Grinding new technology
More than 100 experts attended the grinding technology conference in Fellbach and submitted 19 papers in two days. This year's fifth annual conference was hosted by Carl Hanser Publishing Company with the theme "Grinding Technology in the Trend of Globalization." The papers presented range from analyzing the current trends in machine tool equipment to the impact of new grinding techniques on the grinding process, as well as current and future application requirements. Dr. Hans-Robert Mayer delivered a very important keynote speech at the annual meeting.
Market needs functional and technological innovation
The first keynote address of the annual conference was hosted by Dr. Christoph Zeppenfeld from the Aachen University Tooling Laboratory, with the theme of innovation in tooling technology and parts processing. He believes that innovative product features, modern processing techniques and the application of tools are of great significance. Optimized and innovative products can increase user productivity, such as intelligent processes and process chains to improve user competitiveness and resource utilization.
Dr. Thomas Ardelt from Mahr introduced the measurement techniques of the company throughout the entire process. He believes that the current trend is to adopt measurement techniques that are close to production and integrated into the process. In addition, today's direction is to automatically measure and correct machine tools. Considering the current trend of shrinking production batches, the measurement time needs to be as short as possible.
Dr. Dirk Friedrich from Koerber gave a special presentation on the grinding technology in a global competitive environment. He believes that successful companies should pay attention to market trends and propose that companies must have high transparency and good coordination mechanisms. Successful companies must not only promote their products in the market, but more importantly, increase processing depth and improve relationships with users.
Innovate with the requirements of parts
Dr. Norbert Mueller from the Daimler Mercedes-Benz Gaggenau plant introduced the development of gear forming grinding technology. They use gear forming and profile grinding techniques such as vane grinding, honing chrome plating, and continue to optimize process parameters. A very important boundary condition is formed by the variety of parts, namely: the smallest possible processing batch and the shortest possible preparation time.
Dr. Heinrich Mushardt from Koerber slip ring company informed the market's requirements for grinding technology in the future. He believes that it is imperative to develop systems that monitor tools and production processes to compensate for the high-speed motion of linear and torque motor drives. The most important thing is to extend the range of applications and functions of the grinding machine to complete all machining tasks on one multi-function machine. In this case, the simulation of the process is not the primary task.
Mr. Michael Jung from Bosch briefly described the requirements presented in the process of machining small diesel nozzle modules from the user's point of view. He believes that it is important to match the dimensions of machine tools and components. Machine tool builders are increasingly taking on the responsibility of system integrators, not only to provide modular, reusable machines, but also to integrate state monitoring into the system. For tool manufacturers, he believes that their development direction is to develop adjustable precision CBN grinding wheels and contoured and shape grinding wheels with excellent wear resistance and precise geometry. In addition, he also proposed the requirements for measurement techniques in and after the process.
Since then, Dr. Mueller's presentation has focused on fast tool change systems, tool positioning systems that do not require line stopping, and pre-clamping of tools. As a representative from the front-line production department, he explained why they abandoned the additional features of the old machine tools not long ago - so they could concentrate on the basic process.
Dr. Thomas Schnider from Faessler introduced the honing process for gearbox gears. Through the innovation of cutting tools, machine tools and drive technology, the economics of this precision super-hard machining technology has been improved, and it has become a common processing technology for hard materials such as gearbox gears. It is not possible to use honed workpieces a few years ago, and now the honing process can also be used. Whether it is a large gear or a small part such as a cross shaft or a crankshaft, a honing process can be used. Dr. Schnider believes that gear honing technology will have great potential in the future.
Mr. Axel Krupp from Hermes Grinding Wheel introduced the gear honing tool in the gearbox processing industry. As the development of super-hard precision machining technology has become more and more mature, the global scope has gradually begun to use the honing gear forming process to process the spur gears in the gearbox. The advantage of machining with a honing tool is that it provides better surface structure of the part and reduces the noise generated during the operation of the gearbox. In addition, the mechanical properties of the tooth profile can be increased to increase the bearing capacity of the component. New machine tools and tooling systems improve the anti-collapse performance of the gears, and the gear honing process increases the stiffness of the gears.
Special solution for surface and contour machining
Ms. Rosemarie Bot-Schultz from Saint Gobain Abrasives introduced the use of ceramic materials as raw materials for future grinding processes. The corresponding tool is known for its open structure, the coolant can be sprayed directly into the grinding area, and the wear area of ​​the wheel surface does not expand rapidly. A small amount of power absorption enables higher cutting efficiency without causing thermal damage to the workpiece. Compared with the conventional deep grinding process, the grinding parameters have been greatly improved due to the use of ceramic materials, thereby improving the cutting performance.
The starting point for the speech by Mr. Bastian Maier from Grindaix is ​​that the globalization trend has changed the production requirements. In order to be able to stand in a highly competitive market, a large number of modern processes and processes must be used. Security, utilization and application results can be ensured by implementing a comprehensive knowledge management philosophy. He suggested that you set a goal: to establish a system for the entire process chain of parts processing.
Mr. Alfred Schlaefli from Linear Grinding Technology introduced the continuous surface grinding process in continuous machining technology. First he answered a series of questions: What is the continuous surface grinding process in continuous processing technology? What kind of machine tools and tools do you need? What processing tasks can be accomplished with such a system? Mr. Schlaefli then detailed the scope of application of the technology and showed the relevant processing options.
Dr. Robert Modler from Johann Modler introduced a special solution for planar machining technology and highlighted the fully automated manufacturing island for this special solution. With this independent manufacturing island, even production companies in countries with high personnel costs can produce them very economically, especially when processing large quantities of parts. Dr. Modler emphasized that a special look at machine tools is needed to examine the overall rate of return on capital. Often, start-up investments with special solutions tend to be more economical than with general-purpose machines. Therefore, an open modular machine concept ensures future reliability of the process.
Grinding tools can expand the range of applications of machine tools
Dr. Peter Dennis from Wendt's presentation focused on the use of superabrasive planar lateral grinding technology and explored the future of grinding technology. His view is that the tools in specific situations can greatly expand the range of applications of the machine. Therefore, the tool can not only achieve the required precision in the precision grinding process, but also complete the surface treatment at the same time. This special grinding wheel solution is available now.
Mr. Heino Claussen-Markefka from Elbe Grinding Machine Tool Company gave a brief introduction to the grinding technology for complex contours. After describing the technical solution, he introduced important process parameters such as the amount of cut and the length of the contact. Vertical milling machines, horizontal milling machines and portal milling machines are all special machines of this type. He also highlighted the processing of turbine blades.
Dr. Maichael Poetsch from Atalantic gave a presentation titled "Processing Processes for Metallic and Non-Metallic Spheres". He introduced this very special technique in the form of a circular forum, including sphere manufacturing techniques, ball grinding principles and processes, quality grades and quality parameters, as well as different spherical materials.
At the end of this annual meeting, Dr. Stefan Brand from Vollmer made the following concluding remarks "Machine Manufacturing in the Context of Globalization", which reflected the theme of this event - "Globalization". Companies must rely on unique product development, globally-distributed product strategies, and global HR strategies to address global market demands.
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