Favourite options for optimal grinding

At this year’s GrindTec exhibition in Augsburg, Germany in March, Studer (part of the United Grinding Group) launched a new machine to the market. The Studer favorit is designed to handle longer workpieces with a centre of 1,600mm.

This CNC universal cylindrical grinding machine is designed for grinding both single part and series production and can be fitted with automation. With various options such as measuring control, a balancing system, contact detection and longitudinal positioning, it can be subsequently adapted to other grinding tasks.

Studer says the favorit is a very reasonably priced machine for the market. As with all Studer cylindrical grinding machines, the proven machine bed manufactured from solid Granitan ensures maximum precision, performance and safety. The full enclosure provides an optimal view of the grinding process. The wheelhead, which can be automatically positioned every 3°, can accommodate a belt-driven external and internal grinding spindle.

 

Thanks to the practice-oriented Studer grinding software, with its proven Studer Pictogramming, even less experienced users can program grinding and dressing cycles quickly and efficiently. With the optionally available StuderGrind software, special applications, such as profiling the grinding wheel for complex workpiece shapes, can be efficiently programmed. Development, production, assembly and testing of Studer products are process-orientated and comply with the strict guidelines of VDA 6.4 and IS 9001.

Also at GrindTec Studer introduced a new generation of its WireDress technology. Before now the device took up a lot of space on the table and limited the usable centre length in the machine. The new system is much more compact and sits directly behind the workhead, making it more flexible and also more powerful than its predecessor.

Studer says its WireDress EDM technology saves a significant amount of downtime; it also makes it possible to dress sintered metal bonds with the highest precision in the grinding machine at full working speed.

WireDress: integrated dressing technology for metal-bonded grinding wheels

Michael Klotz, project manager for development at Fritz Studer AG, explains: "It is a well-known fact that metal-bonded grinding wheels are much more durable and dimensionally stable when machining difficult-to-machine materials and ultimately enable higher productivity.

“The problem with this is that metal bonds can only be dressed to a very limited extent using conventional methods in the grinding machine. In addition to this there is a high dressing tool wear associated with a low cutting ability. This is neither an operator-friendly, nor a high quality and process consistent dressing method. That's why the ‘best’ bond – the metal bond – is rarely used.

“Studer has developed, along with technology partners, the machine-integrated WireDress dressing technology. Here, the dressing is done at full wheel speed. In contrast to conventional mechanical or external EDM dressing, WireDress dressing occurs by a modified wire erosion in the grinding machine, where the grinding oil serves as a dielectric.

He continues: “The dressing process is contactless and wear-free. The grit itself is not dressed, the metallic bond around the grit is removed. Depending on how deep the grit is embedded in the bond, it either falls out or remains with original sharpness in the bond. The grinding wheel receives a high grain clearance for maximum cutting capability, lower grinding forces and low burning risk.”

Studer says WireDress enables users to harness the capabilities of metal bond. Using a bond with a high dimensional stability, almost any profile can be precision-contoured in microns. Long dressing intervals can be achieved and the accurate processing of sophisticated or smaller geometries that were neither economical nor possible before, now become feasible.

Compared to grinding with ceramic-bonded grinding tools, significant increases in productivity in the range of at least 30% can be achieved, with resin bonds even more is possible.

Large grain sizes can now be dressed for maximum cutting performance

The new WireDress benefits include: the full centre distance can be used, as there is no restriction from the dressing device; the new generation WireDress is 20% faster than its predecessor; WireDress is a right and left dresser in one, it can be automatically swivelled to two positions; by swivelling the dresser higher shoulders and deeper profiles can be dressed with a universal dressing tool – the wire; now large grain sizes up to B151 (D151) can be dressed for maximum cutting performance (depending on the bond); and finally the system has an extended sensory monitoring capability.

Studer says the new WireDress system means users can massively increase productivity and precision when grinding carbide, steel and ceramics.

Mr Klotz adds: With a sintered metal bonded grinding wheel, users can even go beyond the normal limits – you can just re-dress it in the machine again. With a conventional galvanic bonded grinding wheel, you can only go over the limit once. WireDress means you can maximise these limits without fear, making greater profitability possible.”

Studer www.studer.com/en/home-page.html

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