Grinding machine MTC 500 R130/CF, with working principle trough feed

AXIS DESCRIPTION.

AXIS CONTROLLED BY  CN CONTROL.

X1  axis for control wheel feeding and dressing

X7  axis for grinding wheel feeding and dresser feeding

Z3  axis for control wheel dresser translation

Z2  axis for grinding wheel dresser translation

SP1  Control wheel spindle revolution

SP2  Grinding wheel rpm (alternative not included in the price of the machine.)

CENTERLESS GRINDING MACHINE TYPE MTC 500  R130/CF

working capacity 1 to 150 mm dia.

4+1 controlled axis (X1-X7-Z2-Z3-SP1)  with CN

for plunge and through feed grinding.

 

BASE

welded steel, filled with special antivibration concrete.

Asynchronous three -phases motor Kw 45 – 4 poles, with star -delta starting complete with motor hanger and belt tensioner.

 

GRINDING WHEEL HEAD

with spindle housed on hydrodynamique self-aligning bushings preloaded and adjusted to thermal expansion

Drive through belt type PoliV

Rim speed of grinding wheel: 45/63 mt/sec

Grinding wheel dimensions:

max outside Ø 610 mm

min outside Ø 420 mm

hole Ø 305 mm

width 508(600) mm

CONTROL WHEEL HEAD

with spindle housed on fixed bearings made from special bronze.

Max slant of rest : -2° / +6°, adjustable through screw.

Operation through motor type Brushless, assembled on the rest.

Infinitely variable revolutions: 0 to 300 r.p.m.

Dressing speed: 300 rev.p.m.

Dimensions:

max outside Ø 305mm

min. outside Øext. 240 mm

inside Ø 127 mm

width 508(600) mm

GRINDING WHEEL DRESSER

X7 and Z2 axis controlled by CN.

It  can be  programmed for:

  • number of  dressing passes
  • stock removal for each pass
  • automatic dimension recovery for correction  of diameter to be ground
  • circular interpolation
  • linear interpolation

All programs are loaded directly to CNC by key board.

CONTROL WHEEL DRESSER.

X1 and Z3  axis controlled by  CN.

It  can be  programmed for:

  • number of  dressing passes
  • stock removal for each passes
  • automatic dimension recovery for correction  of diameter to be ground
  • circular interpolation
  • linear interpolation

All programs are loaded directly to CNC by key board.

GRINDING  WHEEL  SLIDES.

N.2 cast iron slides resting on the base with swivel possibilities against the work cross axis up to -1°/1°

Sliding capacity between upper and lower slide on square  guides  with hydrostatic sustenance.

Movement capacity on X7 axis through screw and ball nut screw driven by brushless motor for all working movements and thousandth dimensions corrections.

CONTROL  WHEEL  SLIDES.

N.2 cast iron slides resting on the base with swivel possibilities against the work cross axis up to ±0,5°

Sliding capacity between upper and lower slide on square  guides  with hydrostatic sustenance.

Movement capacity on X1 axis through screw and ball nut screw driven by brushless motor for all working movements and thousandth dimensions corrections.

HYDRAULIC AND LUBRICATION  INSTALLATION.

Equipped with:

-Lubrication pump type Dropsa for dresser slides for grinding and control wheel (Z2-Z3).

-Hydraulic installation for Grinding and Control wheel spindles.-Hydraulic installation for hydrostatic slides (X1-X7).

ELECTRICAL CABIN.

New electric system, control board with CN Siemens 840 D SL, operator’s panel OP10, Siemens servomotors for dressing slide with corresponding encoders, cables and licences for Siemens Software.

Preparation of PLC cycle for machine movements and CNC for grinding and dressing cycle.

Study and implementation of video pages for the operating panel OP 10 – according to standard MTC (registers, selectors, software, alarms, etc.). HMI of the machine will be in English language

LOADING BELT

Installation of a new loading belt, length 2 meter , able to feed the pins with external diameter from 20 to 40 mm

ANSWER BETWEEN POSITIVE AND NEGATIVE CORRECTION.

within  2 microns.

