BUDERUS ML 235Hard-fine machining centre

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BUDERUS SCHLEIFTECHNIK GMBH

BUDERUS Schleiftechnik GmbH is an international mechanical engineering company based in Aßlar. In the field of hard-machin-ing of rotationally symmetrical components, the company is one of the leading suppliers of precision machines for internal, exter-nal and thread grinding, often also in combination with hard turn-ing operations as well as bore honing and other hard machining processes.

BUDERUS Schleiftechnik develops and produces highly efficient machine and automation solutions, which are used particular worldwide in the automotive industry. Gear wheels and shafts are precisely machined with BUDERUS technologies up to the μ and thus ensure the highest degree of precision in modern passenger car and commercial vehicle transmissions.

Cylindrical grinding at gear shaft

Surface- and Taper grinding at gearwheel

The DVS TECHNOLOGY GROUP is made up of experienced machining companies focussing on the turning, gear cut-ting and grinding technologies. The DVS TECHNOLOGY GROUP has more than 1,000 employees worldwide and is one of the leading system suppliers for machines, tools and production solutions for the machining of vehicle pow-ertrain components before and after hardening.

The following divisions make up the DVS TECHNOLOGY GROUP: DVS Machine Tools & Automation: Manufactures and sells high-precision machine tools, automation equipment and the associated services. DVS Tools & Components: Develops, manufactures andsells customised machine components, tools and abrasives. DVS Production: Series production of components for passenger cars and commercial vehicles using DVS ma-chine tools.

DVS International Sales & Service: Local DVS Contactfor Sales and Service on International Markets.

DVS TECHNOLOGY GROUP

Machine Tools and Automation

Tools and Components

Production

International Sales and Service

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Chuck diameter mm 160; 200; 250

Z-axis mm 320

X-axis mm 1.200 - 3.000

Spindle capacity 100% duty cycle

kW 17; 36

Speed rpm 6.000

Rapid traverse X/Z m/min 30; 60 / 20 (feed screw; linear drive)

Grinding spindles rpm 12.000 - 90.000

Technical specifications

ML235 – The Highlights

Modular automation concept – compatible for series production

Complete machining with reduced unit costs

Optimised accessibility for simple tool changing and easy cleaning

Freely configurable work chamber for combined hard-fine or simultaneous machining

Integrated bore hole honing for maximum surface requirements

Compact & adaptive machine design

Automation cell expandable by measuring, marking and

cleaning stations

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BUDERUS Schleiftechnik recognised the advantages of combined machining many years ago and con-tinually advanced development in this field. The work chambers of the resulting modular platforms can be freely configured with the aim of carrying out as many machining processes as possible in a single clamping.

BUDERUS solves complex tasks such as gear wheels from passenger car gearboxes, the functional sur-faces of which have to be machined to precise dimensions as quickly as possible, using the modu-

lar principle. Thus external and internal grinding can take place simultaneously. The front and rear faces are turned and, if necessary, the bore hole can also be honed in the same clamping.

BUDERUS machines are used wherever complex machining processes are to be run with the short-est cycle times and minimum shape and position tolerances are required. In automotive engineering, the tool industry, for manufacturing ball screws or in general mechanical engineering – all over the world.

Combined machining

Hard-fine machining in the BUDERUS COMBINED PROCESS Hard-turning Internal and external grinding Bore hole honing

INTERNAL GRINDING

THREAD GRINDING

EXTERNAL GRINDING

SHAFT GRINDING

BORE HONING

HARD TURNING

Twins grind faster

Significantly reduced cycle times coupled with almost double the output are possible with BUDERUS machines thanks to the intelligent linking of com-bined machining processes with twin workpiece spindles.

Users thus get unmistakably more technologies in just one machine and can considerably reduce both investment costs and the machining costs per component.

Component quality remains high, since the workpieces are almost com-pletely hard-fine machined in a maximum of two clampings.

Two main spindles for twice the number of parts despite only using one machine.

Fast and complete thanks to the second main spindle for machining the front and rear of the component.

