CBN Camshaft Grinders · 2019-02-07 · CBN Camshaft Grinders U.S.Patent on the Machine:4,963,805...
Transcript of CBN Camshaft Grinders · 2019-02-07 · CBN Camshaft Grinders U.S.Patent on the Machine:4,963,805...
Information presented in this brochure is subject to change without prior notice.Available machines or machines shown may vary depending on optional equipment or periodic design changes.The export of products defined as restricted commodities (or technologies) under Japan's "Foreign Exchange and Foreign Trade Act" requires an export license issued by the Japanese Government. Furthermore, similar licenses may be required for re-transfer, re-sale or re-export of such products, therefore please do not fail to contact JTEKT in advance. In order to observe laws and regulations and prevent inappropriate export, re-sale and relocation, JTEKT has equipped all of our NC machine tools with devices that detect relocation. If this device is activated, the machine will cease operation and will not restart until it has been checked by JTEKT. JTEKT may refuse to restart the machine should it be deemed that such an action would amount to the inappropriate export of a commodity or technology, or violate export regulations. In such a case, JTEKT will not be liable for any damages arising from the refusal to restart machine operation and do not bear any liability to perform services pertaining to product warranty.Please contact your JTEKT representative for details. Always read manuals carefully before using any machinery to ensure safe and proper use.
Type of Machinery:Grinder Model Number: GC20Mi©JTEKT CORPORATION 2013Cat. No. M21113E Printed in Japan 131101U
This publication was made using recycled paper for the protection of forests.
CBN Camshaft Grinders
CBN Camshaft Grinders
U.S.Patent on the Machine:4,963,805 and othersThe grinder in the photo is a GC20Mi-63.The grinder in this photo has special specifications.Note : Painting color shall be specified by mutual agreement.
● High-accuracy grinding promising a high accuracy grinding surface.● High-rigidity bed reducing thermal displacement and improving chattering accuracy.
Latest camshaft grinders with linear motor drive.
High-accuracy
● Improved reliability with TOYOPUC-GC70. ● Simplification of wheel replacement.
● Achieving high-speed grinding of difficult-to-cut material.● Reduction of set-up changeover time.
Improvement of productivity
Reassuring operation
Cam shaft for automotive engines
Grinding result
FCD700120m/s4mm
MaterialWheel surface speedStock removal
Actual grinding timeProfile accuracySurface roughness
12s/2cam+5μm~ -1μm1.6 mRz
Profile accuracy +5μm~ -1μm Surface roughness 1.6 mRz
20 m20 m
2.5 m
2.5 m
01 02
High-rigidity bed reducing thermal displacement and improving chattering accuracy.
50%
● High-response wheelhead feed mechanism ● High-response servo system
Reliable and high accuracy High accuracy grinding promising a high quality grinding surface.
Quick-response wheelhead feed mechanism adopting light-weighted wheelhead, static pressure slide way and linear motor drive achieves the wheelhead feed having almost free from lost-motion and backlash.The newly developed high response servo system and high response feed mechanism enhance the accuracy and quality of pin and journal grinding surface
Reduced thermal displacement between wheel and center through optimized rib arrangement and heatproof material as a result of bed thermal analysis.
Avoid resonance caused by wheel rotation frequency through bed eigenvalue analysis.
Difference in relative displacement between headstock and tailstock.
High-accuracy
Stable high-grade grinding
(when φ350mm, 120m/s)
55% reduction
Conventional GC20Mi
Thermal displacement between wheel and center
Conventional GC20Mi
SERCOS*
CNC
High-response wheelhead feed High-response servo system
Linear scale
Linear motor
Servo amplifier
Hydrostatic slide
Grinding wheelWorkpiece
Workhead
TOYOPUC-GC70
* A registered trademark of SERCOS International e.V.
reduction
g espo se ee ead eed
78% reduction0.5
1
0Following error between
no-load and grinding states
Static pressure screw feed Linear motor feed
(Index) Following capability improved with linear motor feed.
Compared with a static thread feeder, wheelhead feed (X axis) following accuracy has improved 4 times.
Profile accuracy* Example of eccentric circle grinding. The result differs depending on profile.
2020μm20μm
g p y
75% reduction2
4
0Following accuracy
Static pressure screw feed Linear motor feed
(Index) Following capability improved with high gain servo.
3-point support bed
● Illustration of 3D design development model ● 3-point support bed
By adopting the 3-point support system, changes in the bed support rigidity caused by changes in the ground surface is minimal, making long-term, stable grinding accuracy possible
Sensor thermal displacement compensation
Thermal displacement compensation by sensor yes
Spec ±0.04mmDatum dimension
15min※Headstock
Weelhead
Footstock
■ Eddy current type gap sensor
■Measuring block
Indexes to the datum position and measures thermal displacement by measuring this dimension.
