Thanks to the large varietyof extensions and versions, a large number of applications can becarried out on this machine according to customers requirements.This is possible thanks to X-axis versions at 0deg or 30deg, andthe possibility of positioning the grinding wheel on the left orthe right side.

Thanks to the versatile machine concept, thismachine permits a selection of the most suitable grinding method,according to individual customer requirements.

This means thatthe machine can master simple and complex tasks in a very highquality.

In the standard version, with the grinding wheel on theright side and a distance between centres of 400mm, this machineis perfectly suited for grinding small and average-sizedworkpieces.

In conjunction with the diamond roll dressingattachment, the S32cnc becomes a highly productive machine.

Ofcourse, thanks to the proven Studer concept it can be automatedeasily.

The use of our C axis turns the S32cnc into a high-powerplunge grinder.

In this context, the hydrostatic guideways of theX axis play an important role as they allow extremely rapid axestraversing with a minimum of axis lag.

Due to the new materialsthat are emerging in the market, the machining process has to beadapted to the situation.

The S32cnc can also master this problemas it can be equipped for high-speed grinding.

With a cuttingspeed of more than 125m/sec, even materials difficult to machine,such as zirconium ceramics or tungsten carbide, can be processedeconomically.

The Studer S40cnc is a highly productive universalinternal and external cylindrical grinding machine.

Its range ofapplications includes any type of external and internalcylindrical grinding task for the automatic production of one-offand series production.

The modular machine structures, the moderncontrol and the programming technique as well as the most recentgrinding technology guarantee a high productivity and machiningquality.

The S40cnc is available with distances between centresof 1000 or 1600mm and centre heights between 125 and 225mm.Wheelheads and workheads for practically any type of use areavailable.

The B-axes is oriented automatically with a resolutionof 0.0001deg so that even the smallest taper angle can be groundto the utmost accuracy with, straight grinding wheels.

We showthe universality of the machine on a complex chuck element.Grinding of forms and threads is always one element of completemachining.

The position and speed-controlled C-axis renders thesegrinding procedures possible.

A measuring system installed on themotor axis of the workhead or on the work spindle providesmaximum form accuracy of the form during the grinding process.Acceleration and grinding forces are easily absorbed by thedynamic rigidity of the axes drives.

With regard to threadgrinding parallel to the axes, the grinding wheel is notswivelled to the pitch angle of the thread, but it remains in thevertical position so that its angle of rotation remains parallelto the Z-axis.

Consequently, while grinding the thread there willbe a distortion of the profile which is compensated by the Studersoftware StuderThreadCNC to a negligible deviation.

Bycalculating the profile distortion and the automatic generationor optimised dressing programmes, thread grinding becomes nearlyas simple as plunge grinding or traverse grinding.

The StuderS60cnc is designed for the grinding of tool holders with theuniversal and production external cylindrical grinding machine.Progress can be obtained by force.

One is tempted to say thiswhen watching the Studer S60cnc in operation.

In order to fulfilthe increasing requirements of the tools, the quality of the toolholding fixtures has to be improved continuously.

The very bestquality of the workpiece is obtained if it can be processed inone single clamping and in one machining pass.

The Studer S60cncpermits complete grinding of tool holders up to the dimensionISO50.

By complete grinding we mean: the V-groove, the externaldiameter, the taper and, if required, the shoulder of the taperin one plunge cut.

Work is carried out by means of a profiledgrinding wheel.

The S60cnc with its elements entirely laid-outfor the production, for instance the grinding wheel width of upto 160mm and the grinding wheel diameter of 750mm, is perfectlysuitable for this type of application and therefore providesexcellent grinding results.

With this procedure, a tool holderISO 50, for instance, is manufactured to quality class AT-3 injust less than 90 seconds.

For this machine, the quality classAT-1 is no problem any longer.

In fact, it is a standardmachining task in a second clamping combined with in-processgauging.

The installation of two programmable surface grinders has allowed toolmaker Tarpey-Harris to reduce lead times by up to 25% and optimise grinding times for dies, moulds and precise parts.

The installation of two Okamoto ACC 450 DXA surface grindingmachines by 600 Centre of Shepshed, Loughborough has allowed theBelper-based toolmaker Tarpey-Harris to reduce lead times by upto 25 per cent, have one operator to look after both machines formost of the day and optimise grinding times for a wide range ofdies, moulds and precision parts. In addition, the company hasfound the Okamoto machines very easy to operate and to make itspurchase justification more significant, the final machinespecification worked out 20 per cent less than comparable surfacegrinders on the UK market. Established in 1969 as precisionengineers and toolmakers specialising in tooling for theinvestment casting industry, Tarpey-Harris is now part of theFairbrook Group.

The 32-strong Derbyshire company producesextrusion dies, injection mould tools, rubber mould tools and waxpattern dies that are mainly used for plastics window elementsand profiles as well as cladding for buildings.

The wax andrubber tooling it produces is primarily used in the manufactureof seals for hatches, doors and other openings for the aerospaceindustry.

However, the company also manufactures injection mouldtooling for a range of medical products and provides a componentmachining subcontract service for an array of different industrysectors.

With over 80 per cent of its machining work involvingtool production, grinding is therefore a key process.

So when thecompany decided to replace a couple of ageing manual surfacegrinders it looked around for the most suitable machine on themarket in terms of performance, accuracy, ease of use andespecially set-up and cost effectiveness.

As works director TonyHarris explained: 'After seeing an Okamoto 450 DXA in actionat a 600 Centre customer, we decided that this machine was idealfor our needs, combining precision with affordability.

Sinceinstallation the repeatability, ease of operation and minimalmanning requirements of the machines has transformed ourbusiness.

