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Maschinenkonzept GRINDSTAR von JUNKER

Grinding instead of turning in series production

When manufacturing small components with a diameter of between 2 and 20 mm, the GRINDSTAR grinding machine from Junker offers an economical alternative to turning. From batch sizes of 200,000, short cycle times and a long workpiece service life can drive down costs per workpiece by up to 25%. Its high productivity makes the GRINDSTAR a particularly interesting alternative, also for large-scale series manufacturing in the automotive industry.

The innovative grinding method enables the entire workpiece contour to be ground in just a single processing operation. In addition, grinding involves far lower cutting forces than those occurring during turning, allowing faster grinding of workpieces. The third success factor of this machine is the perfect coordination it allows between workpiece, abrasive and machine. All three factors act together to enable a significant increase in productivity. The GRINDSTAR is up to three times faster than a lathe.

The automotive and supply industry demands high piece numbers with the fastest possible turnaround. And this is precisely where the strengths of GRINDSTAR are brought to bear: From material cut-off through profiling to ejection, every work step is covered in a single machine. This enhances process reliability and minimizes machine downtime. As a result, GRINDSTAR achieves an impressive availability level of over 96% and a long tool service life. Due to its innovative cooling system, the grinding wheels work precisely and to a consistent standard of quality – for up to six months or a production volume of 300,000 pieces and over.

GRINDSTAR instead of turning also impacts positively on the quality of workpieces, with significantly improved dimensional accuracy and excellent surface quality. The manufacture of burr-free parts during grinding is 100% guaranteed. And unlike turning, no chip impressions are created. The two profile grinding wheels used in the GRINDSTAR require no dressing and use an innovative lubrication method. The flushing system used prevents particles being deposited on the grinding wheels, eliminating the need for the reworking process frequently required when turning. This reduces the production time required and saves the need to invest in additional machinery, for instance for surface grinding or polishing.

When it comes to the choice of material, the GRINDSTAR offers maximum flexibility. Of particular interest for the automotive industry with its increasing demand for lightweight technology: Curable plastics and glass fiber-reinforced plastics can also be quickly and reliably ground. Materials which can be ground include high-alloy tough steels, hardened materials and even ceramics.

CBN or diamond can be used as abrasives. Junker knows which grinding wheel specification is the most suitable for which material. Because with GRINDSTAR, the company offers far more than just a grinding machine. Behind it is a concept permitting adaptation by experts based on their many years of experience. So that every GRINDSTAR is precisely adapted to the specific needs of each customer. From profiling through coating of the grinding wheels to the individual machine settings – Junker uses its in-depth expertise to plan the entire production process. This eliminates the need for laborious and costly test runs by the customer. The GRINDSTAR is quickly and simply up and running, entirely in keeping with the plug and play principle.

When manufacturing small components with a diameter of between 2 and 20 mm, the Grindstar grinding machine from Junker offers an economical alternative to turning.

All work steps take place on one machine in a single clamping set-up. This enhances process reliability and minimizes machine downtime.