Conventional Time required for warm-up operation
Thermal displacement compensation by sensor no
The thermal displacement caused by the difference in machine temperature between the previous day and the morning of the current day is compensated with a sensor, reducing warm-up cycle time. A long-term stable machining accuracy can be maintained.
Equipped with the extremely rigid hybrid-type TOYODA STAT BEARING which provides no metal-to-metal contact and has a high vibration damping capacity, this grinder assures high accuracy and a long service life.High accuracy grinding and longevity of the machine is achieved by using proven JTEKT spindle technology.
Featuring the JTEKT original TOYODA STAT BEARING as the wheel spindle, the heart of the machine
Pressure from pump
Hydrostatic pressure
Pressure from pump
Hydrostatic pressure
Hydrodynamicpressure
■Spindle at restHydrostatic pressure lifts and holdsthe wheel spindle firmlyat the bearing center position.
■Rotation spindleCombination of hydrostatic and hydrodynamicpressures improves spindle rigidityand vibration absorbing performance.
Grindingforce
03 04
High-accuracyPlatformPlatformHigh-accuracy
Realizes high-speed machining of the material being difficult to machine
Keep the grinding removal amount per one rotation of the cam by adoption of work spindle stepless speed control to the best level. Therefore, the leveling of grinding resistance can be done and improvement of profile accuracy and shortening of cycle time can be done at same time.
Improvement of productivity
Directly detects contact between the wheel and diamond roll and cuts in a certain amount from that position, therefore the truing amount is optimal and a stable cut is achieved each time truing is performed.
Safety automatic position memory
Run-out removal, truing, position memory and so on is performed automatically after wheel replacement making work easy and alleviating the workload.
Direct detection type truing system
Reduction of set-up changeover time
We also have set-up changeover items prepared which can respond to workpieces with difference lengths and diameters. This significantly reduces set-up changeover time, contributing to productivity improvement.
●Difference in journal position・Rest traverse specification
●Difference in journal diameter・Supports rest automatic diameter difference
NC spindle movement function
CBN wheel
Truing roll
NC automaticdistance adjustment between centers
Workhead
Workhead
Footstock
Footstock
●Difference in workpiece length ・Live spindle workhead with NC spindle movement function・Tailstock with NC automatic distance adjustment between centers
●Difference in workpiece length ・Live spindle workhead with NC spindle movement function・Tailstock with NC automatic distance adjustment between centers
180°
0°
θ
270° 90°
Cam0° 90°
Conventional grinderGCS
GC20Mi
180° 270°
0° 90° 180° 270°
Grinding removal rate
Grinding removal rate
Work spindle
rotation speed
Work spindle
rotation speed
Time
Time25%Reduced*
One rotation of cam
One rotation of cam
360°360°360°
※ Grinding removal rate = Grinding removal efficiency per angle unit * Result differs depending on profile.
360°360°360°
05 06
Reduction of grinding time & non-grinding time.
Improvement of productivity Details of functions Improvement of productivityDetails of functions
Interference Range
Inching / Handle Mode Axis in motion
Workpiece Workpiece
Retraction of grinding wheelhead
Displays motion direction before operation
Shows motion direction in color
Reassuring operation
Improved reliability with TOYOPUC-GC70.
Stable operation at first-piece grinding and handle operation.
At first-piece automatic grinding and handle operation after set-up changeover, speed is limited within preset interference zones so operations can be performed with reassurance.
Prevention of incorrect manual operation
The GF50Mi Series is equipped with a support function which displays motion direction and notifies the operator of incorrect operations, in order to avoid interference by erroneous operation direction.
Protection against grinding wheel damage during power failure
The grinding wheel is separated from the workpiece if a power failure is detected, thereby protecting against grinding wheel damage.
Letter display
Screen in operation status
Icon display
Iconized operation buttons
Operations can be easily recognized through iconized operation buttons. Buttons can be switched from icons to letters.
Position memory screen
Perfected guidance function
Setup change, maintenance details, input data explanation, etc. can be easily understood from the graphical operation screen, and operations can be carried out smoothly.
Fault lamp Fault display Circuit monitor
Fault occurrence
Simple fault diagnostics
Fault locations are diagnosed directly on the CNC screen from the error display and the circuit monitor.
Perfected preventative maintenance support function
Defective workpieces and machine malfunctions can be discovered early by comparing normal values sampled from electrical current, position deviations, speed data, etc.
Data batch backup function
Allows the batch saving of all data, including grinding conditions, compensation data, parameters, etc. This function can also be of use in fault analysis of machine stoppage.
The intelligent-oriented functions simplify the job and ensure higher accuracy
● Various functions ensure accuracy become standard accessories.