I look out of my office window and they are runningthroughout the day with hardly anybody ever near them.' Some90 per cent of the company's surface grinding work is nowchannelled through the Okamotos for processing a wide range ofdie parts, bolsters, die blocks, top plates, ceramic core diesplus a range of blank strips for components which aresubsequently profiled by wire-cut EDM.

Work can range fromgrinding the ends of 3 mm by 5 mm probes right up to quite largebolster elements, measuring 350 mm by 400 mm.

Although the tableof the Okamoto ACC 450 DXA is hydraulically actuated, the machineincludes a fully automatic grinding cycle controlled viamicroprocessor with digital readout (DRO) in two axes.

'Thisprovides us with maximum flexibility in terms of just how themachines can be operated,' maintains Tony Harris.

Each ofthe Okamoto grinding cycles tend to be split between variousmodes of operation for which a quarter accounts for manual andsemi-automatic cycles but fully automatic operation is nowapplied to half the work flow passing though the machine.Depending on the mix of work, one man can look after the twomachines for most of the time and in a typical working day, theoperator is only present at the machine for as little as 12 percent of the time which includes wheel dressing, outlines TonyHarris.

He maintains: 'This means we get 16 hours worth ofproduction from the two machines each day with an operator inputof around two hours.' However, he says: 'The biggestsingle saving has been the ability to measure components directlyon the machine using its integral, two-axis DRO.

Here thecontribution to productivity is much higher because parts do nothave to be removed from the table to perform key measuring tasksand we reckon this reduces our lead times by some 20 per cent.While the Okamoto's automatic operation, using auto downfeedand crossfeed has proved of major benefit to the company, thisfeature was not high on the list of priorities when the machinewas initially selected.

As Tony Harris recalled: 'Comingfrom purely 'hands on' manual machines, we were not toofussed about automatic cycles.

However, now that we have such aneasy to use facility, we are making more and more use of autocycling on specific types of work because it is dramaticallyincreasing the flexibility of labour.

Combined with quick set-uproutines, the Okamoto machines have proved to be a really soundinvestment and their repeatability is first class.' Equippedwith 450mm by 150mm magnetic chucks, the Okamoto machines areused on a wide range of tooling work - much of it involvinghardened steel elements.

Typical metal removal rates on hardeneddie blocks, for example, is about 0.5mm and tolerances as tightas two microns are regularly achieved.

Maintains Tony Harris:'Surface finish is another important consideration,particularly on mould type work, and the machines regularlyproduce finishes to 0.05 micron Ra.' The installation of thetwo Okamoto machines has made a big impact on surface grindingefficiency, accuracy, productivity and cost-effectiveness.

And asTony Harris concluded: 'When we need additional surfacegrinding capacity we will undoubtedly go back to the 600 Centre,because these two machines have transformed the way we wereworking.

A new versatile, variable speed 3in die grinder offers a torque three times higher than similar units, making it ideal for grinding internal surfaces in polishing and finishing applications.

A new versatile, variable speed 3in die grinder that offers a torque three times higher (27 inch lb.) than similar units, making it ideal for grinding internal surfaces in polishing and finishing applications, has been introduced by Metabo. The new GE900 Plus is geared to run at a lower rpm range than similar grinders, which increases the number and type of usable accessories for sanding, polishing or buffing, such as flap wheels and non-woven abrasive finishing wheels. The new grinder is designed for ease-of-use, featuring a side handle for increased user control and a spindle lock-one wrench feature that enables users to change accessories using only one wrench instead of two.

The switch is ergonomically located on the top of the tool, making it easy to operate with either the right or left hand.

Metabo's Vario-Constamatic (VC) full-wave electronic speed control allows users to vary speed to accommodate a variety of accessories, making the GE900 Plus useful for grinding and cutting a wide range of materials, from hard to soft, including plastic.

The GE900 Plus has a hardened and ground 1/4in collet for accurate balance of fitted attachments, and auto-stop carbon brushes that increase brush life while preventing motor damage that can be caused by worn brushes.

The grinder has a no-load speed of 2,500 - 6,000 rpm and is rated at 7.5 amps, 900 watts.

A collet wrench, spindle wrench, the 1/4in collet, and the side handle are all offered as standard with the GE900 Plus.

Increased machine rigidity, longer X-axis travels and higher speeds and the capability of taking larger wheelheads, feature a new versatile cylindrical grinder.

Increased machine rigidity, longer X-axis travels and higherspeeds and the capability of taking larger wheelheads, feature anew versatile cylindrical grinder. Future models will includehard turning operations. The concept and dimensions of the S41cnccylindrical grinder are comparable with the proven S40cnc, butfeatures some recently developed elements and modifications readyfor a new generation of wheelheads and further peripheralelements.

The S41cnc is the first machine which comes with thenew Studer design concept.

* Increased machine bed rigidity,optimised for workpieces of up to 180kg (396lb).

* Pre-Loadedhydrostatic guideways in the X-axis (feed motion).

To thecustomer's advantage is the optimal dynamic behaviour forform grinding, taper grinding and interpolation grinding,combined with increased rigidity.

* Longer in X-axis travel, now300mm (11.8in).

* Increased axis speed in X, now 15m/min(590in/min).

* Larger distance between the guideways of theZ-axis, providing more rigidity against the feed forces whenplunge grinding.

* Massive layout of the longitudinal guideway.Increased longitudinal table stability.

* Longer longitudinalslide to make sure that dressing attachments and similarequipment can be mounted.

* Longer in Z-axis travel, now 1200mm(47in).

* Increased axis speed in Z, now 15m/min (590in/min).