Simultaneous internal and external grinding

Internal grinding with TwinSpindel

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Configurations in Focus

Two additional axes make internal and external grinding possible simultaneously

Version IA SiMac

External and internal grinding in one clamping

Version IA

Machining of gear wheels and chuck parts Automatic loading – pick-up system

Grinding of shafts in one clamping with up to three spindles

Version 3 A

Grinding of shafts in one clamping with two grinding spindles simultaneously

Version 2 A

Grinding of shafts in one clamping with one grinding spindle

Version 1 A

Simultaneous grinding and turning turret for the complete machining of diameters and faces

Version IA 8TR SiMac

Three tools in one (small) machine for maximum flexibility

Version I A T

Centre bearing and steady rest for the grinding of hollow shafts in one clamping

Version M 2 I

The modular structure makes different configurations possible.

Wellenbearbeitung

Modular automation cells – compact, productive and without increase in cycle times

The loading options of the ML235 are modular too. Standardised automation cells with rotary maga-zine, cage stacking magazine or linear automation for manual loading or process supply of up to two production cells with components. Raw parts and machined parts are always completely separated without a risk of mix-up. Traceability through consist-ent batch management is a matter of course.

The compact automation units with cage or rotary magazines supply the production cells in parallel during primary processing time and without inter-ruption. A multifunctional SCARA robot arm is responsible for the high-speed handling (11 m/s) of different workpieces.

Integrated measuring system

Automation cell with cage magazine system

Centrifugal cleaning station

Rotary magazine on the right

Linear automation with belt on the left

High-precision measuring stations as well as PLC systems and nOK chutes can be integrated in the automation cells, as can cleaning stations or mark-ing systems. Accompanying secondary processes are implemented without increasing cycle times.

Automation module for shaft-shaped components

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The availability of raw materials as well as the switch to renewable energy sources is forcing energy prices up and requiring industry to use resources more responsi-bly and economically. This is exactly the intention behind the pioneering concept for machine tools from the DVS GROUP known as “DVS CleanTec®”. This con-cept will enable the future challenges of sustainability to be mastered through reduced emissions and the efficient use of energy.

Reduced emissions

The first pillar of the “DVS CleanTec®” label which must be considered is the factor “reduced emissions”. In order to minimise downtimes during mainte-nance or cleaning work, the machine

is designed with easy cleaning in mind. Cleaning intervals can be specified and documented through the machine con-trol with the aid of the planned DVS CleanTec® additional software.

The leak-tightness of the machine is also guaranteed, particularly with a view to wet machining. Efficient work space extraction combined with encapsulated automation solutions make a further decisive contribution to reducing emis-sions. Liquids or chip residue carry-over is prevented with the aid of efficient clean-ing stations.

ENERGY-EFFICIENT TECHNOLOGY+ =

CLEAN PRODUCTION

Standard technology

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Efficiency technology

Efficient use of energy

Scientific studies show that the costs for energy, compressed air as well as cool-ing agents and lubricants can account for up to 40% of the operating costs for machine tools. In some cases this even exceeds the purchasing price, which is still considered the main argument for invest-ment decisions.If the entire life cycle of a machine is con-sidered, however, it is worth taking a closer look at the machine’s energy effi-ciency, not least in view of the continued steady increases in the cost of electricity.DVS CleanTec® certified machines have been designed to keep operating costs low without accepting any compromise as far as quality or cycle times are concerned.

Spring clamping systemThe concept does without hydraulic components throughout – even for the clamping systems, where energy-efficient spring-loaded clamping systems are used instead.

Encapsulated work spaceThe encapsulated machine technology prevents emul-sions or chip residue being carried over. This means that even gaseous emissions are retained within the machine.

Cleaning stationA cleaning station at the end of the process chain guaran-tees drip-free output of the workpieces and, together with the dry gripper used in the feed chamber, effectively prevents emulsions being transferred.

Reduced emissions

n Simple cleaning of the machine housing

n Encapsulated machine technology

n Sealed housin no emissions escape

n Efficient work space extraction

n Cleaning station for workpieces

n Software-controlled documentation of cleaning intervals

Energy efficiency

n Hydraulic-free machine design

n Reduction of pneumatic components

n Cooling systems and motors designed tailored to the application

n Use of motors with the highest efficiency classes

n Consistent use of synchronous drive technology

n Automatic standby mode

DVS CleanTecThe sustainability label for BUDERUS machines

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BUDERUS Schleiftechnik has a globe-spanning network of local service techni-cians. These guarantee quick help with any problems and have direct access to regional spare parts stores.

