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Worm shaft grinding

Worm shaft grinding

The high-speed grinding machine JUTWIST and JUMAT of JUNKERs 2000 platform is dedicated to manufacture worm shafts and work shaft profiles from blank. The worm shafts are used, for example, in the automotive industry and in general mechanical engineering, where they are used for transmission and power transmission, and are fitted in various steering systems, servomotors and parking brakes, for example. The production process can be easily transferred to other, geometrically similar workpieces.

Highlights

  • Pre- and finish-grinding in a single setting
  • Long service life for the tools
  • Low tool costs
  • High quality (roundness, concentricity, dimensional accuracy, diameter tolerance)
  • Achievable surface quality of Rz 1 possible following the finish-grinding
  • AQM traverse the process direction <20
  • Process-reliable, high repeat accuracy
  • Integrated deburring station
  • Fast machine changeover

Grinding process descriptions

Thanks to the geometry calculation of the multi-tooth and single-tooth grinding wheel, the grinding wheel is perfectly shaped for the thread of the workpiece. The electroplated profile grinding wheel that is used for the pre-grinding allows for a high cutting capacity and is ideal to process soft but also hardest materials.The threads are finish ground with aluminum oxide, this results in workpieces with outstanding geamoetry and surface quality.

Worm shaft grinding

Multi-tooth process JUTWIST

Multi-tooth process JUTWIST

Pre-grinding

 

Finish-grinding

Single-tooth process JUMAT

Single-tooth process JUMAT

Pre-grinding

 

Finish-grinding

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Technical data: Worm shaft grinding JUTWIST 2000

Wheelheader Number
1
Grinding Length
300 mm
Clamping Length
300 mm
Center Height
150 mm
Component Weight
4 kg
Grinding Wheel Diameter
170 - 250 mm
Swing Diameter
80 mm
WxDxH mm (without peripherals)
3000 x 2750 x 2430
Weight
18000 kg

Wheelhead Worm shaft grinding JUTWIST 2000

  • /30

Technical data: Worm shaft grinding JUMAT 2000

Wheelheader Number
1
Grinding Length
300 mm
Clamping Length
300 mm
Center Height
150 mm
Component Weight
4 kg
Grinding Wheel Diameter
170 - 250 mm
Swing Diameter
80 mm
WxDxH mm (without peripherals)
3000 x 2750 x 2430
Weight
18000 kg

Wheelhead Worm shaft grinding JUMAT 2000

  • /30

Equipment and Options

DEBURRING STATION

With the integrated deburring station, JUNKER offers the reliable and process-reliable removal of the broken tooth on the worm shafts in parallel to the grinding process. The workpieces are transported directly to the clamping system via an internal loading gantry.

SETTING

The worm shaft is clamped on the workhead using a collet chuck. Furthermore, the workpiece is centrally clamped using a steady rest for the stock reference and using the tailstock for the center reference.

POSITIONING AND MEASURING SYSTEMS

The positioning button measures the longitudinal and radial position. The measured values are automatically integrated into the grinding process by the control system. You can also use the positioning button to carry out numerous measuring operations, such as crown and root circle measurement.

DRIVING AND GUIDING THE AXLES

The linear drive of the Z-axis allows for high moving and acceleration values. Furthermore, thanks to the interaction between the A-axis and the Y-axis, the profile's angle of inclination can be adjusted variably. As a result, the new technology provides the flexibility that is required in production. The C-axis with direct drive allows for an extremely high speed range up to 10,000 rpm.

CONTROL SYSTEM

With the comprehensive JUWOP II software, the JUTWIST is optimally equipped and guarantees simple operation, fast loading and perfect programming results. The Erwin Junker Operator Touch Panel was specially developed for controlling grinding machines. All machine components are controlled via the control panel – irrespective of the series or the control system that is used. The identical structure, intuitive menu navigation and visualization of the workpiece geometry make it extremely user-friendly and flexible to operate. It is programmed directly via the control panel or via an external programming tool.

MACHINE BED

The mineral cast machine bed impresses with its damping performance and high torsional stiffness. Thanks to the temperature stability, fluctuations in the environmental temperature can be effortlessly offset. This guarantees high dimensional accuracy 24 hours a day.

LOADING SYSTEMS

Thanks to the optimized arrangement of the grippers for the blank and finished part, the internal V-loader allows for ideal workpiece handling. Within just a few seconds, the workpiece is changed and, thanks to the keyhole transfer, it is transferred to the external loading system – optimal production capacity while also easing the workload of the operating personnel. The loading systems can also be combined with various feeding and unloading systems, such as conveyor belts or systems that have been adapted to meet customer requirements.

As a full-service provider, the JUNKER Group provides tailor-made automation solutions.

DRESSING UNIT

The dressing of the grinding wheel is controlled by CNC. A driven diamond dressing wheel or a workpiece-dependent diamond profile roller can be used. The dressing is carried out via an automatic dressing program with grinding wheel compensation. In parallel to the loading process, a dressing device can be used to dress the corundum grinding wheel. This reduces the auxiliary process times.

ABRASIVE

An electroplated CBN grinding wheel is used for the pre-grinding. Corundum is used as the abrasive for the finish-grinding.

FIRE PROTECTION AND LTA AIR FILTER

In the event of a deflagration, the inside of the machine is automatically hermetically sealed, meaning that a fire is extinguished before it can spread. If required, extinguishing systems (CO² or water mist fire extinguishers) and waste air purification plants can also be installed. LTA Lufttechnik GmbH is a competent partner for fire protection and filtration solutions. The company also belongs to the JUNKER Group and researches, develops and produces filter systems for industrial air purification.

Workpieces

  • Worm shaft

Product Brochures Worm shaft grinding

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