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November 2017

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Grinding Instead of Turning in Series Production

When manufacturing small components with a diameter of between 2 and 20 mm, the GRINDSTAR grinding machine from JUNKER is designed to provide an economical alternative to turning.

All work steps take place on one machine in a single clamping set-up. This enhances process reliability and minimizes machine downtime.

"GRINDSTAR manufactures burr-free parts during grinding. And unlike turning, no chip impressions are created," said a company spokesperson.

"When manufacturing small components with a diameter of between 2 and 20 mm, the GRINDSTAR grinding machine from JUNKER offers an economical alternative to turning," said a company spokesperson. "From batch sizes of 200,000, short cycle times and a long workpiece service life can drive down costs per workpiece by up to 25%. Its high productivity makes the GRINDSTAR a particularly interesting alternative for large-scale series manufacturing in the automotive industry."

The grinding method enables the entire workpiece contour to be ground in a single processing operation. In addition, grinding involves much lower cutting forces than those occurring during turning, allowing for faster grinding of workpieces. Another advantage of the GRINDSTAR is the coordination it allows between workpiece, abrasive and machine. "All three factors act together to enable a significant increase in productivity, up to three times faster than a lathe," said the spokesperson.

The automotive and supply industry requires high piece volume with fast turnaround. "This is precisely where the strengths of the GRINDSTAR are brought to bear: from material cut-off through profiling to ejection, every work step is covered in a single machine," said the spokesperson. "This enhances process reliability and minimizes machine downtime. As a result, GRINDSTAR offers an availability level of over 96% and an extended tool service life. Because of its innovative cooling system, the grinding wheels work precisely and to a consistent standard of quality-for up to six months or a production volume of 300,000 pieces and more."

"Grinding instead of turning also positively impacts workpiece quality, with improved dimensional accuracy and excellent surface quality," said the spokesperson. "The manufacture of burr-free parts during grinding is guaranteed. Unlike turning, no chip impressions are created. The two profile grinding wheels in the GRINDSTAR require no dressing and use an innovative lubrication method. The flushing system prevents particles from being deposited on the grinding wheels, eliminating the need for the reworking process frequently required when turning. This reduces the production time required and saves the need to invest in additional machinery for surface grinding or polishing."

The GRINDSTAR offers flexibility when it comes to the choice of material. Of particular interest for the automotive industry with its increasing demand for lightweight technology: curable plastics and glass fiber-reinforced plastics can be quickly ground. Materials that can be ground include high-alloy tough steels, hardened materials and even ceramics.

CBN or diamond can be used as abrasives. "JUNKER can adapt the GRINDSTAR to suit the specific needs of each customer," said the spokesperson. "From profiling through coating of the grinding wheels to the individual machine settings-JUNKER uses its in-depth expertise to plan the entire production process. This eliminates the need for laborious and costly test runs by the customer. The GRINDSTAR is quick and simple to set up, in keeping with the plug and play principle."

For more information contact:

Erwin Junker Machinery, Inc.

2541 Technology Drive, #410

Elgin, IL 60124


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