Grindsurf

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Unlimited number of non-rouo nd applicaellipses, eccentric shapes, flat, squarese,triangn les, hexagons and much mooreUnmatched diamea ter/lel ngth ratioRadius shapeaccuracacywithin 0.003 mmPerfect tool concentricity within 0.002 mmPrrecision and sizze consistency withtolerances of just a few micronsSHAPEESMART NNP50UNPAPA RAALLELED PERFORRMANCE AND PRECISIONRollomatic intrroduces a new cylindrical pinch/peel grinder ShapeSmart NP50.d as a World Premiere at EMO 2019!Many new innnovations to be discoveredPlease Visit us aat Hall 6, Booth J65 Messe Hannover, Germany.www.rollomaticsa.cominfo@rollomatic.ch

GENERATING GEARGRINDING MADETRANSPARENT Grinding machines Automation Grinding wheels Dressing tools Workholding Technical SupportReishauer AG, Switzerlandreishauer.comHall 26Booth C109

SEPTEMBER 2019COVER STORY 3VOLUME 17 No.4 ISSN 1740 - 1100Tool grinding the smart waywww.grindsurf.comEMO PREVIEW4AEROSPACE REPORT40Production Grinding46Grinding Wheels & Discs54Filtration58FEATURE - DEBURRING62Honing & Bore Finishing66Polishing & Lapping70FEATURE - TOOL & PROFILE GRINDING74PARTS2CLEAN PREVIEW82Component Cleaning88Metal Finishing92At Your Service98Published by Roger Barber PublishingEnterprise House, Foundry Lane, Horsham, West Sussex, RH13 5PXPublisher: Roger BarberSales: 01403 266022 Fax: 020 8916 0033Email: roger@rbpublishing.co.ukAssistant editor: John Barber - 01403 266022Email: john@rbpublishing.co.ukCirculation: Chloe Barber - 01403 266022Accounts: Jackie Barber - 01403 563791Design & Production: Roger Barber PublishingProduction manager: Anna Rodrigues - 01472 210712Email: studio@rbpublishing.co.ukPrint: Holbrooks Printers Ltd, Portsmouth, HampshireGrinding & Surface Finishing is a controlled circulation magazine, availablefree to selected personnel, at the discretion of the publisher.This material is copyright. No part of this publication may be reproduced withoutexpress written permission. Please contact the publisher.NEXT ISSUE - NOVEMBER 2019 Medical Report Blast Cleaning Component Cleaning Dust & Fume Extraction Honing & Bore Finishing SuperfinishingGSF SEPTEMBER 2019Collaboration with industrial robots, automated processes,rigorous data analytics, with more time for higher value tasks are allessential building blocks for the manufacturing industry oftomorrow. “The factory of the future will generate freshmomentum, reduce existing limits and combine previouslyindependent production systems. These systems help to controlproduction while collecting and analysing data at the same time.With the help of collected data, the machines will be able to, forexample, react immediately to temperature changes, reduce nonproductive times, or optimise throughput times,” says Rollomatic’sDamien Wunderlin.For some years now, Rollomatic has been researching highlyskilled, humanoid robots and developing applications for them.The result is the dual-arm NEXTAGE robot, which can supporttraditional robotic units and increase the productivity andprofitability of customer-specific processes. It also takes ondemanding, labour-intensive tasks and carries out easy andrepetitive activities. The robot is therefore able to take a groundtool out of the machine and bring it to the measuring station.In the factory of the future, a network of intelligent systems willwork together to increase overall productivity by enabling shorterlead times and maximum flexibility. Rollomatic will provide animpressive demonstration of how the manufacturing of highprecision tools can be enhanced by Rollomatic’s Smart Factory atEMO 2019.The uniquely designed6-axis GrindSmart 830XW combines linearmotors with a hydrostaticsystem, which virtuallyeliminates any frictionand effectively dampensmachine vibrations. Thisresults in longer grindingwheel life as well asachieving perfect surface and cutting edge qualities, which presenta major unique selling point for manufacturers in the high-end toolsegment.The new 6-axis tool grinding machines from the GrindSmart XWfamily, in particular the GrindSmart 630XW and GrindSmart630XW3, are also characterised by their capability for unattendedproduction. Rollomatic has increased the capacity of the XW3model almost threefold thanks to an ultra-compact grinding wheelchanger for 16-wheel packs, including coolant nozzles. Thissimplifies process management and significantly shortens nonproductive times as well, around the clock and without interventionfrom the machine operator.The ShapeSmart NP50, the latest addition to the series of pinch& peel grinding machines, promises even greater flexibility, fastersetup and even better surface quality. It covers a wide range ofdiameters from 0.025 mm to 25.0 mm, thereby opening upunlimited possibilities, even for unusual length/diameter ratios orcomplex geometries.Rollomatic SATel: 0041 32 7521700Email: matic: Hall 6, Stand J65