DIMENSIONS.

overall dimensions:   2.200 x  4.070 x height 2.260 mm.

WEIGHT: KG  20.000  about.

SIZE CORRECTION DEVICE.

Directly driven by  PLC, programmable to set the preselected corrections.

It can be driven both by drive board or by an automatic  gauge.

CN FOR PLUNGE OR THROUGH FEED GRINDING.

Electronic equipment suitable to execute all working movements of the machine:  pre-selected size corrections and automatic grinding  wheel dressing with dimensions compensation of part to be ground.

And for plunge work cycle:

  • rapid approach
  • working
  • finishing
  • dwell

rapid  return with programmed  speed and length for working speed and movement dimensions.

WHEEL MOUNT AND FLANGE.

An expressly made cast iron base with locking steel flange containing  the  grinding wheel spindle coupling cone.

It is suitable to lock the grinding wheel on the spindle in the correct working position.

TOOL HOLDING WORKREST BLADE FOR PLUNGE FEED GRINDING.

Such tool is used for locking the workrest  blade and it is made in such way  to allow the manual blade lift through adjusting screw.

N.1 CENTERLESS GRINDING MACHINE MOD. MTC 500  R130/CF equipped with 5 axis (X1-X7-Z2-Z3-SP1) CN CONTROL

Marposs wheel balancing system.

Automatic balancer. Special fixture housed inside the grinding wheel spindle permit the automatic/dynamic balancing of the grinding wheel.

Inverter for constant speed on grinding wheel from 33 to 60 m/s (VPC-SP2)

Magnetic and paper  coolant clarifier   – capacity 2600 lt – flow rate 300 lt/min

With: automatic valve for opening the coolant fluid to grinding wheel diamond, control wheel diamond, and working area.

Fume exhauster to be connected to the safety guards.

External grinding machine for groove and Dk, inner rings model: MTE 80 DR

  • Machine bed and vibration isolation pads
  • Wheel slide to positioning, working feed and dressing ( CNC axe ) X1 axis
  • Electro spindle  for grinding wheel support , 18 Kw of power , for 610 mm wheel diameter  and 60 m/ sec constant speed
  • Dressing by one full profile diamond roller installed on one slide above the GW slide X2 axis. The diamond roller is installed on one high precision spindle managed by electric motor able to turn at 4.500 rpm
  • Work head for work piece holding on hard metal shoes (centreless system) and magnetic clamping
  • Loading – unloading device, standard concept whit one arm
  • Inlet and outlet chute with demagnetizer in the outlet chute
  • Fluidic system, in accordance to EEC standards, coolant and pneumatic valve FESTO  lubrication VOGEL
  • Electrical cabinet with MITSUBISHI Q series  and GOT 2000  operator panel touch screen 10,4  color. HMI is as per our special grinding software to manage the machine.
  • Machine pre-arrangement for connection to a central coolant system.
  • Automatic wheel balancer. Acoustic emission system DITTEL and  acoustic emission for   grinding cycle
  • In-Process measuring system MARPOSS P3 ME, plus head R 26 gauge head.
  • One set of tools for test the machine and one wheel from Carborundum Universal..
  • Safety cover to contain the leakage and to preserve the safety of workers, as per CE standards
  • Machine book and all technical documentations in English language.

