Grindstar Replaces Turning With Efficient Grinding

Junker’s Grindstar profile and cutoff grinding machines can replace turning through the use of dressing-free, high-speed, plunge-cut grinding. The company says this high-production concept can open up enormous potential for savings, in particular when working with large production volumes, thereby drastically reducing the cost per piece.

Using a profiled grinding wheel permits plunge-cut grinding of the entire workpiece contour within an extremely short processing period. In terms of quality, finished workpieces demonstrate substantially greater dimensional stability compared to conventional turning methods.

One machine can replace many individual steps. Complete grinding in a single machine significantly reduces process risks and unproductive time. It is said the process ensures manufactured parts are free of burrs. Also, convex or level face ends can be produced. Even difficult-to-machine materials which are impossible to machine using a lathe can also be ground. Soft and hard grinding are also possible.

These high-speed CBN grinding machines feature a CNC-controlled steady rest and a second Z-axis to enable faster cycle times, and increase the flexibility and length capacity of the machine. An in-process gauging system is said to improve the process stability.

The machine also includes turning and drilling tools for more complex geometries and even an in-process heat treatment capability, opening up more potential production options.

Minimal grinding times can be achieved with the Grindstar. This kind of grinding method can be used with both CBN and diamond as an abrasive. The machine is fitted with coolant technology which helps to extend tool life, as small chips are transported away by the cooling medium.

Two different grinding methods are used in the machine — plunge-cut grinding/profile grinding and cut-off grinding. The essential synergy effect is achieved by combining the two methods in a single clamping setup. It is also possible to collate similar parts (part families) to enable economical grinding to be achieved when working with smaller batch sizes.

Junker’s experts can adapt the system to meet the specific needs of each customer, from profiling through coating of the grinding wheels to the individual machine settings.