Mayes and Warwick has utilised the S33 high-precision CNC grinder from Studer to keep pace with the growing demand for its output.

Mayes and Warwick thread and form rolling dies are manufactured using top-quality branded tool steels and high-speed steels.

All are heat treated using vacuum heat treatment facilities to ensure respectable hardness, wear resistance and longevity.

Mayes and Warwick produces a full range of flat thread rolling dies in an infinite variety of thread profiles for rolling all types of screws, bolts and fasteners.

Also manufactured are rolling dies for many kinds of lock bolts and rivets.

Dies can be manufactured for screws and fasteners featuring all standard thread forms, from 1.1mm to 32mm diameter (0.043in to 1.1/4in) with pitches from 0.32mm (>80TPI).

The company utilises CADCAM technology and manufactures its products on advanced CNC milling machines, lathes, turning centres and grinding machines.

To help keep pace with the growing demand for the company’s output, Peter Lawrence, managing director at Mayes and Warwick, undertook a search for a high-precision CNC grinding machine to replace an older Matrix machine.

In addition to other in-house grinding applications, the main work of the machine would be grinding very precise annular grooves onto in-house manufactured crushing rolls.

These accurate rolls are used within a process critical to the accuracy of the company’s products.

The crushing rolls are used to ‘crush’ extremely precise thread forms onto the company’s grinding wheels; the treated wheels are subsequently used to grind thread forms onto the company’s high-quality thread and form rolling dies.

Mayes and Warwick contacted Micronz, the UK agent for Studer; Micronz and Studer understood its requirements and recommended its S33 as the solution.

An in-depth demonstration replicating some of the company’s most challenging grinding tasks convinced Mayes and Warwick to make the purchase.

Now in full production, the S33 is providing the promised levels of high-quality output, Lawrence said.

Manufactured with distances between centres of 650mm (25.6in) and 1,000mm (39.4in), the Studer S33 CNC universal cylindrical grinding machine was designed for grinding medium-sized workpieces in individual and series production.

The machine’s solid Granitan S103 machine base forms the basis for this robust cylindrical grinding machine.

The dampening properties of the machine’s base helps ensure good surface quality of the ground workpieces, extended service life of the grinding wheel and therefore reduced downtime.

Temporary temperature fluctuations are efficiently compensated for by the favourable thermal behaviour of Granitan, resulting in high dimensional accuracy at all times.

The machine’s longitudinal and cross slide, V and flat guideways are moulded directly onto the machine base and are treated with a non-abrasive Granitan S200 slideway coating.

The patented knobbed structure of the guideways largely eliminates the slip-stick effect or floating of the slides observed on conventional setups.

The guideways offer high accuracy through the machine’s entire speed range with high load capacity and dampening levels.

Changing over from grinding between centres to live spindle grinding is said to be particularly easy on the S33; only a few movements are needed to withdraw the tailstock to its park position and free up the space required for internal grinding.

Reference points from grinding wheels to dressing tool and workpiece can be registered quickly with the help of Quick-Set, Studer’s software-controlled set-up device.

An external wheelhead with a belt-driven spindle, which can be manually adjusted to 0deg or 30deg, is available for production applications.

Studer’s turret wheelhead, with two motor spindles and an internal grinding attachment, enables the grinding of more complex workpiece geometries in a single clamping.

Thanks to the machine’s geometry, the entire distance between centres can be traversed with all grinding wheels.

The motor spindles that contribute to grinding accuracy are manufactured entirely in-house.

The S33 universal workhead enables both live spindle grinding and grinding between centres.

The machine can also be fitted with a specially designed chuck workhead for chuck applications.

All low-maintenance workheads are equipped with roller bearings; they also feature good roundness accuracy figures of less than 0.0004mm (0.000,016in), which can be optionally improved to less than 0.0002mm (0.000,008in) during live spindle operations.

Fine adjustment allows for taper corrections within the 1um range throughout live spindle operations.

As with the S33 tailstock, the machine’s workhead is also equipped with a pneumatic lifting device to facilitate movement during set-up and resetting.

An optional C-axis enables thread and form grinding, increasing the machine’s potential applications.

A controlled power chucking cylinder - which actuates a power chuck and spring collets - is also available for automatic workpiece clamping.

The generously dimensioned barrel, designed for the use of Morse 3 (4) taper centres, glides in the tailstock housing.

Centre pressure can be adjusted with the absolute precision required for grinding high-precision workpieces, while fine adjustment enables taper corrections in the range below 1um when grinding between centres.

If required, the S33 tailstock can be equipped with a hydraulically actuated barrel retraction for workpiece changeover, and a pneumatic lifting process facilitates movement during set-up and resetting.

In order to guarantee optimum thermal stability, the S33’s tailstock is flooded with cooling lubricant, as are the barrel and the diamond holder.

The Studer S33 uses a Fanuc 0i-TD CNC control with integrated PC and 15in touch screen.

All controls are clearly and ergonomically arranged, while an important role is played by the manual control unit, which facilitates set-up close to the grinding process.

The mechanical engineering concept of the S33 is complemented by a grinding software program developed in-house by Studer in collaboration with customers.

The user interface, Studerwin, plus the software modules of Studergrind, create a stable programming environment and contribute to the overall efficiency of the machine.