Smart technologies driving tomorrow’s productionEMO Hannover 2019, the world’s premiertrade fair for the metalworking industry, willbe held from 16 to 21 September under themotto of "Smart technologies drivingtomorrow’s production". It will thus beconcentrating on the current paradigm shiftin industrial production operations, whichare no longer focusing just on "better,faster, more accurate" but on thedevelopment and implementation of newfunctions within the framework of Industry4.0. Digitalisation and intelligent networkingin conjunction with numerous newdevelopments, from Big Data, data analyticsand artificial intelligence all the way throughto the platform economy, create thefoundations for new business models, sothat customers and vendors can reach a newlevel of productivity.”The last EMO Hannover had alreadyshown that Industry 4.0 has arrived in themachine tool industry," says Carl MartinWelcker, general commissioner of EMOHannover 2019. "As the world’s leadinginnovation platform, we are progressing thistrend by focusing on the next developmentstep in production operations: the technicaloptions opened up by digitalisation andnetworking, which are being increasinglyreflected in new business models," he adds.“This doesn’t mean that in future we shall nolonger be working on optimising machinesand processes in the traditional way. I am,however, confident that quantum leapsforward in terms of productivity, quality andreliability will be triggered primarily by thenew technologies. So in 2019 we will beseeing an abundance of solutions thatimplement new services for the machinetool industry’s customers.”Rendering data intelligently usableFor new business models on a broad front,firstly the immense quantities of datagenerated by digitalisation and networkingof machines and processes need to bereduced to a usable level. Only if you canextract the relevant data (Smart Data) fromthe superabundance of Big Data can youderive an entrepreneurial benefit fromIndustry 4.0. Last year, scientists at theGerman Academic Society for ProductionEngineering (WGP) in their position paperon Industry 4.0 had already published anaction guide and shown how Big Data canbe rendered manageable using the data4mining method, for example. Besides thisguide, the professors at the WGP contributetheir state-of-the-art expertise to otherbilateral arrangements between theindustrial sector and the academiccommunity. Not least, they utilise EMOHannover in order to showcase for a globalpublic the projects they are conductingtogether with industrial partners.arrangement between Mercedes-Benz andthe graphics-chip manufacturer Nvidia.Together, they are aiming to put anAI-based vehicle on the road in the next fewyears. For machine tool manufacturers, too,artificial intelligence offers an abundance ofpotential.”We are seeing how new technologies areinfluencing and even driving forwarddevelopments in the machine tool industry,”Utilising artificial intelligencesays general commissioner Carl MartinIn recent years, artificial intelligence (AI) has Welcker. ”By September 2019, numerousachieved some amazing breakthroughs.specific solutions will be available on theOne of its capabilities, machine learning,market. I can say this with confidence, sinceenables machines and processes to optimise many EMO exhibitors will be using thisthemselves with the aid of Smart Data. They international shop window, in order todetect patterns in data flows and derive the showcase their corporate capabilities andappropriately responsive actions. Theenhance their profiles.” Industry 4.0, hesystem learns from every situation.adds, creates new customer needs, to whichArtificial intelligence has already arrived in machinery manufacturers must respond inour everyday reality. To ensure that theorder to remain competitive. Companiesmechanical engineering sector also benefits that are quick to embrace this new form offrom this, the VDMA has published a studyeconomy can not only utilise the trend forentitled "Machine Learning 2030", which isnew business ideas, but also get activelyintended as a kind of roadmap. Theinvolved in designing the platformsrecommendations for companies, politicians concerned. Interested parties will onceand researchers are currently being firmedagain find inspiration and specific examplesup and implemented in a VDMA workingof innovative solutions at EMO.group. It’s now only a question of timebefore this futuristic scenario, too, arrives in To register, contact:the factories. The automotive industry, forexample, is already making massive use ofDeutsche Messeartificial intelligence and entering intoEMO Hannover 2019appropriate alliances. This is adequatelyTel: 0049 511890exemplified by the cooperativewww.emo-hannover.deGrinding & Surface Finishing I SEPTEMBER 2019