Internal grinding machine for groove of outer rings model: MTI 80

  • Machine bed and vibration isolation pads
  • Longitudinal slide for wheel positioning (Z axis)
  • Cross-feed slide for work head positioning and working feed (X axis)
  • Dressing unit made by a device fixed on work head slide able to move up and down the dressing tool
  • Work head for work piece holding on hard metal shoes (centreless system) and magnetic clamping.
  • Loading – unloading chuck, fixed on work head housing .
  • Inlet and outlet channel, as to bring the rings from the outside and unload the rings after grind to outside. On the outlet channel a demagnetizer is installed.
  • Housing and safety cover for GMN electro spindle.
  • Safety cover to avoid any leakage and to protect the workers, as per CE standards
  • Electrical cabinet with MITSUBISHI Q series and GOT 2000 operator panel touch screen 10,4 “ colour. HMI is as per our special grinding software to manage the machine and in English language.
  • Machine pre-arrangement as connection to a central coolant system.
  • Fluidic system , in accord to EEC standards , coolant and pneumatic valve FESTO, lubrication VOGEL for slide and ball screw
  • Basic tooling for one kind of ring
  • In-Process measuring system MARPOSS P 3ME plus head Minithruvar
  • Acoustic emission system DITTEL or SBS , for rapid stop and power adaption grinding cycle.
  • One set of tooling to test the machine and one wheel from Carborundum Universal.

  Machine book and all technical documentations in English language.

Double face grinding machine MTD 300 SP -R

  • Machine bed and vibration isolation pads
  • N° 2 slides to support grinding wheel spindle, on bush guide + ball screw and brushless motor
  • N° 2 grinding wheel spindles with high precision bearings, managed by asynchronous motor. The diameter of the wheel is 300 mm, power of motor is 18 Kw, operational speed is 2800 rpm.
  • Special cover for protection working area and fitting dressing arm.
  • Dressing arm, with multi point tool, managed by servo motor brushless + gear box
  • Special rotary loading – unloading system to take the needle  from outside into the wheel, in working area, range of loading from 2 to 10 mm diameter.The rotation of disc is managed by gear box + brushless motor and is fixed by a mechanical stopper .  The axial position of  loading device is adjusted by a manual register .
  • Fluidic system according to EEC standards.
  • Electrical cabinet with SIEMENS 828 D CN and OP operator panel. HMI is as per our special grinding software to manage the machine and is in English language.
  • The machine is provided with one tools set for 1 specific product.
  • Safety cover for contain the leakage and the safety of worker , as per CE standards

Machine book and all technical documentations are in English language.

 Double face grinding machine MTD 300 SP – Tech spec
Operation Grinding of two face
Min OD diameter 2 mm
Max OD diameter 10 mm
Min width 5 mm
Max width ring 30 mm
Diameter of wheel 300 mm
Width of new wheel 50 mm
Max speed of wheel 45 m/ sec
Resolution of axis 0,0001 mm
Precision of positioning 0,001 mm
Total installed power 40 Kw
Power supply 400 V 50 Hz
Air consumption 200 l/min
Air pressure supply 5 bar
Coolant required 120 l / min
Noise level Machine weight less than 75 dB
Wheel balancing device no
Gap eliminator no
Electrical componet SIEMENS
Pneumatic componet FESTO
Ball screw Standard DIN nut SKF or THK
Spindle High precision bearing ,  Driven belt + frequency converter
CNC SIEMENS  828 D solution line safety integrated
Operator pannel TFT 10,4 ” color and qwerty keybboard
CE mark Yes

Centreless machine MTC 500 R for tapered rollers

The machine is designed to grind tapered rollers and consists of the following groups:

  • Machine structure
  • Grinding wheel slide
  • Roller support blade
  • Regulating wheel slide
  • Grinding wheel dressing system
  • Feeding system
  • Machine control system
  • Guarding
  • Cooling system
  • Electrical cabinet

Machine structure is made with an electro-welded cast iron structure, stabilized, that carries all mechanical groups, utilities, pneumatic, electric and hydraulic systems. It sits on rubber adjustable shoes to allow the machine positioning and alignment.

The machine cabinet is designed to avoid undesired spills but in any case a steel tray is always part of the supply.

The machine structure carrys the slides for the grinding and regulating wheels as well as the support blade.

The pneumatic system and the lubrication system are located on the main machine structure to allow quick and safe adjustments and controls by the production operators and setters.

