Reinecker VSC DS applies the vertical pick-up machines for combining machining processes such as turning + drilling + milling + grinding + others - offer a radical approach to production machining. The combination machining of high-precision hardened workpieces is gaining acceptance. Since EMAG introduced, at METAV 1998, the world's first combined turning and grinding center this new technology has spread far and wide.
Within the EMAG Group Reinecker Karstens Kopp is the center of excellence for grinding.
Reinecker, specialist for the precision grinding of chucked components, has been active in this particular field for many decades.
More than 100 Reinecker combined turning and grinding centers from the VSC series of vertical machines are in use in many branches of industry.
Quality requirements, particularly for components in the automotive and the mechanical engineering industry, are constantly getting tougher.
The demand for ever tighter tolerances is accompanied by that for greater machining capability.
Such demands call for the complete machining of components in a single set-up.
Multi-functional machines offer the integration of several different machining processes in one machine tool, with all the advantages for the user: lower capital outlay and component manufacturing costs, shorter throughput times, increased workpiece quality and greater process integrity, a smaller footprint and reduced maintenance requirements.
Add to this the continuing trend towards dry machining, particularly of hardened workpieces.
New areas of application are opening up all the time.
The reasons behind this are the rapidly rising waste disposal costs for coolant and for grinding sludge on the one hand and the compulsion to further reduce production costs on the other.
A drastic reduction in the use of coolant - or being able to do without it altogether - promises economical and also ecological advantages.
Over the coming years the EMAG Group will intensify its search for solutions in this particular field.
In 1992, EMAG was the world's first manufacturer to stand turning on its head with their VSC series of machines.
3,000 of EMAG vertical pick-up machines have since been employed in many countries as vertical turning machines and multi-functional production centers for the machining of many workpieces that can be held in chucks or similar workholding fixtures.
They offer the integration of several production processes: from turning to drilling and milling and from laser applications to grinding.
With their grind-finishing technique the turning and grinding centers from Reinecker combine the advantages of vertical turning with those of vertical grinding.
The main advantages of this technology are: * Vertical hard turning and finish grinding in a single set-up, on one machine.
* The workpiece is finish hard turned where the manufacturing process allows, and only finish ground (after rough hard turning) where tight tolerances and process integrity demand it.
* Improved component quality and increased output rates, as the workpiece is machined in a single operation, whereby the rough hard turning operation leaves a grinding allowance of only a few æm for the Grind-Finishing process.
* Less time-consuming wheel dressing and lower tooling costs, as the wear and tear of turning tools during rough hard turning and of the grinding wheels during Grind-Finishing, is so much less when only a small amount of grinding stock has to be removed.
* Compared to conventional grinding methods, this technology permits, for the first time, a considerable reduction of the grinding allowance, which results in almost no grinding sludge being produced, thus cutting waste disposal costs.
This also creates conditions that permit grinding with a minimum of coolant, or even dry grinding, without burn marks.
* A higher degree of process integrity and a better surface finish through Grind-Finishing rather than just hard turning.
* Compared to surfaces obtained by hard turning only, this machine offers a Grind-Finishing operation that leaves no tool drag out marks.
* Back faces can easily be hard turned.
The overhead inverted main spindle, with the workpiece positioned above the cutting tools and the tooling systems, offers the best possible chip flow conditions - very important considering the growing trend towards hard and dry machining.
All machine components are of rugged design and are vibration resistant.
This is ensured by the machine base in polymer granite Mineralit with its excellent damping properties, and by the work spindle design.
The work spindle forms an integral part of the very sturdy quill unit, which carries out the Z-traverse in a high-precision hydrostatic guideway - a design feature that adds to the damping qualities.
As the tooling systems are static, in accord with the VSC principle, they provide a rigid platform for grinding alone as well as for the combined process employed by the Reinecker turning and grinding center.
This is an important precondition for the stability of the tooling, which results in time savings when rough hard turning and in excellent surface finishes when finish hard turning or Grind-Finishing.
In addition, the number and layout of static tooling systems can be chosen to suit machining requirements.
The machine benefits from thermal stability, as work spindle, grinding spindles, turret and machine base are all fluid-cooled.
The operating temperature is reached quickly and kept within tight limits of the ambient temperature by a powerful cooling unit.
The pick-up concept allows the Reinecker VSC DS turning and grinding center to 'load itself', just like all the other VSC machines.
Expensive, space-devouring gantry loaders and other loading devices that involve time-consuming resetting efforts, are no longer needed.
The options include chuck diameters between 250 and 400mm and a large variety of tooling system combinations of up to 4 grinding spindles and a maximum of 12 turning tools and live drilling and milling tools, arranged as individual requirements demand.
Workpieces with very different bore diameters are machined using 2 grinding spindles with different spindle speeds.
These could be, for example, 1 rough and 1 finish grinding spindle or 1 internal and 1 external grinding spindle, depending on requirements.
Workpieces with variable contours can be machined using 2 grinding wheels with different profiles.
For the additional machining of keyways a further 2 spindles for rough and finish grinding are added.
Depending on type and extent of the process sequences for a workpiece a turret supported on both sides is used, or, where extensive turning, drilling and milling work has to be carried out, a disc-type turret with 12 tool stations for turning and live drilling and milling tools, in addition to the two grinding spindles.
The different tooling systems allow the Reinecker VSC DS machines to cost-effectively machine a wide range of workpieces both with accuracy and process integrity: gearwheels, sliding sleeves, link pins, components for CVT gearboxes, roller races, rocker arms, piston rings and many other components for the automotive and the mechanical engineering industry.