Functions to ensure accuracy such as the F.B. error data smoothing function, the cam lift data smoothing function, the measurement error compensation function and the cam processing analysis function become standard accessories.
Setup of automatic work spindle rotation speed
Wheelhead
FootstockWorkhead
At unanticipated power failure due to lightening, etc.
During grinding
Grinding wheel
Grinding wheel
07 08
Reassuring operation Details of functions Reassuring operationDetails of functions
Reassuring operation
Best design limiting coolant splash range
Reduction in power consumption per workpiece.
Rear side
A local cover concept is used to limit the coolant splash range, and the tailstock and wheelhead, where motors, pressure switches and other electronic devices are concentrated, have been located outside the coolant splash range
An excellent machine configuration for coolant collection.
Designed with optimum slope and a coolant collection route structure that does not disturb chip flow. This has improved coolant flow, reduced chip accumulation and contributed to the shortening of cleaning time.
Centralized arrangement of devices considering workability.
Maintainability has been improved through centralized arrangement of the coolant device panel and the pneumatic device panel.
Simplification of wheel replacement.
Improved proximity to wheel at wheel replacement and adopted a slide method for the upper cover on the wheel replacement side, improving workability.
Reduced power consumption by 13% of conventional grinder GC20M and 27% of conventional grinder GCS through the following measures: - Adopting an energy-saving pump- Eliminating the circulating filter circuit pump by improving cleaning level - Shortening warm-up operation through a low thermal displacement bed- Shortening cycle-time by a wheel with high grinding efficiency and improved sharpness
Wheel - bed end distance 50% reduction
Conventional
660
320
GC20Mi
Conventional grinder(GCS)
(index)
(mm)
10084
Conventional grinder(GC20M)
GC20Mi
27%
73
Annual pow
er consumption
Vertical cover preventing coolant splash Front side
09 10
Reassuring operation Details of functions Reassuring operationDetails of functions
Machine Specifications
TOYOPUC®-GC70 CNC specifications
GC20Mi Recommended package accessory list
Item No. Recommended package accessories
Standard accessories
■Supports one type of workpiece ■Center distance 630mm ■Live spindle workhead (without NC spindle movement function) ■Hydraulic type tailstock (hydraulic stroke: 60mm) ■Carbide tipped center (one each for right and left) ■Wheelspindle (φ350mm) ■Wheel peripheral speed (22kW, 120m/s)■Automatic open/close cover ■Duct opening for dust collector ■Machine transplant detection ■Circular coolant tank (tank capacity 720L) (accessories: magnetic separator (processing capacity: 360L/min), cooler for coolant temperature adjustment) ■Manually tightened drive bracket ■200V power voltage■Japanese nameplates ■Standard paint color (dark grey/silver metallic) ■Instruction manual 1 set (hardcopy) ■Control cabinet cooler ■100V power outlet
Item ItemDivision
Automaticam profileprogrammingfunction
Camgrindingfunction
Others
Wheel truing cycle time ●
Lift data input/output ●
Cam parameter data input/output ●
NC profile data computing ●
Lift input data editing ●
Speed/acceleration data display ●
Override data smoothing function ●
Steps infeed ●
Optional phase angle grinding start ●
Work spindle rotation control ●
Work spindle rotation control command unit 1% ●
F.B. error data smoothing function ●
Measurement error compensation function ●
Manual pulse generator ●
MDI on/off key switch ●
USB flash drive I/F ●
Automatic workpiece data processing changeover □
Cam processing analysis function ●
Host computer connection □
Wheelhead return at power failure □
Cam lift data smoothing function ●
Processing cycle time ●
Grinding cycle time ●
Canned cycle ●
Test cycle ●
Return cycle ●
Single block ●
Rapid feed override ●
Valid handle operation during profile cycle ●
Wheel replacement prediction/min.wheel dia. displa ●
Truing roll replacement prediction/Wheel minimum diameter display ●
Contact detection pin replacement prediction/Wheel minimum diameter display ●
Self-diagnosis function ●
Alarm history display ●
Production maintenance data output ●
Batch backup function ●
Servo sampling function ●
Production counter ●
Wheel truing counter ●
Quality check counter □
Item
Cycletimedisplay
Sequence circuit monitor edit ●
In-process startup function ●Operation
Maintenance
Counter
Division