The S33 has the option of fully integrating in-process gauging and sensor technology for process monitoring, in addition to contact detection and automatic balancing systems.

Windows control enables standardised programming of all of the S33’s different systems.

ASG-550 is a four axle servo-control CNC saw grinder; the grinding angles, the teeth numbers, and the teeth depth can be automatically set up and controlled. No mater face grinding, top grinding or saw grinding, all of these actions can be done in one time. Without spending a long time on grinding, this machine can make the high quality and accurate grinding performance. The following is part of the features of ASG-550:

• Ceramic magnet chucks provide superior holding power that never fades, and it is easy to replace the chucks.
• Relief angle grinding can be finished in one action.
  • This 4 axle servo-control CNC grinder allows setting various feeding curves according to different saw blade diameters.
• Installed the basic automatic lubrication system.
• Equipped with standard spray mist filtration system that with cooling water recycle function.

AUTOMATIC HSS CUTTERHEAD GRINDER

Jeffer Machinery’s grinder is accurate and durable that is well approved by customers in both domestic & export markets. “Our grinder exporting to Europe is CE Certified to European standards, and we have attained high quality standards and believe in providing flawless products to our customers,” Mr. Daniel Lin pointed out the high self-motivation that every Jeffer’s worker has. “And each our product is well checked by our QC team before dispatching in order to make sure that our customers get the finest machine. Our products are precise and perfectly suit the purposes they are meant for.”

It is worth mentioning that Jeffer Machinery Co., Ltd. its production process is well documented to make sure continuous process improvement. The whole production process is carried out in-house, no matter preliminary design, production or the final inspection, they are managed through an IT network with CAD, PDM and CAM capabilities. Besides, all Jeffer Machinery grinders are accepted in the national and international markets and are known for their durability and specialized features.http://www.azom.com/news.asp?newsID=19282

The UltraGrind CNC is designed for the precision production environment such as aerospace and higher volume manufacture including automotive, as well as high-precision sub-contract machining for biomedical, high-end process tool/die sets, F1 and motorsport engineering.

The UltraGrind CNC is designed for the precision production environment such as aerospace and higher volume manufacture including automotive, as well as high-precision sub-contract machining for biomedical, high-end process tool/die sets, F1 and motorsport

Viewed as a key strategic development, a special UltraGrind project team was created to design the machine. They carried out customer surveys not only with J&S customers but many users of other equipment to ensure this project met market requirements now and in the future. From the feedback this team were able to create the specification, build and test the machine to ensure that it achieved the highest levels of accuracy and flexibility always associated with Jones & Shipman machinery. Built on a one-piece bed design, the machine combines great rigidity, stability and stock removal rates whilst maintaining high precision. It incorporates many mechanical, electrical and software features, suggested from the customer research, that ensure it is easier to operate and change over in demanding production environments.

Mike Duignan, Managing Director of Jones & Shipman commented: “The launch of the new UltraGrind machine is an exciting development for the precision grinding industry. The machine brings new standards of accuracy for a one-piece bed grinder, keeping the company at the forefront of the precision tool technologies industries. We will be demonstrating a working prototype at the CIMT so visitors to the Show will be able to see all the machine’s distinct advantages. We have already received a number of orders for the UltraGrind, including one for two machines from a premium subcontractor to the aerospace industry.”

A brand new modular wheelhead design ensures customers have a wide choice of external and internal grinding spindle combinations, effectively allowing the customer to specify a custom machine, but without the cost and build time associated with it. The modular wheelhead design gives wheel sizes up to Ø500 x 100mm (Ø20″ x 4″) and wheel spindle power up to 15kW (20hp), with ultra rigid spindles providing substantially increased metal removal rates and increased productivity.

Angular wheelhead positional accuracy and repeatability are assured via a high precision 1° Hirth coupling. An optional true B axis programmable to 0.001° utilising feedback from a high accuracy encoder mounted directly to the rotational spindle axis, infinitely variable positional resolution can be achieved. The machine currently offers 650mm or 1000mm (25″ or 39″) between centres (with larger machine length capacities planned) and centre heights of 180mm, 200mm and 250mm (7″, 7¾” and 9¾”). The increased diameter capacity (of up to 500mm (19½”)) means there are options to cater for larger mass components up to 450Kg (990lb), and odd shaped components, which can result in high rotational inertia.

The UltraGrind machine uses a brand new Jones & Shipman’s proprietary Windows® based graphical programming software suite, which further builds on the success of the Easy software that removes the requirement for operators to input code, although ISO programming is fully supported and codes can be easily viewed and used if that is the customers preference. The user-friendly software is built around a Fanuc® 320i with touchscreen control system. This reduces the time needed for operator training, machining set-up and changeover times.

Simplicity does not limit flexibility, however. A full suite of dressing and grinding programs are available for the operator. Easy to follow Jones & Shipman set up pages allow the operator to digitise diamond and wheel positions by means of a simple user-friendly touch screen interface. Graphical images that represent programs and set-up are simply touched to program, providing quick and simple input. A wide range of additional options including gauging and autoloading are also available.

http://www.machinetoolsonline.com/article.mvc/More-Power-And-flexibility-

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