Put through its paces
MULTIGRIND
®
CA Machine Check in fertigung magazine
The Haas Newsletter . The latest news fr om the world of grinding Branchenreport Kühlschmierstoffe: Wasser statt Öl? 6 GDX-Schnittstelle Holpriger Start in neues Zeitalter 14
Auf Herz + Nieren Schleifmaschine
Multi-grind CA von Haas 60
Januar/Februar 2011 B 30523, Einz
elpreis � 15,- wwwSonderausgabe .fertigung.de
1-2·2011
GDX-Schnittstelle
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Titelbild und Beitrag Seite 12
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Put through its paces
The Multigrind CA grinding
machine from Haas
Branchenreport Kühlschmierstoffe: Wasser statt Öl? 6 GDX-Schnittstelle Holpriger Start in neues Zeitalter 14
Auf Herz + Nieren Schleifmaschine
Multi-grind CA von Haas 60
Januar/Februar 2011 B 30523, Einz
elpreis � 15,- wwwSonderausgabe .fertigung.de
1-2·2011
GDX-Schnittstelle
Schwerpunkt:
Titelbild und Beitrag Seite 12
werkzeug
werkstück
The Multigrind CA grinding machine from Haas:
at Haas, grinding technology is
defined by the interaction of system components whose functions are finely tuned to
one another and that together form a “grinding cube” with an optimized design. The
CA machine, as a smaller offshoot of the CB machine, exhibits the same rigidity,
pre-cision, and dynamics as its predecessor. And when it comes to the machine’s level of
automation, functionality, and accessibility, it in fact offers additional benefits.
MULTITALENTED WITH A KICK
R
egardless of whether the user is grinding tools or using functional parts from the fields of medical engineering and automotive manufac-turing, with the CA machine from Haas the user can adjust the machine’s de-sign to perfectly match their specific needs.Machine Design
The machine’s components are assem-bled for the customer in the “Haas
Ma-chine Configuration Program,” and the data generated is then used throughout the rest of the workflow to check on the availability of parts, to order parts, to provide information about delivery times, for parts lists, and to calculate prices. This dataset forms the basis for the scope of all further work. The ma-chine’s design, the various compo-nents, all supply lines, and the electri-cal appliances are all available as a CAD dataset. When it comes to the CA
ma-chine’s design, the base of the machine is “completely seamless.” This means that the middle section of the base and the support assembly for the Y and Z axes are cast from a mineral composite with an epoxy content of about five percent into one cube. The machine’s rigidity and precision are achieved through the central placement of the axes, the minimization of protrusions, and calculation of the dimensions of the cast composite cube using FEM
(fi-The CA machine for Haas is mainly used to grind tools. When combined with a wide variety of different avail-able components, it can also be used for high-quality grinding jobs on workpieces from the fields of medical and automotive technology.
Photos: Haas
Initial startup 25.00 24.50
Time until first job 12.50 12.50 Confirmation of processing quality 2.50 2.00 Axis measurement 2.50 2.50 Operator training 7.50 7.50
Ease of maintenance 100.00 87.50
Accessibility for maintenance purposes 25.00 20.00 Accessibility in case of malfunctions 35.00 35.00 Time needed to exchange main spindle 15.00 9.00 Time needed to exchange feeder components 15.00 13.50 Automatic monitoring features 10.00 10.00
Automation 100.00 97.00
Startup / initializing 30.00 27.00 Operating / loading 30.00 40.00 Effort required to load workpieces / transport parts 40.00 30.00
Controls 50.00 46.00
Controls / ease of use 30.00 30.00 Collision inspections 20.00 16.00
Ease of retooling 50.00 48.00
Loading table flexibility 25.00 25.00 Setup effort 15.00 15.00 Multiple loading / mixing models 10.00 8.00
Service 75.00 61.45
Availability of service personnel 30.00 30.00 Spare parts inventory / spare parts manufacture 22.50 15.70 Part drawings archive; online availability 15.00 10.50 Service agreements 7.50 5.25
TCO 85.00 54.40
Analysis of cost drivers available 34.00 20.40 Assessment and figures: downtime / repair time 34.00 20.40 CIP by machine supplier in the event of a malfunction alert 17.00 13.60
Contractual terms 15.00 8.00
Warranty period 5.00 3.00 Payment terms 5.00 3.00 Fixed TCO process 5.00 2.00
Total 500.00 426.85
The Comprehensive Machine Check: Results
You can view the complete
list at www.fertigung.de. Maximum points available
Haas Mul-tigrind CA points scored
PUT THROUGH ITS PACES
Machine Check
Robots with their own Fanuc controllers are used for automated workpiece loading.
The Multigrind CA is a compact machine with an attractive design. The operator pendant is swivel-mounted, and the height of the keyboard can be adjusted for the perfect viewing and ergonomics.
in the area where the two connect; as a result, the entire Z axis does not need to move when rotating the spindle. This design significantly enhances the dynamics of the grinding spindle.
