New development in a class of its own

JUNKER opens up far-reaching options for the future and - very importantly - investment security with the new development of Platform 3. JUNKER‘s grinding technologies are constantly further developed to meet the challenges of the market. With ever more productive grinding concepts, JUNKER offers the perfect solution for permanently increasing demands on cost-effectiveness and precision. The Platform 3 was developed and designed precisely for this purpose.

The Intention

The modular grinding machines of Platform 3 were developed based on the latest market requirements: small lot sizes and increasing part variety. Both combined the need for flexibility of a high-performance grinding machine.

The new JUNICOR covers all conventional corundum grinding requirements in addition to the high-speed grinding machines with CBN and diamond grinding wheels, such as the JUMAT, JUCAM, QUICKPOINT and JUCRANK. Flexibility and precision keep the balance, and our high-performance grinding machines are suitable for producing individual parts in small batches and larger workpiece series.

The Development

Significant objectives of the new development are increased flexibility and cost-effectiveness through optimizing our modular system. Customer will benefit from shorter lead times archived through quicker production through puts. Included in the modular system is a uniform machine bed for all machine models of the new Platform 3, an extension of the base machine is possible by a wide range of configuration options, such as individual table assemblies and grinding spindle heads. The configurations range from standard to custom-made solutions and achieve the best efficiency, flexibility, and economic results.

Platform 3 is versatile and ideally suited to the needs of a wide range of industries, whether small or large series production at Tier 1, 2 or 3 suppliers or one-piece requirements in a research and development environment.

Highlights

Cost effectiveness thanks to modular design
Short delivery and through-put times for single machines and whole concepts
Guaranteed spare part availability
Optimized uptime due to reduced service and repair times
Future oriented investment thanks to flexibility of machine components that allow easy changeovers for second and third product cycle
Highest precision thanks to perfect thermal stability
Highest rigidity due to robust construction
Quick startup due to integrated peripherals
Pioneering operating and software concept
Operator and maintenance-friendly machine platform
Optimized machine layout that requires less floor space

The grinding processes

The new and economical Platform 3 enables a wide range of grinding processes such as; cylindrical and non-cylindrical applications of OD and ID, regular plunge and angular grinding, more complex operations such as profile, face, surface, and groove grinding, as well as the traditional JUNKER QUICKPOINT grinding process.

The machines

The design of Platform 3 allows a high degree of flexibility in machine configurations for specific projects. At the same time, it provides for individual customer requirements with a convincing price-performance ratio.

For different accuracy requirements in both main axes, X and Y, you can choose between different guide systems and drive variants. JUNKER offers the right solution depending on the to be ground requirements.

Another highlight of the new Platform 3 is the integrated automation concept. The machine can be loaded manually or fully automated. The internal gantry loading system can quickly adapt to new part configurations, with little effort and ensures smooth part handling. Easy access to all components on the outside and inside of the machine, combined with optimized setup capability, is the foundation of the entire system.

Equipment and Options

MACHINE BED: The machine foundation is made of mineral casting and impresses with its dampening qualities and torsional rigidity. Its temperature stability makes it easy to compensate for fluctuations of the ambient temperature. This ensures a high level of dimensional accuracy over a longer production period. The innovative back circulation of the coolant ensures that the machine bed is kept perfectly clean.
TABLE ASSAMBLIES: The table assemblies are mounted on a linear guide on the grinding table using a standardized interface. The table assemblies can be adjusted manually or fully automatic and therefore allow flexibility for any part type. This modular concept enables a highly flexible and individual component arrangement for every requirement and also allows the components to be economically reconfigured for future grinding tasks.
MAIN AXES: The cross-slide design of Platform 3, in which the main axes X and Z are arranged under the grinding wheel head, is compact and enables a smaller foot print without restricting the grinding length. The guideways of the main axes are equipped with modular high-precision circulating roller units to efficiently meet different accuracy requirements and ensure an optimum cost-benefit ratio. Platform 3 offers a versatile drive selection, with both cost-efficient ball screws and more powerful linear motors available, both of which ensure high precision and reproducible accuracy.
WORKPIECE SPINDLE AND TAILSTOCK: The workhead for CBN grinding machines is equipped with a high-precision spindle and a patented 3-point interface for different clamping systems. The maximum clamping length varies depending on the clamping system. The JUNICOR workhead is designed as a belt-driven version and prepared for an ISO universal interface accessories; the tailstock is equipped to accommodate a stationary or live center and can be individually adjusted manually or automatically to the respective part length. Maximum clamping length also depends on the clamping system used and the axial length adjustment of workhead and tailstock can be either done manually, hydraulically or NC controlled. Axial displacement becomes necessary when mixing OD and ID operations or for single part productions and retooling means.
GRINDING WHEEL HEAD: The wide range of grinding wheel head variants, with up to three grinding spindles, ensure maximum flexibility. The belt-driven or high-frequency spindles are manufactured by JUNKER and designed precisely for the grinding process. JUNKER offers the right, application optimized configuration for the Platform 3 machines for either CBN high-speed grinding with a peripheral speed of up to 125 m/s or conventional grinding with aluminum oxide and a peripheral speed of up to 63 m/s. The automatic swiveling B-axis with a positioning accuracy of less than one angular second was specially designed for Platform 3 to ensure a high-precision grinding process for every requirement.
IN-PROCESS-MEASURING SYSTEM: The need for efficiency in production cycles, optimized grinding times and increasing demand for part quality require the use of high-precision measuring instruments. A digital measuring head measures the required part dimensions in process. Measured values are stored, and the correction data is calculated in order to minimize process influences due to temperature fluctuations or tool wear. A new feature in this machine class is the use of an absolute measuring system to reduce set-up times between different part types.
LONGITUDINAL AND RADIAL POSITIONING: Part position must be determined precisely after clamping. The length positioning probe measures the axial position of the part using a reference surface to compensate for fluctuations of the part blank. Measured values are automatically used by the grinding process and are integrated by the control system.
DRESSING: Dressing the grinding wheel creates the exact geometry and sets the surface requirements of the part. The dressing process is optimized to increase the wheel life and the surface quality of the part. Platform 3 is able to accommodate fixed and rotary dressing tools, which can be mounted depending on the application on either workhead or tailstock. For high-speed grinding applications, the workhead C-axis also serves as dressing spindle and the dressing disc is mounted directly on the spindle; for maximum flexibility, the dressing spindle can also be mounted directly to the grinding table, actuated by and means of a linear guide.
PERIPHERY: In addition to the powerful grinding machine, the peripherals are the perfect complement. Our focus was to reduce the overall machine layout. Both the hydraulic and cooling units as well as the air filtration system are optimally positioned, the return pump is installed directly at the grinding machine. A standardized system for application specific coolant pressure as well as rinsing pumps for high-speed grinding applications is also available.
LOADING SYSTEM: Another highlight of the new Platform 3 is the integrated automation concept. Various loading concepts are compatible with the Platform 3, this includes manual loading solutions, industrial robots as well as external or internal gantry systems. The internal gantry loading system can be converted to new part configurations with little effort and ensures smooth part handling.
FILTRATION SYSTEM: LTA Lufttechnik GmbH manufactures solutions for compact filtration systems and plans and installs filtration systems for large extraction systems. They cover solutions for oil and emulsion mists as well as dust and chip extraction for particle sizes between 0.001 and 100 μm. Thanks to their expertise in piping systems, flow simulations, safety technology and turnkey solutions, LTA generates a wide range of added value for customers over the entire life cycle of a system.