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DISKUS Face Grinding MachinesPioneering since 1911.
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DISKUS WERKE SCHLEIFTECHNIK2 3
Machine Tools & Automation
Tools & Components
Production
International Sales & Service
DISKUS WERKE Schleiftechnik GMBH
Headquartered in Dietzenbach near Frankfurt (Main), Germany, DISKUS WERKE Schleiftechnik GmbH has been pioneering the face grinding and double face grinding technologies - still referred to as »DISKUS grinding by the industry« - since 1911.
DISKUS WERKE Schleiftechnik is a leading supplier of CNC instal-lations for the machining of flat and parallel surfaces. Assisted by the proprietary IONIC18 measuring and control unit and other means, the face grinding machines of DISKUS WERKE excel in top-level precision and high metal removal performance.
DISKUS designs tailored tools or the appropriate technological extensions in a joint effort with the other member companies of the DVS TECHNOLOGY GROUP.
Doppel-Planseiten-Schleifen
Planseiten-Schleifen
DVS TECHNOLOGY GROUP – Machine. Tool. Production.
The DVS TECHNOLOGY GROUP is made up of ten ma-chining companies focussing on the turning, gear cut-ting and grinding technologies. The DVS TECHNOLOGY GROUP has more than 1.200 employees worldwide and is one of the leading system suppliers for machines, tools and production solutions for the machining of vehicle powertrain components before and after hardening. The DVS TECHNOLOGY GROUP is comprised of the following divisions: DVS Machine Tools & Automation: Manufactures and sells high-precision machine tools, automation equipment and the associated services. DVS Tools & Components: Develops, manufactures and sells customised machine components, tools and abrasives. DVS Production: Operates DVS machine tools for the series production of components for passenger cars and commercial vehicles.
DISKUS Grinding.PRECISE. EFFICIENT. RELIABLE.
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DISKUS WERKE SCHLEIFTECHNIK4 5
Custom face grinding machines equipped with powerful DISKUS grinding technologies built by committed and expe-rienced employees – these are the hallmarks of DISKUS WERKE Schleiftechnik. Further services provided by the face grinding pioneers from Dietzenbach are:
DISKUS GRINDING – PLANAR PRECISION
LARGE VARIETY OF WORKPIECES – FROM PUMP VANES TO CONNECTING RODS
DISKUS WERKE SCHLEIFTECHNIK – YOUR APPLICATION IN GOODS HANDS
DISKUS grinding is grinding with the side faces of the grinding tools. A method for the efficient production of plane-parallel workpieces such as end faces of components like connecting rods, piston rings or bearing rings, which these days have to fulfil maxi-mum requirements in modern en-gines. The outstanding features of the method are high plane parallelism, evenness and extraordinary surface quality.
These allow machining precision to be achieved even with large-scale grind-ing tasks and high volumes of mate-rial removed by cutting, which previ-ously made lapping necessary in many cases. Since the workpieces are usu-ally ground without clamping, even very thin workpieces can be machined without any deformation whatsoever.
Whether small or large, thin or volu-minous – there are hardly any limits to the machining spectrum of plane-parallel workpieces with DISKUS ma-chines. The mass production of flat parts for the rolling bearing and ball bearing industry or the face grinding
of engine components in medium-sized series can be implemented with DISKUS technologies just as efficient-ly as the machining of components made of non-metallic materials such as carbon, ceramic or glass.
Machines: Vertical and horizontal grinding wheel layout Rotatory, linear and oscillating component transport Specially developed measuring technology for
controlling and optimising the face grinding process
System solutions: Application-specific development of grinding tools
with sister company NAXOS-DISKUS Schleifmittelwerke Combined machining such as turning and face
grinding in collaboration with DVS sister companies Upstream and downstream peripherals such as
brushing stations from a single source
Services: Implementation of grinding trials and production of
sample parts in the DISKUS application centre Development of special applications in cooperative
partnerships Global service network with local technicians on site
1911 DISKUS WERKE founded in Frankfurt am Main by engineer Dr. Carl Krug (*11.7.1881 in Stuttgart, † 19.12.1967 in Frankfurt am Main).
