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manufacturing technology


turing all relevant components, the highest levels of precision and surface fi nish, compliance with predefi ned cycle times, and the ability to reuse all current tools and equipment.


Precision On Even the Hardest Materials Before committing to the new investment, the responsible


BMW production engineer worked with a colleague from process engineering to investigate the effectiveness of the Grob machines in cylinder head production. Initially, it was the G550’s near-identical sibling, the G350, that was under consideration. As a fi rst traditional single-workplace machine tool, it already met almost all the main criteria, but the space available inside was too small to accommodate all the re- quired processing tasks. However, the G550 satisfi ed this re- quirement as well. Among other factors, the horizontal design


of this fi ve-axis machine, which has both rotary axes in the work area, contributes signifi cantly to its outstanding rigidity. As a result, axial deviation remains process-compliant at val- ues under 10 µm. The level of precision that can be achieved is correspondingly high, even when processing extremely hard materials, as with valve seat inserts, for example.


“Previously, it might have taken several hours to set up the machine and the workpiece; now it can be done in just a few minutes.”


surface fi nish, with roughness (Rz


The machine also produces a high-quality ) of up to 2


µm. Christian Heiss, applications engineer at Grob, explains a further benefi t of the hori- zontal design: “Tool life can be increased by approximately 30% compared with that of vertical machining centers. And the problem of jammed slivers is almost completely eliminated because they are not able to fall onto the work- piece in the fi rst place, but instead fall right through to the ground.” One of the G550’s strengths is its com- pact size, at only 3800 mm x 6300 mm. However, despite its size, it still features an extremely long Z-axis stroke of 1020 mm, meaning that tools up to 500 mm long can be retracted completely out of the work area and into the so-called spindle tunnel. The swivel-mounted shuttle table is another feature that helps deliver high levels of productivity. While one workpiece is being processed, the next can be clamped and set, thus minimizing costly downtime.


Familiarity with the Siemens CNC used on Grob machine tools made it easier to make a choice when BMW was looking for new equipment.


Programmed and Set In No Time At All Employees fi nd the new Sinumerik 840D sl CNC especially easy to operate because, in the production of BMW cylinder heads, only Siemens controllers are used. Despite this,


40 — Motorized Vehicle Manufacturing 2016


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