subject: Shaft Grinding Process Design: Flexible Manufacturing Is The Core [print this page] For machine tool manufacturers, the automotive industry is the most challenging areas. Automobile industry in the production of quality, cycle times , single- piece cost, annual production , programming and equipment availability, etc. have put forward high requirements. In compliance with certification requirements , corporate standards, and the premise of charter providers , the maximum total amount of investment and after-sales service is also facing increasing challenges and pressures . The new model put in the market increasingly shorter product cycle for the continuous fine-tuning machine has a direct impact , the impact of technology is reflected in both the design and machine configuration . If successful in the market , the international reputation and a large number of items orders will follow. And want to do business with car manufacturers must make the point that is flexible, but also very flexible.
Branching process of an arbitrary operation
Despite such a diversity of framework conditions , in Nuodelahe grinding equipment manufacturers Yong Ke Group has successfully become the car manufacturers over the years, technology partners .
European Automotive Group in Southern Europe in a gearbox factory built , and shaft grinding process design was entrusted to the JUNKER . Potential technology partners , including the production requirements of the two hardened steel grinding the whole shaft ( drive shaft and output shaft ) . Cut -style grinding methods including grinding , face grinding and cylindrical grinding all . In other words, the whole shape contour grinding . Machine tool business to pursue the goal of gearbox production is based on how each branch of the central belt process ( turning, milling, grinding , etc.) to any order for flexible operation , so that small batches or single product to achieve the necessary grinding Operation and grinding parameters change .
When the fit tolerance of about 10m , the machine capability index (cmk) should be between 1.67 to 2.0 . Yong Ke machine has a complete integration of process measurement systems and closed-loop control circuit , can well deal with these issues. In addition, the machinery manufacturers must adapt to the commissioning provider with a single piece bracket and RFID identification chip parts logistics workpiece conveyor belt to ensure that the machine tool and the workpiece within the bracket up and down between the automatic workpiece material . "HMI pro" software from the control device manufacturer Siemens set up , customers for production personnel to establish a unified user interface .
Machine tool business to pursue the goal of gearbox production is based on how each branch of the central belt process ( turning, milling, grinding , etc.) to any order for flexible operation , so that small batches or single product to achieve the necessary grinding Operation and grinding parameters change . In theory, the minimum volume is 1.
Quality and efficient grinding : left on the device used in the EJ50 plated grinding wheels for straight plunge grinding ; the right is the device used in the EJ50 vitrified CBN grinding wheels for the Seamless grinding .
Series production is better than complete processing
Yong Ke experts to further the basic conditions must be taken into account : According to the planned output , the practical application of production schedules and machine availability statistics, including the loading and unloading time to calculate the grinding process , including target cycle times . Yong Ke Group Automotive Division project manager , referring to when the last successful evaluation of the program , said : CBN grinding technology with high efficiency grinding in the field of experience , Yong Ke raised the overall processing solutions. But this package does not help us achieve our goals , because followed by a significant increase in the total investment in equipment . In comparison, the cut into the separate -type grinding and face grinding , and conduct all the contour grinding will save additional costs . Drive shaft through a series of tests to finalize the program can guarantee product quality , production process is quite stable .
Annual capacity of 400,000 for the root of the drive shaft , the customer uses two independent production lines Yong Ke program : a production of two drive shaft of the processing line ( manual and automatic transmission ) from two "Jumat5000/50s" CBN Grinding To cut into the grinding , three "Quickpoint 3000/60" HSG cylindrical grinding machine for grinding contour . Another production of two processing lines from the output shaft of the three "EJ50" constitutes a direct cut into the cylindrical grinder , one of the grinder to cut into the process , another two were no trace contour grinding machine grinding .
The project proved that the existing partnership and within the framework of the principles of cost control , can be original equipment supplier (OEM) into technology providers. Only one wheel in order to make the first frame of the EJ50 grinder can process two different lengths of the output shaft , in product design, according to the project of two spindle types of pairs of cutting methods were designed to adjust accordingly so that you can use the same wheel Group processing , and axial positioning device with integrated grinding wheels can be adjusted to the correct location . Jumat and Quickpoint has B -axis grinding for , you can rotate the workpiece through the week on two different sets of wheels for easy and quick positioning.
With the chip down rapid workpiece material and logistics control
In order to achieve shorter cycle times , on the one hand must be achieved with high efficiency grinding . Not trimmed by the cutting process for plating wheel , profile processing is within the dressing with the machine after the completion of vitrified CBN grinding wheel . On the other hand , workpiece setup time must be included in the rhythm of time , the built-in feeding robot programs which highlight the advantages of out . When the external loading robot must wait for the end of the grinding process , until the loading window can be opened, the built-in loading and unloading have been using W -type robot gripper will be sent to the next workpiece spindle in the vicinity . As the machine has high rigidity , loading and unloading robot will not have any impact on the grinding process , while the built-in online measurement can guarantee product quality and increase process safety .
In addition to the utilization rate of machine tools , machine tools Dress frequency and duration is one of the factors affecting output . In the case of Cut -type grinding , grinding wheel life of close to 20,000 shaft , so as long as the replacement of two to three times a year, grinding wheels , using machine tools Dress assist device can dress up time reduced to 30-60 Minutes . In order to exclude possible interference of the greatest concept of flexible production , machine tools also specially equipped with RFID chips installed in the workpiece holder . Was taken to machine the workpiece before , shaft type and processing status information will be confirmed , if necessary, and the top end of frame position , the use of such grinding wheels grinding machine configuration and modify NC programs . Before the program opens , will the ratings of shaft geometry and the actual values again reasonable test . Once the deviation , will be sorting shaft . After processing is required on the workpiece holder chip to store data to be updated.
Pre-production , production, production upgrade
The first eight machine tools in Nuodelahe for acceptance, have been shipped . Yong Ke equipment customers are given full satisfaction rating: the current project, Yong Ke provide persuasive overall program . Compared with most suppliers , Yong gram scheme can save more equipment investment . In addition, grinding on the same platform , multi- model flexible manufacturing high shaft can be achieved without manual operation , and therefore can more quickly adapt to market demand . In the pre-production and production stage , Yong Ke also provides a high level of staff to assist. As for the service , courage grams and its partners Tecmi provide users , including the timely support , including spare parts supply .
