Future-oriented finishing, grinding targets Industry 4.0

The company within high precision machine tools has developed the first self-regulating flat finish machine based on the well proved and flexible platform MicroStar.

Thielenhaus describes it as a “perfect symbiosis of productivity and variance”. The 8-station-machine for combination machining is not only meant to meet the drawing specifications of high precision workpieces 100% but also to shorten the process chain generating substantial cost reductions.

Especially with constantly changing workpiece types the extremely shortened change-over times increase the output considerably. Last but not least the self-monitoring function of the machine reduces metrology capacity and relieves the operator significantly.

The fastest bearing microfinish in the world

The machine tool manufacturer from Wuppertal presents the KM 90 NC, a high-performance microfinish machine for inner and outer ring microfinish of single and double row bearings, based on a solution proven over many years. This machine incorporates the latest technologies like direct drive for the oscillation unit and double oscillation HyperFinish with superimposed high frequency oscillation and low stroke. The sensational floor-to-floor time of 3.5 seconds for a deep groove ball bearing inner and outer ring, type 625 can be achieved by a direct link to a grinding machine. The set-up time between two pass parts could be reduced to less than 20 minutes. This high-speed gadget for mass production can be changed over flexibly from radial bearing to axial bearing and from ball bearing to roller bearing microfinish. The menu-guided and image-guided programming and operation facilitates the handling of the machine. The life cycle of the machine is increased and the tooling costs are reduced by the innovative wear compensation of the workpiece driver. The fact that set-up steps can be timed shows that Thielenhaus has been developing according to Industry Standard 4.0. The low machine footprint 2,063 x 1,026 mm encompasses the integrated electrical cabinet and can thus be set up in limited production space.

Double disc grinding newly defined

Thielenhaus Microfinish offers a particularly economic and compact machine solution for mass production of flat high-precision parts: The double disc grinding machine features high precision and economic efficiency, operator convenience and compactness. With the design Thielenhaus strictly avoided any expensive extras not necessary for achieving the target. Precision was the paramount goal: Thus importance was attached to a high rigidity achieved by a closed box frame instead of a C frame, forged tool spindles instead of turned ones, sensibly positioned spindle tilting units and double walled frames ensuring temperature resistance. One further important feature is the operator friendliness: One unique patented swivelling transport disc panel allows the operator to exchange the grinding discs a few seconds after their standstill through large openings in the front.

The new benchmark with crankshaft finish

The CrankStar HP, a new line of tape microfinish machines for superfinishing crankshafts with smallest bearing distances is Thielenhaus’ answer to the needs of many engine manufacturers for a flexible machine solution. This machine, developed by the global market and innovation leader, can also be used for smaller crankshafts. For the first time crankshafts with a spacing of 33 mm can be microfinished in a safe and economical process - thanks to the particularly slim microfinishing units featuring an extremely extensive opening angle. Such crankshafts are vital for the new increasingly compact engines demanding higher and higher efficiency. Furthermore, the machine can be used for microfinishing all kinds of crankshafts made of cast iron or steel with a distance between centres of 500 mm through 800 mm and a maximum swing diameter of 210 mm as well as a stroke of up to 100 mm in one or several steps. Apart from the usual surfaces like mains, pins and flanges this machine can also microfinish front journals and deburr the flange bores at the same time. A particular highlight is the optional separate loading system allowing for a loading/unloading during microfinish through an external gantry resulting in cycle time reductions of up to 17 seconds.

Compact microfinish

 More and more small component suppliers see the need for surface and geometry improving superfinish. Many have to be able to adhere to the tightest tolerances regarding dimension and form. A special solution for these applications or for smaller batches will be presented in Hanover by the Swiss Thielenhaus Superfinish Innovation, i.e. the further improved attachments for carrier machines. So it is possible to apply the advantages of the microfinishing process on the present turning, grinding or milling machines for improving the surface, roughness, waviness and load bearing capacity of the workpieces in a safe process. Surfaces to be microfinished may be plane surfaces, flanges and skirts, outer or inner rotationally symmetric surfaces as well as excenters, cams and cam disks. The range of surfaces is even wider up to spherical surfaces like balls, radii and undercuts.

More about Thielenhaus

Microfinishing, also known as superfinishing or short-stroke honing, is the ideal machining process for achieving extreme precision surfaces and component geometries, and removing amorphous surface layers in the magnitude of 2 µm. Honing stones, cup wheels and microfinishing tape or film can be used to generate surface roughness or geometrical accuracy within a previously defined window that often spans a few tenths of a micron. Indicated below are a number of parameters which can be optimised using Microfinish.

Thielenhaus machines are employed by leading manufacturers across the world for a good reason - their high reliability, productivity and production quality. Thielenhaus continuously pushes the limits of precision machining, enabling its customers to achieve workpiece qualities that were previously impossible.

According to the company extreme precision is its specialty. Over the years the manufacturer has built the world's largest portfolio of Microfinish solutions, ranging from industrial equipment for large and small manufacturers to just-in-time tool delivery and other services. When it comes to Microfinish Thielenhaus is the one-stop shop.

The manufacturer adapts the machine solutions to the customer's component, loading/unloading preferences, cycle time requirements and other specific needs. The modular design of the machine platforms accommodates even tricky components.

New challenges and innovation are the passion of Thielenhaus. They are proud of their 430+ patents in surface finishing technology as well as of numerous market-leading platforms and pioneering innovations. Thielenhaus constantly seeks to improve the machining concepts, always keeping in mind the challenges of tomorrow.

Thielenhaus is known as a highly experienced problem solver: Anyone can be a problem solver, but with more than 70 years of developing Microfinish solutions, the Thielenhaus staff have probably seen and solved more Microfinish problems than anyone else in the industry. When it comes to splitting microns, the Thielenhaus in-depth knowledge of the microfinishing process is unsurpassed.

Thielenhaus Microfinish has developed the first self-regulating flat finish machine based on the well proved and flexible platform MicroStar.

The new KM 90 NC, a high-performance microfinish machine for inner and outer ring microfinish of single and double row bearings has a sensational floor-to-floor time and a shortest set-up time between two pass parts.

The new double disc grinding machine features high precision and economic efficiency, operator convenience and compactness.

The microfinish attachments for carrier machines make it possible to apply the advantages of the microfinishing process on the present turning, grinding or milling machines for improving the surface, roughness, waviness and load bearing capacity of the workpieces in a safe process.