Tool grinding the smart wayRollomatic presents a world premiere offering more options for unattended productionRealistic solutions for unattendedproduction are more in demand than ever.This is exactly how Rollomatic SA intends toimpress at EMO 2019. With Smart Factorysolutions, new tool grinding and lasermachines as well as two world premieres, avisit to the stand is definitely worthwhile.The sheer number of buzzwords relatingto Industry 4.0 used in the machine toolindustry shows no sign of stopping.Beginning as a niche application, the idea ofa “Smart Factory” is now sparking interestacross industries. This is increasing thepressure for manufacturers to constantlyinnovate in order not to lose touch withchanging requirements for the comingyears.“We have been firmly following this path,initially regarded by some as simply afuturistic trend, into unattended productionfor years. At EMO 2019, the topic will takeon a new significance, as we will be showingvisitors several interesting ways in whichthey can use our machines to achieve thebest product quality at the highest possibleefficiency,” says Damien Wunderlin, head ofsales at Rollomatic SA in Le Landeron,Switzerland.Smarter productionCollaboration with industrial robots,automated processes, rigorous dataanalytics, with more time for higher valuetasks; these are all essential building blocksfor the manufacturing industry of tomorrow.“The factory of the future will generate freshmomentum, reduce existing limits andcombine previously independentproduction systems. These systems help tocontrol production while collecting andFor some years now, Rollomatic has been researching highly developed, humanoid robots anddeveloping applications with them. The result is the dual-arm NEXTAGE robot, which can supporttraditional robotic units as well as increase the productivity and profitability of customerspecific processesanalysing data at the same time. With thehelp of collected data, the machines will beable to, for example, react immediately totemperature changes, reduce nonproductive times, or optimise throughputtimes,” continues Damien Wunderlin.Using industrial robots achieves greaterautonomy and efficiency, among otherthings. For some years now, Rollomatic hasbeen researching highly skilled, humanoidrobots and developing applications forthem. The result is the dual-arm NEXTAGErobot, which can support traditional roboticunits and increase the productivity andprofitability of customer-specific processes.It also takes on demanding, labour-intensivetasks and carries out easy and repetitiveCollaboration with industrialrobots, automated processes,rigorous data analytics, as well asmore time for higher value tasks,are all essential building blocks ofthe production industry oftomorrow. Rollomatic has beenfirmly following this path intounattended production for years6Grinding & Surface Finishing I SEPTEMBER 2019activities. The robot is therefore able to takea ground tool out of the machine and bringit to the measuring station. This gives themachine operator more time to completeother tasks that a robot is currently unableto carry out.In the factory of the future, a network ofintelligent systems will work together toincrease overall productivity by enablingshorter lead times and maximum flexibility.Rollomatic will provide an impressivedemonstration of how the manufacturing ofhigh-precision tools can be enhanced byRollomatic’s Smart Factory at EMO 2019.Linear motor and hydrostatics offerunmatched surface finishA further highlight of EMO is the uniquelydesigned 6-axis GrindSmart 830XW. Theaim while designing this model was tofurther reduce friction within the machineand maintain virtually zero wear. One of theways in which Rollomatic achieved this wasthrough the linear motors on the x, y and zaxes, which are superior to ball screw drivesin every respect. For instance, linear drivesare extremely accurate in terms ofpositioning with low maintenance costsbecause virtually nothing can wear.However, this was not enough for thedesigners, who also wanted to combine

