New Gains in Grinding Pinions

In building a machine that completely grinds pump pinions in a single clamping Junker presents a unique production technology, and the ability to replace three machines with a single unit.
By Anita Fey

and shoulder grinding to final quality in a single clamping (see fig. radii. The grinding technicians at the company’s Technology Center in Nordrach.010 mm • Surface quality: Rz < 3. 1. uniform dimensional and surface quality. random and flexible production. flexible and economical machines.0030° • Parallelism (pos. As an example.S. and the machine practically runs itself. measured. This means that all operations are performed on one machine. This grinding process uses an abrasive wheel just a few millimeters wide to carry out all machining steps in a single clamping. Illinois— attempts to meet these challenges every day. which contributes significantly to the company’s high-tech reputation. The following qualities were achieved to the complete satisfaction of the customers: • Roundness: < 0. with its U. The most beneficial features of the QUICKPOINT process include its high chip removal rate. since 1985 the company has been promoting its QUICKPOINT CNC OD grinding process. radius grinding. The machining task was as follows: external cylindrical grinding. and cylindricity is optimally improved by the QUICKPOINT . The workpiece data is stored in the PLC and provides the machine with a reference for further production. extremely precise workpiece geometry. and significantly shorter production times. Random production within a workpiece family can be performed without retooling thanks to the automatic workpiece recognition function. angularity.0015 mm •  Concentricity on outside diameter: < 0. method of complete grinding in a single clamping.0035 mm • Axial run-out: < 0. In a recently completed project for a well-known pump manufacturer two plunge-cut grinding machines were replaced by just one QUICKPOINT.005 mm • Straightness: < 0. Junker has developed high-speed grinding with CBN into a key area of expertise. and angularity. high availability. All this is made possible because the grinding process requires no workpiece carriers. parallelism. Mechanical engineering companies are in turn required to develop ever more advanced. and taper to final quality. In building a machine that completely grinds pump pinions in a single clamping. which through punctiform contact with the workpiece achieves a far higher chip removal rate than conventional grinding methods. manages a COMPLETE MAcHINING The QUICKPOINT concept involves removing all of the cutting stock at the fastest possible feed rate in a single pass and at extremely low cycle times using a CBN grinding wheel only a few millimeters wide. continue to employ their expertise to further develop this world-renowned grinding process. Here’s how it works: the host computer. narrow tolerance ranges— ultimately due to CBN—minimized grinding tool costs. The advantage is good concentricity and improved roundness. 3): < 0. location in Elgin. cylindricity. One of the applications they’ve been working to refine is for pump pinions—grinding the entire outer contour. Junker presents the pump manufacturer sector with a unique production technology. and finish ground. The rejection rate is practically reduced to zero since after retooling the workpiece is automatically pre-ground. low manpower operation. Erwin Junker Machinery— headquartered in Germany.003 mm • Angularity (at pos. roundness.004 mm • Pinion width tolerance: < 0. 1/3): < 0. Add to this a completely automatic loading system connected to a host computer. Product quality with respect to axial runout. which is connected to both the machine and the loader.0 µm The project afforded the customer with significant benefits including the first part being a good part. and retooling times of less than one minute. 25-percent lower unit costs. Conventional grinding required three different machines in order to fully grind pump pinions. positions 1-5) in a completely automatic production process. Germany. shoulders. Now all a manufacturer needs is one machine.T The demand for lower costs and higher flexibility are shaping modern production more than ever before.

using a low-wear CBN or diamond wheel only a few millimeters wide. rotationally symmetrical parts weighing up to 5 kg. semiautomatic. aluminium. Thanks to the high cutting speed of up to 140 m/s.indytennis. All these benefits result in unit costs that are up to 25 percent lower than those of the competition. The third version.in. QUICKPOINT means high-speed OD grinding with only punctiform abrasive contact in the finish-grinding area. Due to these extremely small radial and axial grinding forces. Manual. completely machine right and left shoulders. This significantly reduces the grinding forces.sportcomplex. and 52 gearsolutions.net Indianapolis Yellow Cab www. The tilt of the grinding body axis relative to the horizontal workpiece axis creates a relief angle that reduces the contact line to a contact point.circle-centre. Indianapolis Colts www.com Circle Centre Shopping and Entertainment Complex www.com THE CONcEPT The grinding process developed by Junker has become particularly well established on the market in the machining of automotive components. or titanium. drive shafts. and powder metal materials. cones.com . and multiple edges at both ends of the workpiece. also allows the unlimited grinding of right and left shoulders.gov/whiteriver Indianapolis Zoo www. The individual jobs are imported by the scanner. and partial right and left shoulders can also be ground with the QUICKPOINT method. glass. camshafts.com IndyGo-Public Transportation www. complete list of workpieces to be machined in sequence.com Indianapolis Tennis Center www. with two offset abrasives. and the information is then transmitted to the loader and machine for processing. radii.ussindianapolis. and completely automatic loading systems can be modularly docked to each model in the series according to individual customer specifications. One advantage is the low grinding forces. a clamping and grinding length of 150 mm.e. carbide. QUICKPOINT 3000 : Particularly universal.edu Indiana University Natatorium www. faces.edu USS Indianapolis www. as determined according to CDI 3423. The long service life of the CBN abrasive contributes to minimal secondary processing times. resulting in retooling times of under a minute. all in a single clamping and without changing the grinding wheel. In this way the productive utilization ratio—i.indyzoo. The QUICKPOINT series is modularly designed.Recreation Fig. All of this happens automatically and with minimal manpower. The QUICKPOINT allows the operator to THE LINEUP QUICKPOINT 1000: The machines in this series—with a center height of 100 mm. a 500 mm clamping and grinding length. and pump shafts. Typical workpieces include gearshafts. 1: Areas ground on the pump pinion. and a grinding wheel diameter of 350 mm— are suitable for the complete grinding of small. Using the 1000/20 fitted with a grinding spindle. grooves. engine valves. which means that a version can be found for practically any application.indygo. this series features a 150 mm center height.iupui. and plunge-cut grinding. com Brickyard Crossing—Golf www. This means that the workpiece is only clamped and driven between centers. work can be performed without special workpiece carriers.ycindy. Due to the narrow grinding wheel and its point-sized contact area with the workpiece.colts.brickyardcrossing. the technical availability of the QUICKPOINT grinding machine—amounts to up to 95 percent. chamfers. cones. single-sided shoulder grinding. the QUICKPOINT method also enables highly flexible production of many different workpiece geometries and batch sizes.iupui. The 1000/10 version with a permanently mounted grinding spindle and an abrasive is designed for productive external cylindrical grinding. The following section lists the individual machines available that utilize these technologies.org White River State Park www. as well as special materials such as industrial ceramics.com Indianapolis Motor Speedway www. just about any materials can be machined including steel. plastic. indianapolismotorspeedway.