1913 First DISKUS grinding machine
1948 First DISKUS grinding machine with analogue IONIC measuring control for automatic grinding wheel wear compensation.
1969 First grinding machine with machine frame with portal design.
1984 First CNC-controlled DISKUS grinding machine
2017 Presentation of the DFine machine series
2011 Centenary celebrations of DISKUS WERKE at the new Dietzenbach plant.
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rnFace grinding machines from DISKUS WERKE Schleiftechnik stand out through high capacities thanks to ex-tremely short cycle times. To make the very most of this potential, DISKUS automation solutions are customised to the process and developed in line with customer requirements. The spec-trum of automation options ranges from manual loading by hand to fully automatic loading by robot arm.
AUTOMATION – KEY TO HIGH PRODUCTIVITY
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Compact and modern on the outside, individu-ally configurable on the inside, a precise match for your face grinding or brushing application – the DFine machine platform from DISKUS WERKE Schleiftechnik.
The broad-based DFine technology module has been designed for ma-chining a wide range of different plane-parallel components with a diameter of up to 250 mm. One-sided or two-sided face grinding, the grinding of shouldered surfaces or even brush machining – the DISKUS DFine can do it all. Even complex requirements such as the precise incorporation of defined step dimen-sion and evenness as well as the exact production of run-ning qualities, parallelism in the µm range and perpen-dicu-larity can be realised in a reliable process thanks to integrated DDG technology.
Diskus DFine – Face Grinding redefined.
THE TECHNOLOGYDISKUS DEFINED GRINDING – or DDG for short – describes the grinding tech-nology that makes the defined production of dimension, shape and position of shouldered and non-shouldered faces pos-sible on plane-parallel compo-nents for the first time. The offset and angle of inclination of the work-piece axes can be adjusted to produce a defined grinding pattern or a crowned or convex surface. Offsetting the axes to one another provides the choice be-tween aligned grinding or cross-grinding. Inclining the axes to one another results in concave or crowned faces.
Workpiece geometry
Single-spindle Multiple-spindle
Height [mm] 3-80 3-80
Diameter [mm] 100 (-8), 170 (-4), 250 (-2), 10-170(Number of tool spindles)
Ø Grinding wheel [mm] 20-100/310-400
Dimensions/weight
H/W/D [mm] 2.350/1.480/1.970
Total net weight without automation [kg] 3.500
One- and two-sided face grinding
Max. workpiece Ø 250 mm
Number of workpieces 2
Workpiece carrierfloating or clamped
Number of tool spindles
1
1-2Max. workpiece Ø 170 mm
Number of workpieces 4
Workpiece carrierfloating or clamped
Number of tool spindles
1
1-4Max. workpiece Ø 100 mm
Number of workpieces 8
Workpiece carrierfloating or clamped
Number of tool spindles
1
1-8
Face grinding of shouldered surfaces and brushing
Max. workpiece Ø 170 mm
Number of workpieces 4
Workpiece carrierfloating or clamped
Number of tool spindles
4
B 1-4Max. workpiece Ø 170 mm
Number of workpieces 4
Workpiece carrier clamped
Number of tool spindles
4
4-4Max. workpiece Ø 170 mm
Number of workpieces 4
Workpiece carrierfloating or clamped
Number of tool spindles
4
B 4-4
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Through-feeding face grinding with straight workpiece feeding
THROUGH-FEED GRINDING Especially suitable for large batch sizes
Offers a high degree of application flexibility
THROUGH-FEEDING PLUNGE-CUT GRINDING Suitable for medium batch sizes
Extremely flexible in application
Ideal for high allowances
CONTINUAL THROUGH-FEEDING PLUNGE-CUT GRINDING Medium to large batch sizes
Flexible for sensitive workpieces
Suitable for high allowances
PLUNGE-CUT GRINDING Small to medium batch sizes
Extremely flexible in application
Suitable for high allowances and high quality requirements
With the DDS XR range, the workpiec-es are conveyed on a transport plate through the grinding gap. This method allows workpieces with widely differ-ing geometries to be ground coplanar. Depending on the machine equip-ment, there are four different grinding methods available for machining. This makes the DDS XR range ideal for ma-chining a wide workpiece spectrum flexibly, economically and in top quali-ty. Thanks to the compact design and only one loading side, the grinding ma-chine is easy to automate and also suit-able for the manual loading of smaller batch sizes.
