Grinder Offers Alternative to Turning High-Volume Automotive Parts

When manufacturing components between 2 and 20 mm in diameter, Junker’s Grindstar grinding machine offers an alternative to turning. From batch sizes of 200,000, the machine’s short cycle times and long service life can reduce cost per workpiece by as much as 25 percent, the company says. Its productivity suits it for large-scale series manufacturing in the automotive industry.

The grinding method enables the entire workpiece contour to be ground in a single processing operation. Because grinding involves lower cutting forces than those occurring during turning, workpieces can be ground faster. It coordinates the workpiece, abrasive and machine to increase productivity over that of a lathe.

Every step, from material cutoff to profiling and ejection is covered in a single machine, enhancing process reliability, minimizing machine downtime and increasing turnaround with high piece volumes. Because of this, the grinding machine achieves an availability level of more than 96 percent and an extended tool service life, the company says. Its cooling system enables the grinding wheels to work precisely and consistently for up to six months or a production volume of 300,000 pieces.

Grinding instead of turning also improves the dimensional accuracy and surface quality of workpieces, and guarantees burr-free parts. Grinding machines also do not create chip impressions. The machine’s two-profile grinding wheels require no dressing. The flushing system prevents particles from being deposited on the grinding wheels, eliminating the need for reworking, reducing the production time, and eliminating the need for surface grinding or polishing. The machine grinds materials including high-alloy tough steels, hardened materials and ceramics. CBN or diamond can be used as abrasives.

The company can adapt the machine for the needs of each customer, eliminating the need for test runs, and its quick and simple setup keeps with the principle of plug-and-play.