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Totally new machine concept to be introduced by Kellenberger at EMO 2017
The strength, diversity and technical expertise of member companies in the Hardinge Grinding Group has resulted in Group member Kellenberger creating a highly innovative new machine concept – Kellenberger 100 – that will be debuted at the forthcoming EMO trade fair.
Kellenberger and other Group members – Voumard, Hauser, Tschudin and Usach -are all represented in the UK by Leicester based Jones & Shipman who in their own right offer an extensive range of universal and cylindrical grinders.
The Kellenberger 100 series platform sees the high-performance, economical grinder segment in the Group’s portfolio being completely overhauled to make it fit for future
manufacturing demands. Based on a modular design, it incorporates key elements of Kellenberger’s Vista and Vita model ranges, the Jones & Shipman Ultramat CNC and Ultragrind 1000 and the Tschudin T25, aspects of which have been integrated into the new range.
The challenge presented to the Kellenberger engineers in St. Gallen, Switzerland, was to develop a platform on which diverse machine concepts could be realised totally in line with customer budgets and performance expectations. In effect, offering the most diverse range of configurations to achieve the widest range of grinding operations at a highly competitive price.
In terms of functionality the new 100 platform far exceeds the capabilities of many existing grinding machines. Because of its modular configuration, assembly of 100 series machines is simplified making it possible to optimize manufacturing costs for the machine and ensure an excellent price/performance ratio for the purchaser. Numerous ‘standard’ options can put the customer’s finishing touches on each individual machine.
The user-friendly and ergonomic design of the Kellenberger 100 machines also features a new, simple operator guidance system with an intuitive touchscreen panel. The machines are equipped with the latest Fanuc 31i CNC controls with 19″ touchscreen and a newly designed cycle programming or workpiece-related graphic programming is an option.
Other features include an innovative, collision-free, compact tandem wheelhead, the ability to fit larger grinding wheel diameters for internal grinding and a choice of ten wheelhead variations for optimum layout of the machine dictated by the components to be processed.
There is also increased drive power at the grinding wheel, a newly designed Z guideway and a C axis with direct drive for high precision, non-circular grinding.
Finally, there is a service-friendly design permitting faster maintenance and service operations with good access to components requiring frequent attention.
The machine featured at EMO will be the 1000mm between centres variant, the other option being a 600mm unit.
Other machines featured on the Hardinge Grinding Group stand are a Kellenberger Varia and a Hauser H40 although representatives of all Group companies will be present throughout the show.
Kellenberger Varia 1000
With more than 1000 Kel Varia machines in use worldwide, the VARIA universal cylindrical grinding machine model range DNA has long stood for the best in working and surface quality among Kellenberger’s range of products. It has consistently been upgraded throughout its 20 year life but now, with its larger work space, distinctly longer machine table and distance between centers of 1600 mm, it is equipped for a very wide range of machining possibilities.
Aimed at demanding environments involved in high-precision production of prototypes and small and medium-size components, typical areas of use include machine construction, the production of tools and moulds, the fabrication of precision components for the automotive, electronics and aircraft industries and sub-contract shops with their wide variety of needs.
Latest generation machines feature ultra precise hydrostatic guideways to provide excellent damping, stick and slip-free operation, high rigidity and a constant machine temperature, resulting in outstanding surface quality and more process and operation reliability without any friction loss and wear. Because of the direct drives on the rotary axes, fast positioning speeds and accuracy are guaranteed.
Stability is crucial for achieving high precision and productivity and the solid machine table with the reinforced machine bed once again improves rigidity. The increase in stability means VARIA can now work with workpieces of up to 300 kg.
Drives are optimized for performance moving the longitudinal and cross slides at speeds of up to 20 m/min and at an axis resolution of ten nanometers. The hydrostatic B axis is also equipped with a direct drive. This means that the revolving wheelhead pivots roughly three times as fast as without a direct drive and positions with a precision of less than one arc second.
The VARIA is available with distances between centers of either 1000 or 1600 millimeters, and heights of centers of either 200/250 or 300 mm as required. More than 30 wheelhead variations with external and internal grinding spindles permit an array of machining possibilities and the right application-specific configuration at all times.
The H40-400 is the successor to the well-positioned H35-400 model, which set industry benchmarks in terms of precision and performance in the jig grinder sector. Like the H35, the H40 is a universal jig grinder with proven technical features such as automatic taper grinding, automatic grinding tool changer (ATC) and automatic pallet changer (APC). It can be expanded easily to an autonomous grinding unit.
The new H40 not only meets the demand of the market for combined grinding and hard milling on a single jig grinder, but also enables further improvements in machining precision to meet future requirements.
The main technical feature is the dual-frame design, which significantly increases the rigidity of the grinder and therefore ensures even higher precision. In this box-type design, the machining head is positioned centrally within the machine frame, thus enabling machining forces to be optimally controlled. Almost no transverse forces are created – the prerequisite for ultra-high geometric precision machining. Since the tool machining point is located at the center of the machine, practically all thermal expansion effects are eliminated.
With higher dynamic axis movements and significantly greater rigidity, the H40 gives the best possible conditions for finishing with hard precision milling. The overall result is a significant increase in productivity not just for hard milling but for ultra-precise grinding processes.