The technology of through-feeding face grinding with straight workpiece feeding was developed especially for the cost-efficient machining of large quantities of flat workpieces. Thanks to the straight workpiece supply, a very high material removal rate and very short cycle times can be achieved. This design can be used for machining workpieces with a width of up to 500 mm.
DDS XLThrough-feeding grinding for large quantities
Machine DDS 457 XR/EDDS 600 XR/E DDS 750 XR/E
Workpiece geometry
Height/width [mm] 0,8-80/8-0 0,8-80/8-250 1-80/8-405
Ø Grinding wheel [mm] 457 600 750
Dimensions/weight
H/W/D [mm] 3.100/3.300/2.800 3.300/3.500/3.000 3.300/3.500/3.000
Total net weight without automation [kg]
10.000 14.000 14.000Machine DDS 600 XL DDS 900 PL
Workpiece geometry
Height/width [mm] 0,8-80/15-210 2-80/30-500
Ø Grinding wheel [mm] 600 900
Dimensions/weight
H/W/D [mm] 3.000/2.600/3.300 3.600/4.400/4.700
Total net weight without automation [kg]
11.000 21.000
DDS XRRotating feed for high requirements
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DISKUS DDW XRMaximum precision for large quantities
DISKUS DDW XLThrough-feeding grinding for mass production
If high quality requirements have to be met for large batch sizes, there is no alternative to a DISKUS DDW XR.
A transport plate guides the work-pieces into the grinding gap, where they are machined to the re-quired dimension by rotating movements on both faces.
The horizontal alignment of the grind-ing wheels and the extremely rigid machine bed are the basis for excel-lent machining results with high plane-parallelism.
The DISKUS DDW XL was developed for mass and class, being able to pro-duce extraordinarily high quantities at consistent surface quality in minimum cycle time.
Different workpieces can be machined at one and the same machine. This flexibility is particularly useful for ball and rolling element manufacturers.
THROUGH-FEEDING OR PLUNGE-CUT GRINDING WITH TRANSPORT PLATE For high output and medium allowance
Especially for non-shouldered connecting rods or pre-shouldered shouldered connecting rods
THROUGH-FEEDING OR PLUNGE-CUT GRINDING WITH CLAMPED COMPONENTS For high output with medium allowance
Clamped grinding with high perpendicularity requirements
Especially for pump vanes or rolling elements
Machine DDW 400 XR DDW 600 XR DDW 900 XR
Workpiece geometry
Height/width [mm] 0,8-80/8-205 0,8-80/8-250 1-80/8-405
Ø Grinding wheel [mm] 400 600 900
Dimensions/weight
H/W/D [mm] 3.100/3.300/2.800 3.300/3.500/3.000 3.300/3.500/3.000
Total net weight without automation [kg]
8.000 9.000 18.000
Machine DDW 660 XL DDW 760 XL
Workpiece geometry
Height/width [mm] 0,8-80/8-250 1-80/8-405
Ø Grinding wheel [mm] 660 760
Dimensions/weight
H/W/D [mm] 4.300/2.100/3.000 3.300/3.500/3.000
Total net weight without automation [kg]
10.000 10.000
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DISKUS DHS Machine engine blocks more efficiently and precisely
Engine blocks (cylinder crankcases) are made of aluminium or cast iron, in rare applications a magnesium-alu-minium compound structure is used. The piston does not always run di-rectly in the engine block material, however, since this material does not fulfil higher tribological requirements. The re-placement of pistons and cyl-inders as the main wearing parts is also significantly more complicated. For this reason, a cylinder liner is often
fitted. The inner surface of this liner is generally drilled after fitting (in the case of “wet” cylinder liners before fitting) and then honed to precision. This guarantees the geometrical shape and surface roughness required by the manu facturer to meet the technical and ecological characteris-tics required. Cast iron or aluminium alloys have proved their worth as ma-terials for cylinder liners.