EMO PREVIEWlinear motors with a hydrostatic system,which virtually eliminates any friction andeffectively dampens machine vibrations.This results in longer grinding wheel life aswell as achieving perfect surface and cuttingedge qualities, which present a majorunique selling point for manufacturers in thehigh-end tool segment.The sixth axis of the GrindSmart 830XWopens up new options for pioneeringinnovations in tool design, particularlyRollomatic has increased capacities for thewhere high-precision tools with diameters of GrindSmart 630XW3 almost threefold thanks to an1.0 mm to 32 mm and flute lengths of up to ultra-compact grinding wheel changer for 16wheel packs, including coolant nozzlesWith its linear motors, hydrostatic technology, and6-axis kinematics, the GrindSmart 830XW allowsfor perfect surface and cutting edge quality200 mm are required. The arrangement ofthe grinding spindle axis on this machineenables an extreme freedom of movementon both sides via a total rotation angle of240 . This means that both right-hand andleft-hand tools can be ground with the samewheel pack. The sixth axis also makes itpossible to tilt the grinding wheels duringgrinding. Thanks to the increased flexibilityand freedom of movement, it is also mucheasier to grind the radii and reliefs ofcomplex tool geometries. In addition, thesixth axis ensures that the contact point onthe grinding wheel remains constant at alltimes, which achieves ultra-high precisionfor the finished tool.Enhanced accuracy and efficiency withsix axesThe new 6-axis tool grinding machines fromthe GrindSmart XW family, in particular theGrindSmart 630XW and GrindSmart630XW3, are also characterised by theircapability for unattended production.Rollomatic has increased the capacity of theXW3 model almost threefold thanks to anultra-compact grinding wheel changer for16-wheel packs, including coolant nozzles.This simplifies process management andsignificantly shortens non-productive timesas well, around the clock and withoutintervention from the machine operator.First world premiere revolutionisesmachining timeDiamond (PCD or CVD) has become anirreplaceable cutting material in allindustries. However, the hardness of thematerial has imposed enormous limitationson the geometry design options for tools –until now. Rollomatic has achieved abreakthrough with its latest development,the SmartSpeed Pack. This opens up awhole new environment for laser machining.No other technology is as productive asRollomatic diamond laser machining.Machining speeds have been increased upto four times faster, without compromisingon quality. Laser machining is therefore wellon the way to completely replacingtraditional machining methods for diamondmaterials.Using the new LaserSmart 510, forexample, the chip breakers and especiallythe circular land can be applied to a PCDtool without time-consuming grinding onseparate OD grinders. “The fact that ourmachine completes the entire process in asingle step saves time and significantlyincreases productivity,” explains Sven Peter,laser product manager at Rollomatic SA.“During cutting, it achieves smoothersurfaces thanks to the circular land as well asoffering efficient chip removal via thecorresponding chip breakers.” Four built-incameras monitor and map all the machine’smovements on the control unit, from therobot to measuring probes. The toolmeasuring process is therefore much moreefficient and user-friendly than before.Second world premiere optimisescylindrical grindingRollomatic has revolutionised peel grindingwith the SmartPunch process fornon-round applications. The ShapeSmart NP50, the latest addition to the series ofpinch & peel grinding machines, promiseseven greater flexibility, faster setup andeven better surface quality. “Peel grinding isa proven method and representsRollomatic has revolutionised peel grinding withthe SmartPunch process. The ShapeSmart NP50,the latest addition to the series, promises evengreater flexibility, faster setup and better surfacequalityoutstanding performance in cylindricalgrinding. The ShapeSmart NP50 covers awide range of diameters from 0.025 mm to25.0 mm, thereby opening up unlimitedpossibilities, even for unusuallength/diameter ratios or complexgeometries,” says Damien Wunderlin. “Wewill be keeping the other features under lockand key until EMO but I promise that theyare spectacular!”UK Agent:Advanced Grinding Solutions LtdTel: 024 76 226611Email: rindingsolutions.co.ukA revolution in laser machining: thanks to the newSmartSpeed Pack, machining times on theLaserSmart 510 are up to four times faster withoutcompromising on qualityRollomatic: Hall 6, Stand J65Grinding & Surface Finishing I SEPTEMBER 20197

UNITED takes leading grindingtechnology to EMOand drilling operations and a measuringprobe for quality or workpiece positionchecks. The powerful spindle enables thecombining of different grinding processes,such as creep freed grinding with corundumor grinding with CBN. Full performance anda high torque are available even at lowspeeds, while the grinding process isoptimised with a grinding wheel cleaningThe UNITED GRINDING Group is one of the function.world’s leading manufacturers of precisionThe second generation of the JUNG-Jmachines for grinding, eroding, lasering and series is even more focused on precision andcombination machining. With eightsurface quality. Launched at EMO in 2013,company brands, all leaders in theirthe machine has been further developed toparticular field, UNITED GRINDING offersmeet customer requirements. These includebroad application knowledge, an extensive a Windows 10 Toolmaking Operatorproduct portfolio and a complete array ofInterface enabling 25 percent fasterservices for surface and profile grinding,programming, more stability againstcylindrical grinding and tool machining.thermal factors, contact detection withAt the recent Grinding Symposium 2019 atacoustic emission, integrated measuringthe Thun Exhibition Centre, the Groupprobe and JUNG measuring cycles. Theshowcased an impressive display oflatter comprise simple determination of themachines with a comprehensive series ofworkpiece position in the

Enterprise House, Foundry Lane, Horsham, West Sussex, RH13 5PX Publisher: Roger Barber Sales: 01403 266022 Fax: 020 8916 0033 Email: roger@rbpublishing.co.uk Assistant editor: John Barber - 01403 266022 Email: john@rbpublishing.co.uk Circulation: Chloe Barber - 01403 266022 Accounts: Jackie Barber - 01403 563791 Design & Production: Roger Barber Publishing Production manager: Anna Rodrigues .

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