The grinding wheel is a Carborundum Universal resinoid type with the following specifications:

  • Outer diameter: 610 mm
  • width: 600 mm
  • inner diameter: 304 mm
  • maximum cutting speed: 45 m/s

It is located on a hydrostatic slide moved by a system composed by a brushless motor and a ball screw of Umbra.

The slide is designed to ensure trouble free operation and easy scheduled maintenance. The grinding wheel is mounted on a hydrodynamic spindle , equipped with a self balancing unit.

The slide is equipped with automatic lubrication system controlled by the electronics to ensure proper operation condition and production accuracy.

The rollers are supported, during machining, by a steel support blade located in fixed position on the machine structure. Such blade is designed with hard wear resistant carbide inserts that ensure long life operation and high quality on machined parts.

The rollers are supported, during machining, by a steel support blade located in fixed position on the machine structure. Such blade is designed with hard wear resistant carbide inserts that ensure long life operation and high quality on machined parts.

The blade is mounted with suitable spacers to adjust the roller position inside the grinder and to achieve the best working geometry.

Those spacers are interchangeable to allow different blade installation and to compensate normal blade consumption during operation and periodical refurbishment. A multiple bolt locking system ensures the maximum stiffness and vibration free operation.

The second main machine hydrostatic slide takes care to support the regulating wheels and related systems. It is moved by a brushless motor and a ball screw system, sized to ensure a long life and low maintenance operation.

The regulating wheel support system ensures a quick change over and allows also vertical and angular adjustments for an optimal setup and fine adjustment even in case of minor geometrical variations in the tooling set, usual during normal production, frequent tooling repair and machine setup.

Those adjustment systems is equipped with measuring gauges to ensure a reliable and repetitive positioning during change overs and normal operations. The Carborundum Universal regulating wheel is acted by brushless motor and an angular gearbox and is able to run from 0 to 1000  RPM.

The grinding wheel dressing device is located on the grinding wheel slide. It is composed by two cross-mounted high precision hydrostatic slides. Both slides are controlled by brushless motors and roller screws and take care of the longitudinal movement of the dressing device on the grinding wheel and the dressing compensation.

To guarantee a perfect wheel profile the dressing device position is controlled by a template that avoid undesired vibrations, therefore low dressing quality. The system is designed to mount both single point, blade or cluster type diamonds and is equipped with an automatic device rotation system.

The raw rollers are loaded into the machine using a roller pump. Their ingress into the regulating wheel, therefore in the grinding process, is acted by a rubber block and hydraulic actuator.

This system guarantees trouble free operation and just requires size specific components to ensure a quick change over.

The electronic control system is designed to fully control all machine functions and setup. The CNC takes care of the following operations:

  • grinding wheel positioning and fine size adjustment;
  • regulating wheel horizontal positioning;
  • grinding wheel dressing cycle;
  • grinding wheel cutting speed;
  • regulating wheel feeding speed;
  • size compensation using external measuring devices.

The pneumatic unit and related components are positioned on the machine base, together with the lubrication system. The CNC and the control keyboard and buttons are located in a hanging air cooled cabinet directly connected to the machine frame.

A box with emergency stop button and manual size adjustments is located on the machine side, to allow quick manual adjustment, if required.

The system is designed to store all produced p/n data with a maximum of 50 p/ns. In any case the Customer has opportunity to choose the produced p/n from a list and all machining parameters are automatically recalled to set the machine.

The machine guarding is equipped with an exhaust tube to allow oil mist evacuation with local or central systems. The machine enclosure is designed to guarantee total safety protection during operation, according to latest international standards. The enclosure is designed to prevent cooling fluid spills as well.

The machine is equipped with opening doors and inspection safety windows. During normal grinding operation the machine doors are automatically interlocked to prevent any undesired risk for operators and setters. The door interlocks aren’t released until the spindle has completely stopped and the cooling flow has been switched off.

