POWER OF SIMULTANEOUS MULTI-STATION GRINDING

RTG is a multi-station grinder built with the challenge of obtaining high production rates and a complete tool in a single machine without sacrificing tool quality. The machine consists of four separate stations, three grinding stations and a loading station. A vertical column mounted through the center of the machine base is equipped with an index table featuring six collet workheads that are mounted vertically with the collet facing downward. This machine concept combines the production rate benefits of a cell grinding operation with the quality benefits of producing a complete tool in one clamping such as drills, endmills, or similar tools. The standard machine is equipped with up to 20 + 6 CNC axes, automatic lubrication system, grinding coolant assembly, 3 grinding stations, 6 collet workheads and all necessary grinding spindles.

HOW IT WORKS

The Fanuc™ robot loads a tool to the first station while grinding operations are already in process in each of the later stations. The table will be indexed at the end of each grinding cycle. Once all six collets have been loaded, the cycle time for the machine is equivalent to the time of the longest operation plus the time between table indexes. This dramatically reduces production time, yet tool quality is not sacrificed because each tool is only clamped once. In addition, the tools are
supported ideally in each grinding station and wheel configuration can be maximized to 10in. or 250mm. RTG has the ability to grind parts in collets and between-centers. In the fixed collet scenario, parts are ground inside a precision bushing and on a traveling steady-rest tool support. In the floating collet scenario, parts are held between the collet and a precision center which travels and provides the support required for tight tolerance grinding.

THE PRODUCTION DILEMMA SOLVED

Production is the key factor in tool manufacturing. The challenge is obtaining high production rates without sacrificing tool quality. Traditionally this has left manufacturers with one of two choices; produce tools complete in one machine or use a grinding cell concept. Producing tools complete, in a single machine, helps to ensure tool quality by eliminating multiple clampings, but results in longer cycle times. The only way to shorten these cycle times is to increase feedrates; often resulting in undesirable surface finishes.

The RTG Multi Station Grinder was built with these limitations in mind. This machine concept combines the production rate benefits of a cell grinding operation with the quality benefits of producing a complete Tool (Drills, Endmills or similar Tools) in one clamping. RTG resembles a compact grinding cell consisting of up to 5 precision grinding stations connected by a high speed rotary transfer mechanism! The RTG stations can be configured to grind Flutes, OD-Relief, Points, Face, Counterborers, Chamfer, Groves, Endteeth, Endface ID, flip parts, and production of parts that require multiple surfaces to be ground. With up to 20 + 6 CNC controlled axes, setup time is fast (less than 15 minutes), making the machine economical for both large or small production runs.

For further information regarding ITM’s Rotary Transfer Grinders, contact us at (386) 585-8166