*The absolute length measuring systems of the axes X and Z makereferencing at machine start unnecessary.

* Larger swivel radiusof the B axis: I e a larger wheel-head can be installed.

* Newmaintenance and service-friendly enclosure concept.

* Better workarea accessibility when loading from the top (i e portal loader).* Energy supply on the Z-axis prepared for additional options.

*New control FANUC 16i or 160i.

With the control 160i, thismachine is now entirely compatible with Windows applications andwith both control types connections to networks via Ethernetinterfaces are possible.

* Generally, actuators and sensors areconnected by means of ASi-Bus.

This simplifies retrofits.

Futureapplications and procedures - further developments will follow,especially with regard to wheelhead layouts.

A glance towards thefuture of the S41cnc reveals the following: * Dual motor spindlewheelhead with up to four grinding wheels 500mm (20in) diameter.* Integration hard turning operations, either with a single tool(only one turning operation, e g internal profile turning of anHSK taper shoulder) or by means of an indexing tool holder.

*Y-axis to grind longitudinal grooves.

* A-axis applications togrind threads with slanted pitch angles.

The S41cnc has beendemonstrated hard turning and grinding a HSK63 tool holder.

A cylindrical, external grinding machine offers much wider scope with regard to accuracy, quality and concept, and at an extremely competitive price.

The cylindrical, external grinding machine eco650 offers muchwider scope with regard to accuracy, quality and concept, and atan extremely competitive price. The machine is many times provenin job shops in the field of tool making. There is also therevolutionary eco1000 for machining long and shaft-likeworkpieces to the well-known Studer quality.

Also this machine issold at a price which is outstanding in its category.

The mostimportant features in brief * Distance between the centres: 1000mm/40in.

* Centres height 175 mm/6.9in.

* Machine bed in StuderGranitan S103 with 3-point support.

* Vee and flat guideways withthe patented knob-type coating in Studer Granitan S200.

* Rotarymeasuring system for the axes X and Z with a revolution of0,0001mm/0,000,004in (a linear measuring system is available as aretrofit kit).

* grinding wheel layout on the right hand side,orientable to 0 degree and to 30 degrees for straight and plungegrinding.

* Rigid, roller bearing grinding spindle with a drivepower of 7.5kW/10HP.

* Grinding wheel diameter up to 500mm/ 20in.* Roller bearing workhead for grinding between fixed or rotarycentres, with tool retention taper MT5.

* tailstock with quilldiameter 50mm/1.97in and retention taper MT3.

* Orientablelongitudinal table, tilt up to 8.5 degrees for grinding highlyaccurate tapers.

* CNC control FANUC 21i.

* Programming with theStuder prictogramming software.

* Compact layout and attractivedesign.

* Excellent view onto the working process and optimalaccess.

* Additional equipment in the shape of retrofit kits isavailable.

Such devices can be installed by the customer and nospecial knowledge or training is required.

S31leanCNC withdistance between centres of 1000 mm/40 - this machine conceptcannot be compared to anything else with regard to universal usein the field of complete machining.

With the S31leanCNC1000 allyour requirements and wishes can be fulfilled.

Maximumflexibility thanks to the proven turret-type wheelhead withexternal grinding wheels on the left and on the right side togrind diameters and shoulders as well as internal operations oncomplex workpieces, in a single clamping.

Interactive hand wheelmode - this operator-friendly element which plays an importantrole in the successful history of the S30leanPRO is now alsoavailable on the S31leanCNC.

The most important features are, inbrief: * Distance between centres: 1000mm/40in.

* Centre height175mm/6.9in.

* Machine bed in Studer Granitan S103 with 3-pointsupport.

* Vee and flat guideways in the patented knob-typecoating in Studer Granitan S200.

* Rotary measuring to aresolution of 0,0001mm/0,000,004in on the axes X and Z.

*Universal, orientable wheelhead, manual positioning 2,5deg andoptional automatic positioning in1deg.

* Motor grinding spindlewith infinitely adjustable speed control and a drive power of7,5kW/10HP.

* Grinding wheel diameters up to 500mm/20in, rightand left side.

* Workhead with roller bearing for grindingbetween stationary or rotary centres with tool taper ISO50.

*Tailstock with quill diameter 50mm/1.97in.

and tool taper MTK3.

*CNC control FANUC 2li.

* Programming by means of the Studerpictogramming software.

* Hand wheels to influence the grindingprocess manually through the axes X and Z, by means of the StuderInteract software.

Safety critical machining of fuel injection components in large series, or universal machining of small series, always within tolerances of a few microns: these are the jobs for internal grinders.

Safety critical machining of fuel injection components in largeseries, or universal machining of small series, always withintolerances of a few microns: these are the jobs for Studerinternal grinding machines, which are built in differentversions. On the S145cnc with up to four spindles, for instance,complex components in small and average series can be groundeconomically. Featuring a centre height of 175mm a maximumgrinding length of 200mm and a substantial table load, themachine is suitable for a wide range of applications.

Grindingspindles according to requirements of 24000 rev/min to 120000rev/min installed on the indexing turret head allow high-accuracymachining of bores up to diameters of 200mm and the manufactureof smallest bores of less than 3mm in diameter.

This is the idealmachine for the production of small and average series as well asfor mould making applications.

For internal production grinding,the S140cnc is available.

Based on its modular concept, thismachine is suitable for a large number of production tasks.

Thestandard version is equipped with hydrostatic guide-ways; thisbasic version of the Studer S140cnc provides the ideal basis forhigh accuracy machining.

Simple machining tasks with one grindingspindle can be achieved by means of the S140 modular kit, as wellas complex elements including simultaneous external and internalmachining.