The piece cooling and chip removal during machining is guaranteed by the coolant supply system. The machine is equipped with a main valve and a distribution manifold. The coolant flow is provided by the Customer system at the desired pressure.

Two main circuits supply the coolant to the machining zone using metal nozzle blade and/or shoe tipe.mTwo secondary circuits provide periodical machine cleaning to remove metal chips and swarf.

The machine structure acts as a tray and the used coolant is recovered from the machine bottom by gravity. No auxiliary tank or pump is part of this supply.

The machine is fed by a 5 bar compressed dry air system. A safety control system prevents operations in case the air pressure drops below a minimum value.

A cooled electrical cabinet contains all equipments and is positioned close to the machine main body. At least 25% free space is available inside the cabinet.

The grinding machine change-over time will take no longer than 60 minutes

Following the rough grinder a belt conveyor ensures the transportation of the machined rollers to the pre-finish centerless machine. It is a special rubber type straight conveyor and is equipped with the following features:

  • sensors to detect presence/absence of rollers;
  • system to detect inverted rollers;
  • contrast wheel system to ensure roller feeding to the pre-finish machine, avoiding any additional belt;
  • automatic roller gauge system.

The roller conveyor is connected to the rough and pre-finish grinder in a way to ensure a quick change over time. The roller conveyor electrical and control systems is located in the rough centerless grinder electrical cabinet.

The conveyor change-over time takes no longer than 10 minutes.

This roller gauge system, positioned on the roller conveyor, is responsible to keep the roller race size inside the required tolerances, communicating with the rough centerless grinder machine CNC to adjust the machining size according live roller measurement.

The system is designed with an universal gauging system based on Marposs LVDT probe and electronic unit and uses p/n specific measurement shoes.

During normal operation, with a specified frequency according roller size and cycle time, a machined component is automatically picked up from the conveyor and positioned on the measurement shoe. The Marposs gauge automatically detects the roller body size and the difference between the actual measurement and the nominal value.

The system is able to automatically compensate for size differences if the rollers are found inside the required tolerances and, in case the rollers are outside those specifications, to manage at the same time the machine control and the scrap of out of conformance rollers.

The measurement frequency is set to ensure reliable process without requiring a time consuming 100% control.

The roller gauge control systems is located in the hanging cabinet directly connected to the machine frame and that contains the CNC main panel.

The gauge system change-over time takes no longer than 10 minutes.

End-face grinder machine for taper rollers (MTF130)

Machine base is in electro welded steel structure, heat treated and machined, with levelling pads.

Rotary disc transports the rollers from the inlet station to the working station, where a special shoe in PCD materiali s fixed. The rotary disk step by step rotation is managed by servo motor.

Pressure clamp by regulation wheel with all the necessary adjustments is managed by servo motor.

The pressure clamp wheel rotation is managed by a special gear box, plus asyncronous motor controlled by frequency converter.

Grinding wheel spindle is positione on one side, as to feed the wearing of the grinding wheel by air sensor and servo motor. The grinding wheel spindle rotation is managed by a special spindle servomotor connected on the same axis of the spindle and it is water cooled.

All the adjustments needs as to set up and resetting the machine will be managed by servomotor in automatic way.

The machine is equipped with all the necessary fluidic devices, lubrication, pneumatic and coolant.

Safety cover as per CE rules.

Electric cabinet to manage the whole machine is with SIEMENS S 7 300 series, brushless motor and card, digital 1 FT7 series and operator panel touch screen 10.4 “ color as to manage all the HMI and parameters.

Technical documentation, hand book and all the diagrams are supplied with machine as per CE marking and certification.

All the grinding machines supplied through ICT can be designed and developed according to the specific customer demands. Whatever is your request and technical expectation about your grinding needs, just get in touch with us at info@consulting-trading.com or through the contact form of this page to provide your inputs. We will provide our feedbacks in a very short time.

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