From grinding to high performance cutting

They offer modular concept of machines ranging up to hybrid additive manufacturing (hybrid machine). Another highlight is the new werkService concept (factory service concept) for overhaul and retrofit of used machines.

Grinding machines come in a wide variety of designs and applications, from simple 3-axis flat grinding machines to more than 40-axis special machines. Whether simple, long-lasting and precise flat grinding machines for nearly all ranges of applications or completely automated production systems for multi-axis and multi-spindle machining of, for example, airplane engine components or interlinked systems for the automotive industry, Elb-Schliff Werkzeugmaschinen GmbH and aba Grinding Technologies GmbH can offer an extremely broad spectrum, based on their experience that lasts back more than 100 years. "I have not yet come across a customer request for which we have not found a solution", says managing director Dr. Markus Stanik. "The secret to our success is our modular machine construction kit; that provides a flexibility that enables assembly of flat grinding machines as well as ones for complex profiles."

Three machines - one modular concept
A typical example of modular design is the smartLine-machine manufactured with a 2-part machine base made of mineral castings. The existing front and back parts can be combined freely, resulting in a variance width emcompassing four different grinding lengths. Depending on the application, the machine is so flexible, that a broad range of grinding spindles with different performance values and dressing devices can be implemented. These start with a fixed single point diamond, to overhead dresser to multi-axis table mounted dressers, all of which are available for this machine concept.

smartLine machine



Flexible grinding center - smartLine BG Helical
At the moment, Elb-Schliff has the machine series "smartLine BG Helical" in its program.

smartLine BG Helical

The grinding machine center is equipped with a tool changer. Its grinding spindle can be turned +/- 120° around its Y-axis which is advantageous for twisted broaching tools. The helix angle can also be pivoted, for example, in order to grind dies. This enables, together with the tool changer, automated and flexible manufacturing of these parts. The automated loading device places the component in the machine. Instead of aligning it to the machine axis, its position is detected by a measuring probe that  the angle of inclination can be automatically compensatd. The required grinding wheel is made available via the integrated tool changer.  Dressing is done from the machine table. For this machine, Elb-Schliff has specifically developed a new, directly driven motor spindle. Occupying smallest possible space, it offers highest performance data, with 48kW and 270 Nm at a speed of 1700 rpm. The components can thus be processed not only employing pendular grinding but also productive cre
 ep feed grinding. Thanks to the tool changer and swivel axisalso chamfer can be machined.

millGrind with tool changer
millGrind with fast tool changer: fully automatic changes of grinding tools up to a diameter of 500mm, dressing wheels, milling tools and measuring probe for milling and grinding in one machine.

The "smartLine millGrind" is much more complex. The grinding machine presents itself as a highly flexible machining center with a range of machining technologies. Next to profile or flat grinding, further machining methods such as milling can be utilized, thus enabling the machine to be used for complete machining. The millGrind has its advantages in applications where a high proportion of grinding is required. The multi-technology concept for complete machining reduces throughput and shortens idle times thus lowering production costs. In addition, one-time clamping improves dimensional accuracy. Elb-Schliff recommends employing millGrind also for high performance mill cutting (HPC, High Performance Cutting) in combination with highly precise grinding. The machine uses the benefits of both methods: fast material removal by milling and precise fine machining by grinding.

grinding wheel
Reliable tool change; grinding and dressing spindles with automatic HSK interface. 



Hybrid machine for additive machining
As a further option for multiple processing, a laser head is available. This, too, can be changed via the tool changer in order to realize functions such as laser beam hardening, marking and additive laser cladding. "Our hybrid machine is on the market for one year and our customers achieve very good results in terms of additive production support", confirms Dr. Markus Stanik, managing director Elb-Schliff Werkzeugmaschinen GmbH. Elb-Schliff's experts place the machine primarily in the aerospace and supply industry as well as at tool and die manufacturers, where specific components are pre-machined in a first step and then ground. Dr. Stanik knows the advantages of the system; "Laser cladding is a very precise and fast method for metal welding, thus particular suitable for precision components used in aircraft construction. Both production processes outstandingly complement each other in a hybrid CNC machine". Grinding is particularly economical where difficult materials, such as nic
 kel based materials and its superalloys have to be machined. millGrind uses conventional abrasives with superabrasive capabilities. Its XYZ-resolution is 0.1 micron. "Hybrid machining enables us to offer a new level of precision in machining", assures Elb-Schliff's managing director.

Laser cladding

Laser cladding (image with laser head): millGrind from Elb-Schliff combines three process steps with grinding and milling in one machine.

Retrofit by werkService
Elb-Schliff currently has expanded its services. Next to the overhaul of used machines, technological retrofits are also offered. Generally overhauled machines can be extended with measurement sensors and fingerprint to support monitoring in preventive maintenance. For the first time, at Metalloobrabotka in Moscow, the werkService (factory service) is presented. In its own "Service & Retrofit Center" old grinding machines are brought back to state-of-the-art, overhauled and on request upgraded, i.e. a complete technological retrofit is done. Whether overhauling or retrofitting, the customer receives a machine made in Germany including factory warranty. The focus is on overhauling standard grinding machines, usually typical stand-alone-machines such as those used for regrinding in repair shops or for surface grinding in toolrooms. They are being upgraded one-to-one to the latest state of the art whereby the functional area remains identical.

An example is the retrofit of an old machine with V-flat guides and hydraulic drive to be replaced by linear guides and linear drive. In addition, measuring systems can be integrated enabling in-process measurement to reduce set-up times. Also highly important is the replacement of the complete control elements so that latest NC-programs can be used. A further benefit is the higher productivity of the machine. When it has been equipped with new, more powerful drives, completely different feed rates are possible, which in comparison with conventional grinding enables high speed grinding.

Machine before/after
Standard grinding machine before (image left) and after overhaul at Elb-Schliff werkService: On request, the machines can be delivered in the customer's company colors and/or with overhead straight trimmer retrofitted.