IMTS Pavilion: Abrasive Machining/Sawing/Finishing
OD grinding wheel and three ID spindles of different speeds— covering a speed range from 6000 to 90,000 rpm—so that ID and OD can be done in a single setup.” And premiering at IMTS will be the Usach 75, a small and compact precision cylindrical bore and face grinding machine: “We’ve modified a Quest-based Hardinge hard-turning lathe and equipped it so it can be used as a grinding machine.” Rey explained. “It can be set up as a hard-turning lathe combined with a grind- ing spindle or else equipped—as it will be at IMTS—with two grinding spindles.”
Gunning for Drill Business
In solid carbide drill manufacturing, there is a trend to produce super-long drills that can do the work of gundrills, said Eric Schwarzenbach, president, Rollomatic Inc. (Munde- lein, IL). “The reason is that if a component needs gundrilling, then the component has to be taken to a dedicated gundrilling machine.” If a solid carbide drill can do the equivalent deep- hole drilling but as part of the machining center that’s doing the rest of the work on the component, it can save setup time and capital investment:
lomatic has developed a six-axis CNC drill grinding machine, the GrindSmart 528XF, that focuses on deep-hole drills with coolant through-feed of up to 150 times diameter. The ma- chine has a twin steadyrest system that accounts for the back taper as it supports the long drill as well as a camera to locate the flutes according to where the cooling holes are.
“We’re seeing increased demand for surface and profile grinding machines that perform multiple processes such as grinding, milling and drilling, and make automation integral to the machine’s functionality.”
“The carbide blank is thin and has these coolant holes in it, but because it’s a spiral-fluted drill, the coolant holes also have to be spiral-fluted so that when you flute, you don’t hit those holes and open them up,” Schwarzenbach said. “The camera picks up where the holes are and the machine will accommodate them when fluting the drill.” Schwarzenbach believes that there is a US market for these fluted solid carbide drills that can replace the need for dedicated gundrill equipment. “Many of these drills are cur- rently imported to the US from manufacturers in Germany and Japan,” he noted. “With the right equipment now available, domestic toolmakers could fill this niche.”
Handling the Tough Stuff
United Grinding’s Mägerle MFP 100 surface and profile grinding center.
“With a spiral-fluted drill you can leave the component on the machining center, and you can do all of the other opera- tions—milling, boring, anything—and also do the deep-hole drilling on this same machining center.”
The challenge with deep-hole drilling is that coolant needs to reach the drill tip efficiently, Schwarzenbach explained. Rol-
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ManufacturingEngineeringMedia.com | August 2014
“The precision engineering markets are constantly trend- ing toward ever tighter tolerances and more challenging materials,” said William Lang, manager, Technical Business Development for Norton–Saint-Gobain (Worcester, MA). “Aero engine makers require higher engine temperatures and weight reduction for fuel efficiency, and this has led to advanced materials such as PM sintered nickel alloys, TiAl and CMCs. These are extremely difficult to machine and are driving en- gineered ceramic grain and superabrasive grinding technolo- gies; even traditional SiC based abrasive technologies have received increased research attention.”
At IMTS, Norton will be highlighting new abrasive tech- nologies such Vitrium3, Paradigm and Rapid Prep Surface Conditioning Material that handle the tough new alloys and CMCs, Lang said. “For example, Norton’s new Bear-Tex Rapid Prep designs offer features which allow LF, RF and XF
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