JUNKER developed a game changer for rotor shaft manufacturing

All in one grinding machine - JUNKER developed new technologies that allow the complete grinding of screw compressor shafts in highest precision. The fully automatic grinder exceeded the customer expectations and revolutionizes the grinding market.

As world market leader in grinding with CBN - JUNKER provides a new milestone in rotor shaft manufacturing. As partner for precision JUNKER simplified processes and developed a flexible and efficient grinding machine concept that provides highest quality with in process measuring of all critical dimensions including form scanning and automatic shape correction.

Faster, efficient and with the highest quality

Sullair LLC. located in Michigan City Indiana, a JUNKER customer since 2011 has changed their finishing process to eliminate the demand to pair shafts and achieve highest compressor efficiency. In the past, the process required multiple grinding machine setups to finish a shaft. Diameters and faces of the shaft were ground on the JUNKER QUICKPOINT prior to grinding the compressor flutes on form grinding machines. Today with the JUMAT 6L all of this is done in one setup and one machine.

In addition, for faster changeovers and to control process quality the machine in process measuring systems measures key features and automatically adjust the process to produce highest quality without operator intervention. JUNKER developed the capability to measure the complex compressor flute profile and correct the dressing path to dress the CBN wheels complete automatically.

Cost-effective complete grinding with optimum accuracy

The correction is essential as tool pressure varies depending on the contact zone of the shape. It is necessary to apply a wheel with an incorrect shape to make a perfect part. The JUNKER grinding machine masters this with ease and for an optimum accuracy, the machine produces parts with a total lead variation of +/- 3 microns and a profile accuracy of less than 6 microns.

JUNKER ensures productivity with intelligent processes

For the different flute shapes and for rough and finish grinding - the machine is equipped with a wheel changer. The machine programs call up the correct wheels and manage their life span. If a wheel has reached the end of its life, the controller requests a new wheel and alerts the production manager to purchase a new one. The parts are presented to the machine on a conveyor with an autonomy of a full shift. Parts are loaded into the machine by an internal gantry system. With that, the safety of the entire system is safeguard and grinding with straight oil possible.

Economical, intelligent and highest dimensional precision

JUNKER rotor shaft technology provides the capability to grind highest efficiency compressor shafts in one setup with controlled part quality by the grinding machine. The JUMAT from JUNKER is a game changer for the grinding market.