Maschine DHS XOZ
Workpiece geometry
Height/width [mm] 5-240
Ø Grinding wheel [mm] 457
Dimensions/weight
H/W/D [mm] 3.200/3.000/2.250
Total net weight without automation [kg]
10.000
Machine DDW 900 DDW 1060
Workpiece geometry
Height/width [mm] 20-850/20-240 120-1000/20-240
Ø Grinding wheel [mm] 900 1060
Dimensions/weight
H/W/D [mm] 3.200/5.400/5.700 3.400/5.400/5.800
Total net weight without automation [kg]
18.000 22.000
DISKUS DDW XOZOscillation for precision
Specially designed for very solid com-ponents whose weight does not al-low them to be supplied to the ma-chine by transport plate, as well as for components with machining sur-faces on different levels, such the shouldered connecting rod installed in the engine, the DDW XOZ excels with top marks for precision. The
Plunge-cut grinding withoscillation movement
components are supplied to the work chamber using a slide which creates an oscillation movement during the plunge-cutting of the grinding wheels. During machining the work-pieces rotate non-clamped between the grinding tools.
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Local service for international markets
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International DVS locations
International DVS representatives
Repairs Maintenance Remote diagnosis Spare parts supply
Training Production support Retrofit
To make your machine life cycle as long as possible, we offer the following services:
DISKUS IONIC18The process under control for 100% safety
Process safety and consistent machining quality form the basis for a zero-error strategy during grinding. To achieve this, DISKUS WERKE Schleiftechnik has developed the process controller IONIC18 which communicate with the machine control. In the case of tolerance deviations at the workpiece caused by grinding wheel wear, for example, the IONIC18 adapts the distance between the grinding wheels during operation, thus guaranteeing consistent machining results.
DVS UGrindCustomised hard-fine machining for shafts and chuck parts
Job order production and shops within larger mechanical engi-neering companies often face one and the same challenge: How can the metal-cutting machining of metal com-ponents be made more efficient even for small batch sizes? The focus is particularly on reducing the work required be-tween initial clamping of
the workpiece and achievement of the final dimensions.
The UGrind was specially developed for the hard finishing of small series of shafts and chucking components. Thanks to the smart operating inter-face, combined processes and high thermal and dynamic stability, overall machining time can be reduced by more than 50% with the UGrind.From the outset, the machine was de-veloped with the objective of achiev-ing optimised reproducibility taking the requirements of shop fabrication into account.
Radial grinding
Cylindrical grinding Face grinding
Cone grinding
Internal grinding
Internal turning
Groove turningFace turningExternal cylindrical turning
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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 – Gewindeschleifen – Bohrungshonen – HartdrehenI.D. grinding – O.D. grinding – Thread 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-universal-grinding.de Kombinierte Hartfeinbearbeitung für Klein- und MittelserienCombined Hardfine Machining for small and medium size batches
PITTLER T&S GmbH | www.pittler.deVertikal-Drehbearbeitungszentren & Pick-up-Systeme – VerzahnungszentrenVertical turning centers and Pick-up systems – Gear cutting centers
PRÄWEMA Antriebstechnik GmbH | www.praewema.deVerzahnungshonen/-schleifen – Verzahnungsfräsen – Anspitz-/HinterlegungsfräsenInternal and External Gear honing – Gear grinding – Hobbing/Fly-cutting – Chamfering
WMS Werkzeugmaschinenbau Sinsheim GmbH | www.wms-sinsheim.deService-Dienstleistungen – Generalüberholungen – Reparatur von BaugruppenMaintenance – Machine Retrofit – Repairs
WMZ 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 Technology America, Inc. | www.dvs-technology.com DVS Sales & Service in USA, Canada & Mexico
DVS Technology (Shenyang) Co., Ltd. | www.dvs-technology.comDVS Sales & Service in China
DVS Technology Europe GmbH | www.dvs-technology.comDVS Sales & Service in Europe
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DISKUS WERKESchleiftechnik GmbHJohannes-Gutenberg-Straße 163128 DietzenbachGermany
www.dvs-technology.com
Tel +49 (0) 6074.48402 - 0 Fax +49 (0) 6074.48402 - 36Mail [email protected]