Reductions of cycle times of up to 40% can beobtained.

Specially adapted machining modules, such as internaland external grinding spindles, workheads and different dressingattachments, can be installed on the standardised machine tableaccording to requirements.

The machine tables with hydrostaticguide systems, in conjunction with the optional, alsohydrostatically- operated drive spindle guarantee a smooth motionand perfect surface quality of the workpiece.

Up to threeinternal grinding spindles with ceramic bearing systems andspeeds above 100,000 rev/min installed on a slide allow machiningof extremely small bores to the narrowest tolerances.

Roughingand fine machining can be carried out without time-consumingindexing of a revolver.

Simultaneously to internal roughgrinding, finish grinding of external diameters or surfaces canalso be done.

The installation of a handling system withintegrated gauging and palletising units converts the S140cncinto an unmanned machining centre.

In three shifts and seven daysa week, elements for diesel injection systems, for instance, inhighest quality, can be machined.

Ceramic? Silicon? Quartz? Glass? Tungsten? - whatever the hard or brittle material, slicing and surface grinding and vertical profile grinding machines perform consistently and accurately.

Chevalier (distributed in the UK by Dugard Machine Tools) offerthe essential hi-tech grinding machines for high-precision andefficient performance across a large range of industrialapplications. Ceramic? Silicon?

Quartz?

Glass?

Tungsten?.whatever the hard or brittle material, the Chevalier range ofslicing and surface grinding machines and vertical profilegrinding machines are designed to perform consistently andaccurately.

For example, take the FSG-H818CNC or the B818CNCmachines.

Both are high efficiency, high precision multipurposegrinders particularly suited to intricate profiles and moldcomponents such as those required in for aerospace, automotive,electronic, medical and defence applications.

Both provideexcellent rigidity and precise positioning with full Fanuc OMautomation - and both offer outstanding versatility for all typesof grinding (multilevel surfaces, punch, slice, plunge, pitch,side-wheel, profile, form, index and creepfeed).

Or there are theFSG-2040TC and 2060TC column type, high precision three-axissurface grinders.

These programmable machines provide rough orfine grinding for mass production.

The precisely balanced spindlemotors are air cooled to ensure accuracy and the wheelhead isfinely positioned to ensure downfeed repeatability to within0.002mm.

For two-axis, submicron surface grinding Chevalierprovide the ULTRA-H612CNC or the ULTRA-B612CNC.

Both of thesemachines provide mirror sufacing (surface roughness) to within0.25mm; a positioning accuracy to within 0.5mm and a grindingaccuracy to within 1mm.

The extra long guideway design of thespindle seats on these machines provides high rigidity and helpsto overcome the cutting resistance.

An optional linear scalesystem can be mounted on the column to compensate for pitch errorand to ensure accuracy.

For a smaller, multifunction surfacegrinder, Chevalier offer the SMART-H818 which is designed to meetthe needs of novice and experienced CNC operators alike byproviding the simplicity of a manual grinder and thesophistication of a CNC machine.

Without requiring complexprogramming codes, the SMART-H818 can still be programmed inG-code format or can download from a CAD/CAM system.

The tablespeeds vary from 0.02 - 25m/min.

Meeting the financial needs ofthe industry today - 'Cost is the major issue intoday's industry,' says Eric Dugard, Managing Directorof C Dugard.

'Our customers need accuracy, reliability,performance and high productivity - but at the right price.

Toenable them to achieve this we offer a range of innovative andpractical rental schemes and finance packages to help them spreadtheir investment over a period of time.

We also provide fullinstallation, support and maintenance packages - plus extendedwarranties - so that our customers can choose the option thatsuits them.

Flexibility is the key word in order to meet the everevolving needs of our customers.' 'As ourcustomers' requirements become more and more sophisticated,Dugard offers them the very latest in technology (both in themachines themselves and in the control systems) to help them stayat the forefront of today's industry.

At the same time, wemaintain our fundamental policy of providing affordable qualityplus performance.' CD-ROM catalogue - Eric Dugard adds,'Many of our customers have been requesting our new CD-ROMcatalogue of products.

This is a recent innovation for Dugard andit was particularly well received at the recent MACH 2002 show.While our website already provides up-to-date details on ourproduct ranges, services and financial packages, many customersprefer to use our CD-ROM in order to browse through our ranges(off-line) at their leisure.

This is just another way in whichDugard continue to make it as easy as possible for our customersto access the information they need.'

Two large angle 7in or 9in wheel grinders designed for cutting and grinding applications incorporate a two-step power switch at the rear of the tool, allowing users to tackle large jobs safely.

Two new large angle grinders designed for both cutting and grinding applications have been introduced by Metabo. Featuring a 7in or 9in wheel, the W23-180 and W23-230 grinders incorporate a two-step power switch at the rear of the tool, allowing users to tackle large jobs safely. Users must have the first button depressed to engage the power switch, preventing accidental turn-on during operation.

The tools feature a flexible rear handle that rotates 90deg for comfort during cutting operation.

A 3-position side handle for left- or right-handed operation allows users to turn the tool 90deg to cut vertically, while still having a firm grasp on the grinder.

The grinders incorporate Metabo's Marathon motor with epoxy resin powder-coated field coils, which make the motor extremely resistant to destructive grinding dust and help prevent overheating.

Also included in each grinder is a winding protection grid that deflects harmful airborne debris away from armature winding, increasing motor life by up to five times.

The grinders feature an easy-to-use wheel guard that requires no tools to adjust, and auto-stop carbon brushes for longer service life.