Filemanagement
Division
Display
Controlledaxes
Coordinatesetting
Compensationfunction
●X : Wheelhead feed
●Z : Wheelhead traverse
□WF : Footstock quill stroke
□WW: Work spindle stroke
●Structured data management
●Lift data memory : 500
●Maximum of 64 grinding data
●Process data / each workpiece : 30
●compensation
●Step difference compensation
●Operation monitor
●Manual operation switches and lamps
●Work procedure
●Inspection,Maintenance data
●C : Work spindle rotation
●Display unit 12 inch color TFT
●NC profile data
●Lift input data
●Position memory(Wheel OD,Truing roll outside diameter,Detection pin length)
●Wheel wear compensation
ItemItem
OD
Maximum width
Surface speed
Feed method
Feed method
Type
Center
Rapid feedrate
Minimum input increment
Rapid feedrate
Minimum input increment
Maximum spindle speed
Distance between centers
Center height
Grinding diameter
CBN wheel
Wheelhead
Wheelheadtraverse
Workhead
Swing over table
Drive motor
Footstock
Power supply voltage
Machine weight
Tankcapacity
Workhead
Spindle
Truing roll
Type
Center
Hydraulic stroke
Wheel spindle
Wheelhead feed
Wheelhead traverse feed
Wheel spindle bearing oil pump
Lubricating oil
Hydraulic oil pump
Lubricating oil pump
Spindle bearing lubricant
Hydraulic oil
Minimum input increment
GC20Mi-35/63
350/630
1,120
φ10~φ300
φ350 [ φ100、φ150 ]
20
[φ100 wheel:60]
[φ150 wheel:80]
φ350 wheel:120[ 80 ]
Hydrostatic slideway. Linear motor drive
V-slideway, Ball screw drive
Live spindle
MT No.4
φ40
φ0.0001
20
0.0001
250
φ320
2.5
0.75(2P)
GC20Mi-35/63
Hydraulic
MT No.4
60
22[ 30 ]
9.8
2.9
3.7(4P)
200
40
11,000
0.75(4P)
0.4(4P)
70
25
0.0001
Unit
mm
mm
mm
mm
mm
m/s
m/min
mm
m/min
mm
min-1
mm
kW
kW
Unit
mm
kW
kW
kW
kW
V
L
kg
kW
kW
L
L
°
Packagedesignationoption
Recommendedpackage options
Select option
Additionaloption
WorkheadFootstockTruing deviceWheel peripheral speed specificationsWorkpiece rotation fault confirmation unit
Electrical control
Coolant tank
Steady rest
Drive unit
Coolant tank
Steady rest
Drive unit
Wheel peripheral speed specifications
Electrical control
Nameplates
Paint
Wheelspindle rotation fault and stop confirmation unit
Hydraulic-related
Wheel balance unit
Tools
Jig craneWorkpiece temporary supportDust collector
Submitted documentation
Rotating headstock with NC spindle travel function (MT No.4, NC process: 100mm) Tailstock with NC automatic center adjustment (MT No.4, NC process: 190mm) Truing device with built-in AE sensor30kW, 120m/s Workpiece rotation fault (proximity type)Thermal displacement compensationElectric-saving circuitWarm-up operation circuitGC70 grinding status display
High cleaning level coolant tank2 rests (2 rest shoes) 3 hydraulic rests (3 rest shoes) Collet chuck
High cleaning level coolant tankCentralized coolant processing(Standard) round coolant tankRound coolant tank (accessories:: magnetic separator (processing ability of 360L/min), cooling equipment for coolant temperature adjustment, SPICLON) 2 rests (2 rest shoes) 3 hydraulic rests (3 rest shoes) Auto rest (Made by Arobotech) GR-3520V-NX (φ20mm to φ35mm)Collet chuckManually tightened drive bracketCollet chuck with shift functionKey extracting unit (for collet chuck key groove method)(Standard) 22kW, 120m/s22kW, 80m/s 30kW, 120m/s 30kW, 80m/s(Standard) 200V power voltage380V, 400V, 415V power voltages(Standard) Japanese EnglishChinese(Standard) JTEKT standard colorDesignated color
Wheelspindle rotation fault and stop confirmation unit (proximity method)Application of Fire Service Act to pump unit (submission of manufacturer's autonomous examination)Air gunCoolant splash gun (for cleaning)Wheel balancing unit - MarposStandard toolsWheel hoisting bracketJig craneWorkpiece temporary supportDust collector CRD-750Instruction manual (on CD) Instruction manual Additional submission (1 copy)
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Division
[ ]: option
※ The specification may be restrained according to the accessories and the tooling of customer.
●: Standard □: Optional
Sizing Sizing grinding cycle □
●: Standard accessory ○: Optional A accessory □: Optional B accessory* When an optional A accessory is chosen, the corresponding standard one is not supplied.
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AccessoriesSpecificationsMachine Specifications / CNC specifications Specifications
The grinder in this image has standard cover specifications.
4,955
1,720
1,120
2,250
R600
R800
2,775
R704
227
2,540
710
690
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Machine layout & dimensions
Machine layout Specifications