For optimum preparation of “Start of Production” BUDERUS Schleiftechnik offers intensive training for machine operators and accompanies them with technical expertise during the first few weeks after SOP.

Alongside training and servicing work, BUDERUS Schleiftechnik also overhauls tried-and-trusted machinery. The BUDERUS retrofit program ranges from complete overhauling to the replacement of individual assemblies.

Contact our Service department at:service@buderus-schleiftechnik.de

• Remote diagnosis• Spare parts supply

• Service• Retrofit

• Training• Production support

Worldwide service network –For quick help in case of problem

• Repair • Maintenance

Mitglieder der DVS TECHNOLOGY GROUPMembers of the DVS TECHNOLOGY GROUP

DVS MACHINE TOOLS & AUTOMATION

DVS TOOLS & COMPONENTS

DVS PRODUCTION

DVS INTERNATIONAL SALES & SERVICE

BUDERUS Schleiftechnik GmbH | www.buderus-schleiftechnik.deInnenrundschleifen – Außenrundschleifen – Bohrungshonen – HartdrehenI.D. grinding – O.D. grinding – Bore honing – Hard turning

DISKUS WERKE Schleiftechnik GmbH | www.diskus-werke.dePlanseiten-Schleifen – Doppel-Planseiten-Schleifen – SonderbearbeitungFace grinding – Double face grinding – Special machining

DVS Universal Grinding GmbH | www.dvs-technology.comKombinierte Hartfeinbearbeitung für Klein- und MittelserienCombined hard-fine machining for small and medium size batches

PITTLER T&S GmbH | www.pittler.deVertikal-Drehbearbeitungszentren & Pick-up-Systeme – Verzahnen in der KomplettbearbeitungVertical turning center & Pick-up systems – Gear cutting for complete machining

PRÄWEMA Antriebstechnik GmbH | www.praewema.deVerzahnungshonen/-schleifen – Verzahnungsfräsen – Anspitz-/HinterlegungsfräsenGear honing – Gear grinding – Hobbing/Fly-cutting – Chamfering

rbc Fördertechnik GmbH | www.rbc-robotics.deKamerageführte Roboter-AutomationssystemeCamera-guided robot automation systems

Werkzeugmaschinenbau Sinsheim GmbH | www.wms-sinsheim.deService-Dienstleistungen – Generalüberholungen – Reparatur von BaugruppenMaintenance – Machine Retrofit – Repairs

Werkzeugmaschinenbau Ziegenhain GmbH | www.wmz-gmbh.deDreh- & Kombinationsbearbeitung wellenförmiger Bauteile – MotorspindelnTurning & Combined machining of shafts – Motor spindles

DVS TOOLING GmbH | www.dvs-tooling.de Werkzeuglösungen und Technologiesupport für das PRÄWEMA VerzahnungshonenTool solutions and technology support for PRÄWEMA gear honing

NAXOS-DISKUS Schleifmittelwerke GmbH | www.naxos-diskus.deKonventionelle Schleifwerkzeuge – CBN & DiamantwerkzeugeConventional grinding tools – CBN & Diamond tools

DVS Production GmbH | www.dvs-production.deDVS Technologien in der Serienfertigung für PKW-KomponentenDVS Technologies in mass production for passenger car components

DVS Production South GmbH | www.dvs-production-south.deDVS Technologien in der Serienfertigung für Nutzfahrzeug-KomponentenDVS Technologies in mass production for commercial vehicle components

DVS Precision Components (Taicang) Co. Ltd.Präzisionskomponenten des Antriebsstrangs in der Serienproduktion für Pkw und Lkw auf DVS-Maschinen Precision powertrain components in series production for passenger cars and trucks on DVS machines

DVS Technology America, Inc. | www.dvs-technology.com DVS Sales & Service in USA, Canada & Mexico

DVS Technology (Taicang) Co., Ltd. | www.dvs-technology.comDVS Sales & Service in China

DVS Technology Europe GmbH | www.dvs-technology.comDVS Sales & Service in South Europe

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BUDERUS Schleiftechnik GmbH Industriestraße 3 35614 Aßlar Germanywww.dvs-technology.com

Tel. +49 (0) 6441 8006 - 0Fax +49 (0) 6441 8006 - 16Mail info@buderus-schleiftechnik.dewww.buderus-schleiftechnik.de