The W23-180 is rated at 2,300 watts, has a torque value of 124in.lb, operates at 8,500 rpm using a 15.0A motor, and weighs 13.3lb.

The W23-230 is rated at 2,100W, has a torque of 150in lb, operates at a no-load speed of 6,600 rpm using a 15.0A motor, and weighs 13.6lb.

Hydrostatic bearings in surface grinding machines have programmable variable pressure to achieve flatness and straightness levels within 0.5 micron/m machine table stroke.

The latest 'groundbreaking' development in adding programmable variable pressure to hydrostatic bearing technology by Okamoto of Japan, the world's largest manufacturer of grinding machines, enables some four times greater levels of rigidity to be obtained over conventional surface grinding machines that use hydrostatic bearings. As a result, flatness and straightness levels within 0.5 micron can now be held per metre stroke of the machine table in the latest UPG-84NC Ultra Planarization surface grinder while supporting table loads up to 700kg. Now available from the 600 Centre of Shepshed near Loughborough, the UPG-84NC is the most compact of the latest UPG machine range of 13 machines which can be specified having table lengths up to 4000mm and all are capable of generating the same degree of flatness.

The technology was originally developed by Okamoto's special purpose application engineering team to create a new order of 'mother' machine capability with minimum inertia and vibration when the table reverses.

The idea was to create new orders of flatness and straightness for production grinding its own surface grinding machine tables, beds and bearing guide rails.

The latest UPG range is ideal for grinding tasks such as dies, master granite surface plates, metrology equipment, LCD and semiconductor production.

All the machines in the range have been completely re-designed using totally enclosed stainless steel guarding giving easy access to the grinding area.

The programmable Okamoto 'non-contact' hydrostatic slide system reduces the oil supply to the bearing by one-third of a conventional hydrostatic system and improves the strength of the guideway structure of the machine giving improved table loading performance.

As a result, it achieves a consistent level of accuracy throughout the grinding plane giving a longitudinal straightness of 0.5 micron/1000mm and 0.4 micron/800mm on the cross axis.

In addition, it is possible to establish a minimum 10Nm input increment and work within a resolution of 2Nm in both axes.

Traditional hydrostatic slideways vary the thickness of the oil film layer formed on the surface of the guideway according to the load on the table.

Maintains Okamoto, by controlling this oil film layer grinding accuracy can be improved by some 400%.

Also, by avoiding high levels of hydrostatic oil pressure combined with traditional temperature control techniques, this significantly reduces running costs of the machine.

Automatic compensation is applied to the Okamoto slideway bearings that have six faces all under variable hydrostatic control through the Okamoto developed software in the Fanuc 31i Model A control system.

The hydrostatic oil, hydraulic oil for the table longitudinal axis drive and the coolant fluid are all temperature controlled on the UPG to within +/-0.1 deg C and an ultra-accurate hydrostatic spindle is also part of the standard machine specification.

A recent Okamoto grinding demonstration on a larger UPG 408 NC machine, able to accept a table load of 5.5 tonnes, illustrated how a coating roller die some 2000mm long could be ground to a flatness of 0.15 microns.

Normally a die of this type, which is used to apply glue to postage stamps, is ground, lapped by hand and polished to achieve a flatness of 0.3 micron.

The UPG-84NC has a table size of 850mm by 400mm and an electro-permanent magnetic chuck size of 800mm by 400mm by 100mm.

Grinding wheel size is 305mm by 38mm by 127mm driven by a 5.5kW motor and distance between wheel and table surface is between 50mm and 550mm.

The X-axis longitudinal table speed is variable between 0.3 and 25m/min, vertical and cross-feed rate is between 1 and 790mm/min.

The Fanuc 31i-MA control provides two-axis simultaneous movement in Z and Y and interpolation in the X-axis.

Options include automatic dynamic balancing of the grinding wheel, linear glass scale feedback for the vertical axis, gap elimination and a table longitudinal axis crowning.

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.

Superabrasive machining and turning systems deliver massive reductions in product cycle times - in some cases by over 80% - and equally impressive tool cost savings.

Holroyd's new Edgetek range of superabrasive machining andturning systems is providing European industry with a uniqueopportunity to improve competitiveness by delivering massivereductions in product cycle times - in some cases by over 80% -and equally impressive tool cost savings. Designed for use onwide range of standard and ultra hard and exotic materials,including ceramics, nickel, tool steel, Waspalloy, Inconel,Hastelloy, powdered metals and Stellite, the Edgetek machinesdeliver improved quality and part consistency as well as offeringsimplified set-up to optimise manufacturing time. The launch ofthe Edgetek machines further strengthens Holroyd's positionas the world leader in the manufacture of machines and turnkeymanufacturing cells to produce worm and helical gears and helicalscrew rotors.

Manufactured in the UK, at Holroyd's factoryin Rochdale, the multi-axis, CNC controlled machines deployproven high efficiency deep grinding (HEDG) techniques, usingCubic Boron Nitride (CBN) wheels at surface speeds of up to9000m/min.

This enables them to achieve high depths of cut andoptimised metal removal rates far exceeding those of moreconventional machines, such as CNC lathes, milling and machiningcentres and grinders.

In addition to improving product cycletimes, the 'low heat' HEDG system also produces astronger finished component that, when compared to those producedby other techniques such as creep feed grinding, is less likelyto be deformed.

Fundamental to the Edgetek machines superiorlevels of performance and precision, is a unique granite polymerbase and column.

Developed to satisfy the need for extremerigidity and enhanced vibration damping, the polymer basetypically weighs 3 tonnes and has no resonant frequency.