< NCB-100 < C-520NC About the author: Cosen’s New CNC Coldsaw NCB-100 will be featured at Booth# 12078 877. and fast retooling and setup. as well as small and medium batch sizes. These machines can therefore grind the complete length of a workpiece up to the ends. The 4L is also available with two carriages. This version is intended for large workpieces with a maximum clamping length of 3. Thus. This includes parts used in railways. Another customer benefit is the compact design. the new Platform 4 enables the realization of complex grinding concepts tailored precisely to the customer’s workpiece. from the automotive industry and suppliers all the way through to mechanical engineers. In addition. 50. as well as wind turbines—shafts and axles—or ship drives.com. Its benefits are the graphical display. also providing customers with the usual basic benefits such as an identical guide system. can significantly minimize production times while increasing product quality. 40. even at high speeds.943.com Cosen's saws offer a faster return on investment against competing brands. all input and information go through the operating platform known as the Erwin Junker Operator Panel EJ-OP. Thanks to the wide variety of wheelhead versions.junker-usa. as this reduces the footprint. Anita Fey is marketing consult at Erwin Junker Maschinenfabrik. Germany. This large series is available as a 10. This includes the patented three-point mounting system for abrasives and for sensors and drivers..cosen. reduced training requirements. NC 28273 | 704. and a uniform. has grown to include the new 6 XL. The Platform 4 is intended for workpieces with a maximum clamping length of 750 mm and a maximum workpiece weight of 130 kg. The former has a grind ing wheel that swivels 180° and 15° at the work level. For instance.943. USA. and their suppliers. CEO Horst Zemp at (847) 488-0406. To learn more call Erwin Machinery. 54 . MINIMIZING COSTS AND COMPLEXITY The Pinnacle of Cutting Performance With all three series. The machines permit fast and flex- ible adaptation in machining parts from large workpiece families. for example. due to the use of two grinding carriages it is also possible to machine workpieces in parallel in the future. and it can be used for workpieces weighing up to 15 kg.com]. QUICKPOINT 6: The Platform 6. The 3000/60 version is fitted with three swiveling grinding spindles offset by 120°. In addition. which almost doubles the output quantity. All the Platform 6 machines can be provided both as single-carriage as well as two-carriage versions. For this reason Platform 4 represents an interesting concept for a multitude of sectors.1030 | 704. users benefit from the largely similar design of the machines. or go to [www. which is achieved by means of shorter and superimposed travel within the machine.com www. These are thus clamped without complex adjustment for an axial runout accuracy of approximately 1 µm. For complex grinding tasks. It is especially due to this sort of complete grinding that production facilities in the automotive industry. with its two S and L versions. a large number of identical parts. QUICKPOINT 4S and 4L: The Platform 4 machines are each available in 4S and 4L versions. | Charlotte. round cover shape with the EJ-OP operator panel. or threads can be machined on a workpiece in quick succession in a single clamping. or 60 version. Inc.SAWING1 11626-B Wilmar Blvd. In addition to the versions already mentioned there are also the 3000/40 and 3000/60 versions.a grinding wheel diameter of 350 mm. outer diam eters. e-mail info@junker-usa. the electrical industry.000 mm and a maximum workpiece weight of 300 kg. 20. for example. and environmental technology. and right and left shoulders without any limitation. Once trained. Erwin Junker Machinery produces customized grinding solutions to fit its customers’ needs and criteria. QUICKPOINT 5000: With this series users can also benefit from the advantages of the QUICKPOINT process for workpieces meansuring up to 1000 mm in length and up to 280 mm in diameter and weighing up to 130 kg. plunge/relief cuts. Platform 4 supplements the already existing Evolution² platforms by Junker. interactive processes for programming and operation.1031 fax | info@cosen. the same design characteristics of all three series ensure high accuracy and minimal setup times. Evolution² increases the output by reducing cycle times.com gearsolutions. The automatic balancing system integrated in the abrasive holder provides optimal smooth rotation. employees can operate all QUICKPOINT machines from all five series or platforms.