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The unique element of CDCF is the rotary-driven dresser unit situated above the wheel, with a separate CNC axis dress- ing into the wheel simultaneous to the grinding process. This is controlled via special grinding macro programs to maintain programmed infeed dress rates at a constant rotation speed that is matched to an ever-changing wheel diameter. “A typical part would start with material procurement, usu- ally bar stock,” said Herb Stuckart, vice president, manufac- turing. “We cut it, grind it, drill holes, tap and mill to bring the material to the required form.” A family of parts might include 25–50 different items, different radii, starting at 0.0005– 0.500" (0/01–12.7-mm) diameter. Parts may be a 0.250" (6.3 mm) square, 0.00030" (0.008-mm) thick to 36" (914-mm) long. Lakes sends the parts out to heat treatment, and Qual- ity Control releases them for manufacturing. The parts are run through the vertical through-feed grinders to grind flats, edges and ends and prepare the parts for the Mägerles or the Blohms. The profiles are then ground to size with repeatability from part to part and a finish of at least 8 Ra.
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Close up of CDCF with dresser mounted above the wheel for continuous dressing of the grinding wheel.
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Lakes Precision purchased its first Mägerles around 1988 with the Blohms following shortly thereafter. It is something of an understatement to say these machines are “vintage.” But as these old machines start to experience too much down- time, they became candidates for retrofitting. The company felt the machines were mechanically sound and retrofitting the right old machine would be the smartest thing to do. “We decided to retrofit our three Mägerles with new Siemens 840D controls,” said Stuckart. “These machines me- chanically were very sound, because we meticulously main- tained them for all that time, nearly 25 years, and we never abused them; if anything, we babied them,” said Stuckart. Because of the age of the electronics, Lakes simply couldn’t get parts to fix the controls, even if they knew what was wrong. They might get replacement parts, but the drives and things like that were just no longer available because of the changes in control technology. “UGT’s Total Lifecycle Solutions Group came in and did an initial survey of everything on the three Mägerles before they even began the retrofits: all the geometrics, the tables, the runouts on the spindles, and they couldn’t find anything that couldn’t be tweaked in,” said Stuckart. The first retrofit took three weeks, while the other two took about two weeks, from the time the team walked into the plant until the time they walked out. This was great, because Stuckart was expecting a longer period of downtime, and that didn’t happen. “That in itself is something almost unheard of,” Stuckart said. “Since the
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ManufacturingEngineeringMedia.com | April 2013
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