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GRINDSTAR machine concept from JUNKER

Replace turning with grinding in high volume production

The JUNKER GRINDSTAR offers an economical alternative to turning for small components ranging in diameter from 2 to 20 mm. Short cycle times and long tool life reduce piece part cost by up to 25% for batch sizes stating at 200’000. Its high productivity makes the GRINDSTAR an interesting alternative for high volume production in the automotive industry as well.

The innovative method includes grinding the entire workpiece contour in a single operation and more quickly, as grinding utilizes lower cutting forces than turning. Lastly, the GRINDSTAR allows for perfect coordination between the workpiece, abrasive, and machine. These factors harmonize to enable a significant increase in productivity. The GRINDSTAR is up to three times faster than a lathe.

 

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GRINDSTAR

 

 

The automotive and supply industry demand high volumes with the fastest possible turnaround. This environment is precisely where the GRINDSTAR shines: from material cut-off through profiling to ejection, this single machine covers every work step. This versatility enhances process reliability and minimizes machine downtime. As a result, the GRINDSTAR achieves and impressive availability level of over 96% and a long tool life.

Due to its innovative cooling system, the grinding wheels work with precision and consistent quality for up to six months or a production volume of 300,000+ pieces. Replacing turning with grinding also improves the quality of workpieces, including dimensional accuracy and surface quality.

And, unlike with turning, grinding creates no chip impressions. The flushing system prevents particle deposition on the grinding wheels, thereby eliminating the need for a reworking process – frequently required when turning. This reduces both production time and investment in additional machinery such as surface grinders or polishers.

 

 

The GRINDSTAR offers maximum flexibility in choice of material. It quickly and reliably grinds lightweight technology such as the curable and glass fiber-reinforced plastics so often required in the automotive industry. The machine further handles high-alloy tough steels, hardened materials, and even ceramics.

Imagined from the start as a fundamentally adaptable machine, the GRINDSTAR is fit to use either CBN or diamond abrasives. JUNKER’s experienced design team customizes each machine to the specific needs of each customer. From profiling through grinding wheel coatings to machine settings – JUNKER can design the entire production process. The GRINDSTAR also features a quick, hassle-free start up, eliminating the need for time consuming and costly test runs.

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