As aresult, it enables higher precision machining to be achieved.Like other unique components in the design, the base reflects themanufacturer's determination to develop a machine range thathas been engineered specifically for high performancesuperabrasive machining.

Holroyd Sales Director, Paul Hannah,explains: 'Unlike other manufacturers, Holroyd is notoffering a range of existing machines that have been adapted.Rather, we are providing a comprehensive product range that hasbeen designed from scratch, incorporating new and sophisticatedtechnology which has been developed specifically withsuperabrasive machining in mind.' 'Every aspect ofHolroyd's Edgetek range has been engineered to provideunsurpassed performance coupled with a level of versatility thatis sure to appeal to the widest possible range of manufacturingoperations.

The massive productivity gains and cost savingsexperienced by those who have made the switch to superabrasivemachining speak for themselves and prove that the technologicaldevelopments pioneered by our machines represent a highlysignificant breakthrough for the future of machining.' Theflexibility of the Holroyd Edgetek design, and the huge varietyof machine types and multi-axis configurations available, enablesthe machines to provide unparalleled levels of precision andproductivity 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 actuationcomponents, 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.

In all of these industries thesimplified set-up of the Holroyd machines ensures that muchproduction time is saved.

At the same time, tooling costs aremuch reduced as the CBN wheels do not suffer from excessivelevels of wear as a result of being subjected to the interruptedcuts experienced on conventional machines, due to their set-uplimitations.

Further emphasising the case for CBN wheels is theremarkable accuracy and metal removal rates that can be achievedby Holroyd Edgetek machines on a wide range of ultra hard andexotic materials and carbon-rich metals.

The large depths of cutthat can be achieved, and the accompanying lower temperature ofHEDG techniques are particularly relevant to aerospacemanufacturing processes, promoting dramatically improvedproductivity, less surface deformation, improved accuracy andbetter surface finish.

Superabrasive technology using CBNgrinding wheels is also a highly successful method of machiningcomponents made from powdered metals popular with automotivemanufacturers.

Although valued for their homogeneous andstress-free composition, materials which have undergone thesintering process are notoriously difficult to machine and aretotally unsuitable for conventional turning.

A combination ofHigh Efficiency Deep Grinding techniques and CBN grinding wheelshas proved extremely successful for the accurate and efficientmachining of powdered metals and has earned Holroyd'sEdgetek superabrasive machining centres growing support amongmanufacturers of components such as gears and sprockets.Providing an ideal complement to the Edgetek machinesmanufacturing flexibility - while at the same time improvingproduction rates, is a unique, Holroyd-designed, 3-dimensionalscanning and measurement system.

Powerful in operation, thesoftware based system measures 500 separate points and comparesthem against the perfect profile while the component is still inthe machine.

Any deviations are corrected automatically beforecompletion of the machine cycle.

If the deviation is greater thana set norm, however, then the system program alerts the operatorto the fact that the wheel may need re-dressing.

Holroyd ismanufacturing Edgetek machines in all types and configurations,3, 4 or 5 axes.

The machines offer state-of-the-art controlfeatures such as Fanuc CNC controls, automated parts handling,customised workholding, cooling systems, programming and processdevelopment and CBN wheel development.

The machines can betailored to suit specific applications and supplied as completeturnkey solutions as part of a manufacturing cell.

They aresupported by a worldwide service network and benefit frommanufacturer developed preventative maintenance plans..

A CNC grinding machine builder has now included cycle programming in its control system, permitting very easy programming for grinding any type of workpiece by the aid of pictogramming.

Experience, market observation and feedback from our customershas encouraged us to develop the existing and proven StuderNCbasic package further. The package includes cycle programming,permitting very easy programming for grinding any type ofworkpiece by the aid of pictogramming. The new version has nowbecome a real desktop platform of grinding technology.

From thisdesktop, all data related to grinding are available forpractically any component.

The new version V5.x of StuderNC alsofeatures the calculation of grinding process data.

This includesmachining data as well as time and cost calculation.

All theother software packages, StProfil, StForm, StPunch and StThreadare related to functions and can be called up as perrequirements.

Philosophy - in our engineering work we made greatefforts to create advantages for our customers.

Our aim was,comparable to StPunch (Software for grinding non-round punches),to integrate the grinding technology in order to guaranteereproducibility, to ensure constant high quality and to reducegrinding times as much as possible.

Data storage should beworkpiece-related and logically clear and straightforward for theuser.

The idea was to preserve the customer's know-how andto call up the respective data later in order to adapt it to thenew machining task.

The process of component machining has beenmade transparent in every detail in order to make use of all theoptimising potential.

This is definitely the only method forincreasing the efficiency continuously: preserving the provenknow-how and to make it accessible to any other user a laterdate.

,Look and feel' This means: the appearance andoperation correspond as much as possible to the commercialWindows applications as they are known in conjunction withMicrosoft products.

High operator ergonomics was one of our maingoals.

The integrated grinding technology improves the efficiencyof the machine considerably.

Experience based on practical workin the range of fine machining by cylindrical grinding haveproved that rather often the operators of grinding machines workwith values resulting from their experience, which isastonishingly far away from the optimum.

So-called machiningtasks which can be defined by our customer's or by our ownspecialists help to produce components in a constantly goodquality and time independently from the operator who carries outthe job.

A machining task defines the behaviour of a certaingrinding tool in a specific material.

By doing so, the coolant,the rigidity of the component, the machinability of the materialand many other factors can be taken into consideration.

Byincreasing the quality of the optimisation of machining tasks,the optimising times can be reduced considerably for new, similarworkpieces.

For the production of individual parts and series,one will always be able to operate with former, highly optimiseddata for the same combination of tool and material.

