提高磨矿生产率

北方工具和齿轮公司(NTG - 01241 872626)，英国最大的家族拥有的精密齿轮分包商之一，在过去几年投资了超过200万英镑的新设备，以提高其作为“一站式”齿轮制造商的能力。亚博全站官网登录网址作为最近投资的一部分，这家60岁的公司选择了一台Jones & Shipman Ultragrind 1000数控外圆磨床(0116 201 3050)。该投资是由位于苏格兰的Arbroath公司进行的，目的是替换现有的J&S Series 10外圆磨床，该磨床已为公司提供了13年的生产服务。工艺改进是这笔投资的关键因素，因为董事总经理戈登•斯特拉坎(Gordon Strachan)的公司即将重新谈判一份为期三年的汽车合同，为新一代变速器总成的7个部件重新谈判。现有的变速箱已经由NTG从原型开发到批量生产，以证明项目的成功:“超过3500套已经提供，加上备件，没有一个被拒绝，”他说。“有了这台新机器，我们的中心之间直径可达300毫米，中心之间直径可达1000毫米，可以多功能研磨重达200公斤的部件。到目前为止，由于触摸屏和Jones & Shipman软件的优势，我们发现循环时间提高了15%左右，设置也大大减少了。”他补充说，由于机器固有的内置精度和刚性:“我们现在很容易保持1到2微米，不需要可选的过程中直径测量单元，这进一步减少了设置时间。”Ultragrind配备了最新的发那科320触摸屏控制系统，内置Windows XP。斯特拉坎坚持认为，在重置作业时，这是理想的选择，因为平均批量大小在15个左右。“我们经常只磨一两个部件，最大的一次可能是150个部件，这意味着重置对生产率有很大的影响。”图片:NTG选择Jones & Shipman Ultragrind 1000数控外圆磨床来支持赢得一项汽车合同 万向轮由于工作范围广，90%的生产通过机器基于淬火和回火的EN36, NTG开发了一个500毫米乘100毫米的通用规格的车轮，并使用单点修整，这是“如此容易和直接编程在这台机器上”，再次缩短了切换。订购这台机器时，一个重要的因素是控制的简单性，其完整的图形图像支持，可以由J&S在前端进行定制，以适应应用程序和操作员。虽然最初的培训对夜班和白班的setter/operator都只需要三天时间，但随着他们越来越熟练，他们要求进行小的更改以适应他们的应用程序，J&S能够很容易地适应。该控制提供了三种完全交互式编程模式-图形化，文本视图和ISO的磨削和砂轮修整周期。操作人员可以选择宏，并在图形图像周围输入直径、速度和进给量的关键数据，只需触摸屏幕。此外，ISO是完全支持的，正如G和M代码编程，操作员可以在任何时候使用。图形界面和G和M代码页彼此无缝更新，因此每个操作员和每个班次都有真正的灵活性。Ultragrind有一个模块化的轮头设计，使多达四个外部或内部轮轴，或任何两者的组合，以适应应用。b轴，可编程为0.0001°，旋转和定位这些车轮，并允许为每个车轮创建三个独立的基准，以提供充分的灵活性。NTG选择了一个普通的90°方法外仅轮头。 However, Mr Strachan arranged for J&S to include a further contour generation macro, in addition to the existing ISO contour grinding facility, now a standard machine feature. NTG has ground a whole series of components, including multi-diameter parts up to 200 mm diameter by 800 mm long and weighing up to 160 kg to tolerances of 0.015/0.020 mm. Other parts have been ground with up to 12 diameters and adjacent faces in a single cycle. The range of different transfer gearbox components has involved the production of up to five diameters, four traverse ground and one involving a plunge grind cycle. Cycle times are up to seven minutes each. At Mayes & Warwick, Burntwood, Staffordshire, which has earned a world-wide reputation for its range of thread and form rolling dies, a Studer S33 has replaced an older Matrix machine. In addition to other in-house grinding applications, the main work of the new machine would be grinding very precise annular grooves on to in-house manufactured crushing rolls, which are a critical element in maintaining the accuracy of the company's products. The crushing rolls are used to 'crush' precise thread forms onto the company's grinding wheels; the treated wheels are subsequently used to grind thread forms onto the company's thread and form rolling dies. Mayes & Warwick produces a range of flat thread rolling dies in a variety of thread profiles for rolling all types of screws, bolts and fasteners. Also manufactured are rolling dies for lock bolts and rivets. All products are made to a level of accuracy that ensures each die is interchangeable and can be set in a stack off the machine, optimising both tool life and machine running time. Dies can be manufactured for screws and fasteners featuring all standard thread forms, from 1.1 to 32 mm diameter (0.043"to 1.1/4"), with pitches from 0.32 mm (>80TPI). Special form rolling dies can also be designed and manufactured for specialist applications, while products can be developed in conjunction with customers. Managing director Peter Lawrence explains the purchase of the Studer: "Having formulated a list of technical criteria for our proposed new high precision CNC grinder, we investigated the alternatives. Disappointed with the inability of several potential machine tool suppliers to satisfy our wish-list, we contacted Micronz (01352 75 88 40), the UK agent for Studer Grinders. "Micronz, and subsequently Studer, immediately understood our requirements and were able to recommend the S33 as the answer to our needs. An in-depth, successful demonstration, replicating some of our most challenging grinding tasks, together with the reputation enjoyed by Studer for the quality of their machines, convinced me to make the purchase. "Now in full production, our S33 is providing the levels of high quality output promised by Studer. In fact, as we are learning new ways to exploit our new Studer grinder, the machine is becoming ever more productive."图片:Mayes & Warwick生产一系列平面螺纹轧制模具，各种螺纹型材，用于轧制所有类型的螺钉、螺栓和紧固件，Studer技术帮助该公司做到这一点 箱项目 新的磨环寿命更长Tyrolit(01788 824500)推出了一系列新的齿轮珩磨环(上图)，使用了特殊熔合磨料，据说其使用寿命几乎是市场上类似消耗品的两倍。被称为MIRA，不仅环持续时间更长，而且循环时间也减少了，因为进料率可以提高。这两个因素结合起来使珩磨生产率提高了30%，而不需要在新机床上进行资本投资。在豪华汽车的手动变速器中，多达70%的齿轮都要在侧翼进行珩磨。因此，需要在硬化状态下对大量齿轮进行精珩磨，正是这种趋势促使Tyrolit为其MIRA环开发了新的磨料规格。Tyrolit的MIRA专利珩磨环有三种类型。树脂粘合环使用嵌入环氧基体的氧化铝。复合环采用了一种新型结构，包括嵌入树脂基体的玻璃化砾岩，从而获得了出色的颗粒保留和库存去除，并结合了环氧树脂良好的阻尼特性。第三组产品包括用于高性能齿轮珩磨的玻璃化环，能够去除每侧面高达0.1毫米的存量。图片:据说，一种新的齿轮珩磨环的使用寿命几乎是市场上类似消耗品的两倍 首次发表在《机械》杂志，2011年4月