GRINDSTAR

Highlights

Grinding Process

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GRINDSTAR

GRINDSTAR - Profile and cutoff grinding machines

Replace turning with grinding

The GRINDSTAR machine concept replaces turning through the use of dressing-free high-speed plunge-cut grinding, enabling extremely short grinding times and significant cost-saving potential, from economical high-volume production to flexible prototype and zero-series manufacturing. For an automated and efficient material flow, the bar feeder handles both the storage and feeding of the bar stock material.

Highlights

Minimal piece costs due to:

   - Shorter grinding times through plunge cut grinding of the entire contour
   - Long grinding wheel service life
   - High process reliability
   - Simultaneous grinding of the front and back
   - Reduced downtimes

Customer-specific process and technology configuration
Grinding of difficult-to-machine and hardened materials possible
No chip removal problems, as small chips are transported away by the cooling medium
Machine availability greater than 96 %
Low-manned production and cost benefits due to grinding directly from bar stock
No burr formation

Grinding process descriptions

With the GRINDSTAR, extremely short grinding times can be achieved. This innovative grinding process can be used with both CBN and diamond grinding wheels, delivering substantial cost-saving potential, particularly in high-volume production applications. For flexible small-batch production, corundum is the ideal abrasive. The grinding wheel can be precisely profiled to meet specific part geometry requirements, and new profiles can be dressed quickly and easily.

The machine features an innovative coolant system that maximizes tool life and ensures exceptional operational reliability, with machine availability exceeding 96%. The machine offers two different grinding processes: plunge grinding/profile grinding and cut-off grinding. The key synergistic benefit lies in combining both processes in a single setup.

Grinding

Turning

Unique economy: Greater quality and machine availability

Using a profiled grinding wheel permits plunge-cut grinding of the entire workpiece contour within an extremely short processing period. In terms of quality, finished workpieces demonstrate substantially greater dimensional stability compared to conventional turning methods.

: One machine to replace many individual steps

Complete grinding in a single machine significantly reduces process risks and unproductive time. Manufactured parts are up to 100% guaranteed to be free of burrs. Convex or level face ends can also be produced. And even difficult-to-machine materials impossible to machine using a lathe can also be ground. Soft and hard grinding are also possible.

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GRINDSTAR

Technical data: GRINDSTAR

Grinding Length: 400 mm
Grinding Wheel Diameter: 520 mm
WxDxH mm (without peripherals): 2400 x 1800 x 2100
Weight: 4500 kg

Equipment and Options

SYNCHRONOUSLY CONTROLLED WORKPIECE: The two synchronized workpiece spindles enable seamless and precise workpiece transfer during both profile grinding and cut-off operations. Their speed can be continuously adjusted from 1 to 6,000 rpm to suit a wide range of applications. A hydraulically actuated collet chuck ensures highly precise concentricity and exceptional clamping accuracy.
MAXIMUM STABILITY FOR HIGHEST PRECISION: To ensure maximum stability throughout the grinding process, the machine is equipped with steady rests positioned on both sides of the workpiece. These provide reliable support, creating the foundation for exceptional precision and outstanding grinding results.
AUTOMATIC BALANCING FOR OPTIMAL GRINDING RESULTS: An integrated balancing system within the grinding spindle automatically balances the grinding wheels, providing the foundation for optimal grinding performance and consistently high-quality results.
RIGID MACHINE BASE FOR EXCEPTIONAL MACHINING PRECISION: Built on a rigid, torsion-resistant machine base, the system delivers exceptional stability throughout the machining process. The optimized slant-bed configuration promotes efficient chip removal and minimizes thermal distortion, ensuring consistently precise and reliable machining results.
HIGH-PERFORMANCE COOLING TECHNOLOGY FOR HIGH GRINDING QUALITY: Two high-efficiency pump systems ensure consistent cooling of the workpiece during grinding and continuously clean the grinding wheel through an effective flushing process. Optional frequency converters are availbale for energy optimization.
EFFICIENT MATERIAL FLOW: Designed for maximum productivity, the integrated bar feeder manages both bar stock storage and feeding, with capacities of up to 4 meters as standard and up to 6 meters as an option. Bar remnants are automatically removed through the same system. A pneumatically controlled pressure valve integrated into the right-hand secondary spindle ensures precise workpiece positioning, while a part catcher and conveyor belt provide reliable, fully automated discharge of finished components.
EASY-TO-PROGRAM CONTROL SYSTEM: The machine features a CNC control system with a modular hardware and software architecture. Programming is simple and intuitive, based on the familiar operation of conventional lathes. This allows for efficient, flexible production with minimal training requirements and rapid operator adoption.
VARIABILITY OF ABRASIVE: Depending on the application, galvanically bonded CBN or diamond is used as an abrasive. The grinding wheels feature durable steel cores that can be recoated after extended service life.
ADVANCED MEASURING SYSTEM FOR EXCEPTIONAL PRECISION: Tailor-made measurement systems, individually adapted to the workpiece and customer requirements, deliver exceptional precision. Measured values are continuously evaluated and automatically applied for dimensional correction, ensuring consistently high part quality throughout the production process.
MAXIMUM PROTECTION AND MAXIMUM RELIABILITY: The full protective cover provides the highest level of safety within the work area and complies with all applicable safety regulations. An integrated pressure relief valve offers additional protection and further enhances operational safety.
360° PROTECTION POWERED BY SMART SAFETY TECHNOLOGIES: An advanced safety concept ensures comprehensive machine protection. In the event of a deflagration, the machining area is automatically sealed to contain the incident and suppress a potential fire before it can develop. Optional CO₂ fire suppression systems, water mist technology, and exhaust air filtration solutions provide an extra layer of protection for both personnel and equipment. All filtration and fire protection systems are supplied by LTA Lufttechnik GmbH, a company within the JUNKER Group.