This willreduce the running-in times to a level corresponding to that ofsame components which are machined repeatedly.

By indicating theexact time of each individual process, those for dressing andtraversing as well as the auxiliary times such as longitudinalpositioning by means of a length positioning, one should obtaininformation about the productivity.

The calculation should giveaccurate information for the quotation.

In addition, thecalculation of costs can go much further than that based merelyon the grinding time for a component.

For instance, toolingexpenses have to be taken into account.

This is extremelyimportant for job planning and for quotations.

* Dressing: Roughdressing cycles to profile, respectively reprofiling grindingwheels - for profiling, new rough dressing cycles are now atdisposal.

Roughing means - similarly as for milling or turning -creating an optimal assignment of cuts in order to remove as muchmaterial as possible in the shortest possible time.

By doing so,the set-up times are reduced to a fraction compared to those ofthe conventional method.

* The advantages - by using StuderNC andthe respective options for profiling and dressing the grindingwheels as well as for thread grinding and grinding non-roundsections of components, the customers gain an extremelysignificant increase of functionality for their universalcylindrical grinding machine.

In the simplest case this meansthat set-up, programming and grind-ing times will be reducedconsiderably.

In other cases, it may even be possible to avoidthe use of special machines, such as thread and cam grindingmachines.

Partially, the same also applies to special clampingfeatures such as eccentric chucks.

From this point of view, theinvestment will certainly be written off in a very short time.

*Range of applications - the range of application of StuderNC isalso intended for the real grinding Professional.

The system iscompletely open and allows changes in every section.

However,this product is useful even for the inexperienced user who,thanks to this application, can operate with littlegrinding-specific know-how.

Also standard Macro's defined inadvance by Studer cover a wide range of components.

In addition,this software is also useful for the job planning, namely forestablishing quotations and process data for the properproduction.

Eliminating the backing pad and tapered flange nut from portable grinding wheel securement results in a lighter unit to ease operator control and comfort and reduce fatigue.

Metabo Corporation, a leading international manufacturer of professional grade portable electric power tools and abrasives for various industrial, construction and welding applications, has introduced the Type 29 Z-Plus grinding wheel that eliminates the need for a backing pad and tapered flange nut. The Type 29 Z-Plus weighs less than half of a typical 4-1/2in grinding wheel. This significantly increases the operator's control and comfort while decreasing fatigue, particularly with small grinders used in tight spaces and at odd angles.

The wheel's slightly concave profile also lessens the grinder's angle of attack, reducing operator fatigue.

The Type 29 Z-Plus, with its aluminum oxide abrasive, is well suited for blending and surface weld removal on steel, stainless steel and aluminum.

The wheel, a refinement of Metabo's Type 29 grinding wheel, can also be used to grind other non-ferrous metals, as well as most plastics and resin or fiberglass-based structural materials.

The Type 29 Z-Plus is available in 4-1/2in or 7in diameter, with a 7/8in arbor or 5/8in-11 hub.

A research project using superabrasive machines has achieved a significant breakthrough in machining superalloys - in terms of reduced cycle times and better surface finish and accuracy.

A research project undertaken by a team at CranfieldUniversity's School Of Industrial and Manufacturing Sciencehas employed Holroyd's superabrasive Edgetek machines toachieve significant breakthroughs when machining Nickel basedsuperalloys; materials which are notoriously difficult to work.The breakthroughs, in terms of reduced cycle times, bettersurface finish and improved accuracy, have been achieved usingthe latest high efficiency deep grinding (HEDG) techniques. Theyare likely to have a profound influence on the way thatsuperalloys are machined in the future within the aerospaceindustry. The Cranfield team, led by Professor David Stephenson,carried out lengthy 'Burn Threshold Studies' on Inconel718 - a superalloy commonly employed for gas turbine components,using Holroyd's 'Edgetek' Superabrasive Machiningprocess.

Manufactured at Holroyd's UK factory in Rochdale,the multi-axis, CNC controlled Edgetek machines deploy provenhigh efficiency deep grinding (HEDG) techniques, using CubicBoron Nitride (CBN) wheels at surface speeds of up to 200m/s.This enables them to achieve high depths of cut and optimisedmetal removal rates far exceeding those of more conventionalmachines, such as CNC lathes, milling and machining centres andgrinders.

An Edgetek machine (a five-axis unit) was specified forthe Cranfield research project due to its ability to machineNickel-based superalloys such as inconel 718, which are extremelydifficult to work.

The ability of these alloys to retain much oftheir strength at elevated temperatures means that wear rate onconventional tooling is rapid, even when cutting at low speeds.In addition, problems such as workpiece burn and poor surfaceintegrity are common, due to the alloys low thermal conductivity.Over the last 30 years developments in creep feed grindingtechniques have addressed some of these problems, notably inachieving higher rates of metal removal, but economic pressuresto reduce manufacturing costs further, and to improveproductivity, still remain.

As a direct result of thesepressures, a growing interest in HEDG (high efficiency deepgrinding) has developed, which can be considered as a combinationof creep feed grinding and high speed grinding, using high wheelspeeds often in excess of 200m/s.

A main area of research hasbeen to attempt to prove a commonly held HEDG theory that veryhigh stock removal rates are associated with low work-piecetemperatures.

Key to this, were the grinding trials carried outat Cranfield University.

The trials were undertaken on blocks ofInconel 718 measuring 40 x 40 x 40mm, using a 'downgrinding' mode and grinding parameters were varied over thefollowing range: depth of cut: 0,05 - 1,5mm, work speed: 0,05 -55mm/s and wheel speed: 50-150m/s.

For each test a series of 15mmwide cuts was taken and resultant forces were measured using athree-axis dynamometer.

