Matrix Machine Tools is demonstrating the new 6950 High Helix Thread grinding machine at IMTS 2006. The machine has been designed specifically for the fast and accurate grinding of long lead/high helix components. The machine incorporates the latest advances in CNC and servo technology to provide the dynamic performance and smooth running characteristics required for precision grinding applications.

The radical Matrix 6950 is the first machine which controls the grinding of the high helix via software rather than by mechanical means, the only technology available until the introduction of the innovative Matrix technology.

Controlling the grinding of the high helix by software is a far better production method because it is more flexible and faster than any mechanical system.

In grinding a high helix, the geometry changes constantly because the wheel is always getting smaller.

The Matrix system dresses out the interference, which would be caused by the change in grinding wheel shape without operator intervention or the need to change the diamond roll.

The Matrix-created software programme 'NutOpt' predicts the grindability of the component.

The innovative technique developed by Matrix uses a corrected compound angle approach of the spindle, in conjunction with the two axis CNC dresser, which continually corrects the grinding wheel profile and allows components with a higher than usual helix angle to be successfully ground.

The NutOpt software allows the component designer to predict the grindability of part and make any necessary changes at the design stage.

The interaction of design and production engineers creates a better component which is easier and less expensive to manufacture.

The software has been created by Matrix research and development engineers in response to the recognised production problems being caused by the need to grind a high helix.

The development of the linear motion systems to produce faster axis movement on any product controlled by ballscrew and nut assemblies has meant that pitch/lead has increased and that thread helix angles have become larger.

On these larger angles it is difficult to insert a grinding wheel within the bore of a nut at the correct helix.

To overcome this problem the grinding wheel has to be introduced at a smaller helix and the profile corrected.

The Matrix system for high helix grinding gives substantial cost savings in this traditionally difficult area of grinding because a reduced number of tools are required, set up times are reduced, and human error is removed from the process.

This is because the Matrix process is entirely programmable, eliminating the need for specialised mechanical tooling.

Only one diameter disc is needed to profile the wheel, completely removing the need for specialised tooling specific to individual combinations.

This diminishes substantially set up times and operator involvement in the process, improves accuracy and minimises scrap.

David Giles, vice president of Matrix Machine Tools, said: 'This is a new standard and sets the benchmark against which all other machines operating in this manufacturing sector can be judged.

The NutOpt software allows the component designer to predict the grindability of part and make any necessary changes at the design stage.

The interaction of design and production engineers creates a better component which is easier and less expensive to manufacture.