Although the results of the trials arenaturally very detailed, the general trend shows a reduction inspecific grinding energy as specific stock removal ratesincrease.

Commenting upon this, Professor Stephenson said:'The thermal modelling results correlate well withexperimental observations of grinding burn.

Modelling indicatesthe potential benefits associated with HEDG, using high workspeeds and large depth of cut to minimise the finished surfacetemperature.

Thermal modelling also highlighted the significantcontribution that CBN abrasives can make to heat removal.'These results, highlighting the large depths of cut andaccompanying lower temperature work-piece characteristic of HEDG,have significant practical relevance in terms of aerospacemanufacturing processes, in that the two promote dramaticallyimproved productivity, less surface deformation, improvedaccuracy and better surface finish.

'We are delighted, butnot surprised by these results,' said Holroyd SalesDirector, Paul Hannah.

'The massive productivity gains andcost savings experienced by those who have made the switch toEdgetek superabrasive machining speak for themselves and provethat the technological developments pioneered by our machinesrepresent a highly significant breakthrough for the future ofmachining.' In addition to its key role in the BurnThreshold Studies, Holroyd's Edgetek machine is also centralto another Cranfield project, 'Ultraflex', which isrunning simultaneously.

'Ultraflex' is a European /automotive industry-funded project, for the development ofinnovative manufacturing technologies for reducing processchains.

Its specific objectives are to develop and to demonstratethe following two processes: * Cost-effective and highproductivity machining process of high-alloy steel beforehardening operation and hardening process.

* Ultra-precision andenvironmentally friendly machining process of high-alloy steelafter hardening operation.

The Edgetek machine is playing a keyrole in developing these processes and in achieving the twoperformance targets for the project: (1) working towards opticalquality, machined surface finish levels of Ra 0.0micron and (2)the ability to rough finish a high alloy steel CVT gearshaft inless than 2 minutes.

The groundbreaking research carried out byCranfield University on both Burn Threshold Studies and projectUltraflex and the positive results obtained, proves conclusivelythe effectiveness of Superabrasive machining on difficult to workmaterials, not only within its 'traditional' sector ofhigh volume production associated with milling machineaccuracies, but also on very close tolerance work with highlevels of surface finish.

However, despite these results, neitherCranfield University nor Holroyd are resting upon their laurels.Holroyd is conducting ongoing technical developments at itsfactory in Rochdale which complement the innovative researchcarried out by Cranfield University, developing further thepotential that exists in this rapidly growing area of machinetool technology.

Stressing the latter point, Holroyd's PaulHannah said: 'Feedback from customers and the results ofdetailed research into superabrasive machining both support theview that this exciting technological breakthrough has massiveimplications for the future of a wide range of machiningoperations.

The dramatic reduction in cycle times and toolingcosts which result from a switch to Holroyd's Edgetek'superabrasive machine tools contribute to significantimprovements in overall productivity for every company usingthem.'.

Cylindrical grinder provides a highly flexible, single-cycle universal solution to the finishing of one-off parts or small batch runs.

Developed to provide a highly flexible, single-cycle universalsolution to the cylindrical grinding of one-off parts or smallbatch runs, the latest Danobat G-41 cylindrical grinding machineis able to accommodate external, internal diameters, faces andtapers. Now marketed through 600 Centre of Shepshed nearLoughborough, the Danobat G-41 Universal 'U' machinecan also be specified as a lower cost 90 (degree) approachconventional cylindrical grinder designated 'S'. Themachine has been developed in order to maximise the potential ofcubic boron nitride (CBN) wheel technology through high orders ofdesign rigidity.

This means high performance, accuracy andrepeatability have been developed into the machine.

When thesefeatures are combined with Danobat's DanOp, DanBop andDanCad software modules, flexibility and operationalfunctionality provide a high performance grinding package forcomponents up to 348 mm diameter by 1,000 mm long.

Built on astabilised pearlitic cast iron base with integrated 'doublebody' table, the machine is compact, stable and very rigid.Table swivel is +9 degree to -2 degree.

The servo driven table isable to swivel between +45 degree and -15 degree and the workheadwill accept components weighing up to 125kg between centres withstepless programmable speed range between 30 and 1,000 revs/min.The indexing universal wheelhead has zero, 30 degree, 90 degreeand 180 degree working positions and the ability to carryexternal, face grinding or internal grinding spindles.

Theuniversal wheelhead has a 7.5kW drive, 45m/sec wheel speed and500mm by 80mm by 203mm external grinding wheel and a facegrinding wheel.

It also has the ability to carry one of a rangeof four internal grinding spindles having up to 30,000 revs/minspeed and the capacity to grind bores up to 160mm diameter.

Withthe option of a 90 degree approach wheelhead, this has a 5.5kW,45m/sec grinding speed and wheel size of 400mm by 63mm by 127mm.Based on Fanuc 210i control system, software development was seenas important to the Danobat specification.

This has resulted inthe DanBop machine control software being classified to be assimple to operate as a manual machine and this is achieved bysimply selecting the type of work required.

It can incorporatefully or semi-automatic cycles and accommodate dressing,measurement and changes to grinding parameters.

The DanOpsoftware module accommodates machine functions with soft keyprogramming for set-up, wheel management, work cycling andproduction management.

DanCad incorporates graphic support directfrom CAD systems to enable programming based on componentgeometry and is able to optimise tasks such as wheel profilecreation and dressing.

Options include gauging, gap eliminationand crash detection devices, steady rests and a range offiltration and coolant systems.

Dynamic balancing, workholdingand a portable handwheel unit are available to help in machineoperation..

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.