Haas manufactures the grinding spindles used in the CA machine itself, and they are directly powered and fine-ly balanced. The standard version comes equipped with an HSK-50-E tool holder. If both ends of the main spindle are to be loaded with tools, the tools are mounted using a taper. Before being installed, all spindles must un-nite element method). The guides for
the linear axes (X, Y), which are em-bedded in the composite, are aligned using a high-precision template and then connected to the base with an ad-hesive thus further enhancing the ma-chine’s level of precision. The Z slide carriage is located directly in the center of the machine, which means that its kinematics and kinetics are perfect for the grinding process. The CA machine’s Z axis has also been redesigned. Here, the integrated C axis is only pivot-mounted to the bolted-on main spindle
The heart of the grinding machine is the grinding spindle: it is symmetrically fitted in the grinding cube. The vibration-cush-ioned mineral-composite base, the em-bedded guides, and the machine’s well-engineered kinematics lend the machine precision and process reliability.
Facts and Figures: Machine Data
Haas Multigrind CAWorkspace (mm) 630 × 345 × 430 Machine table (mm) 1,000 × 440 C axis, angle of rotation 300° A axis 1,000 rpm; optional: 2,600 rpm Height of centers 175 mm Tool holder for working spindle HSK 50E Spindle option: 1 spindle end 8,000 rpm;
11.5 kW (100%); 14.4 kW (40%) Spindle option: 1 spindle end 18,000 rpm 11 kW (100%); 12 KW (40%) 2 spindle ends mounted taper 31.75 mm;
8,000 rpm; 11.5 KW (100%); 14 KW (40%) A axis tool holder SK 50;
HSK 50/63/80 optional Tool changer (number of tools) 8 up to Ø 250; 16 up to Ø 100; 13 up to Ø 250; 27 up to Ø 100 Time to change tools 10 seconds without grinding wheel guard
Controller Siemens 840 D sl (Haas software for grinding cycles) Footprint (mm) 2,621 × 2,400 × 3,200 Weight 8.5 metric tons Base price: about 210,000 euros without optional equipment
Multigrind CA Grinding Machine from Haas
■ ■ Multifunctional■X■axis ■ ■ Attractive■overall■design ■ ■ Good■accessibility ■ ■ Own■software■for■NC■and■PLC ■ ■ Numerous■preprogrammed■grinding■cycles ■ ■ Dedicated■service■team■ Weaknesses: ■ ■ The■implementation■of■a■database■for■service■ analyses■is■missing Strengths: ■ ■ A■rigid■machine ■ ■ High-precision■basic■geometry ■ ■ Numerous■available■modules■(2,500■total) ■ ■ Flexible■tool■changer ■ ■ Structurally■well-designed■and■flexible■coolant■ unit■ ■ ■ Intelligently■designed■mineral-composite■ma-chine■body ■ ■ Expertise■in■spindle■manufacturingdergo a 24-hour endurance test. Haas also offers a high-frequency spindle that rotates at 70,000 rpm as an op-tional accessory. This spindle is held up by the main spindle housing and is de-coupled to reduce vibrations.
The CA’s machine table is highly flex-ible thanks to the built-on X axis and the integrated A axis. A total of 15 dif-ferent variations of the table are avail-able; so when it comes to length, tail-stock design, grinding between tips and steady rests, and grinding longer tools, no customer need will go unfulfilled.
The CA machine comes standard with a 12 kW spindle that rotates at 8,000 rpm (or 18,000 rpm) and two grinding wheel ends. A high-frequency spindle that rotates at 70,000 rpm can also be at-tached to the front flange.
Machine Check
PUT THROUGH ITS PACES
Haas has delivered, about 90 percent are equipped with an automatic tool changer and about 70 percent with au-tomated workpiece loading. For load-ing, robotic solutions are used that are controlled independently from the ma-chine and only communicate with it through interfaces. On the CA machine, these are located on the right side, and they are on the left side of the CB ma-chine.
Service / TCO
The service department is comprised of a small, dedicated team of four that is always available; after-hours calls are forwarded to an emergency hotline. If necessary, personnel from the final as-sembly department can also be called upon. On-site service is offered within 24 hours. If the customer has a mainte-nance agreement, service can be pro-vided even faster. Technical personnel are always available in the service de-partment; this means customers are provided troubleshooting support over the phone or by modem from the very first step.
All service operations are recorded in a PP system, which makes it possible to conduct life cycle and cost analyses. These are carried out manually; fixed, preprogrammed assessment algorithms have not been defined, however. The daily quality meeting directly covers malfunctions experienced by actual customers, and this backs up the state-ment: “Two or three malfunctions can-not be allowed to happen one after the other.”
EdwinNeugebauer
require fewer grinding wheels, then a segment of the changer can also be used to store workpieces.
The highlight of the tool changer is the Haas-patented cooling unit. Since the position of the cooling nozzles in re-lation to the grinding wheel has a sig-nificant effect on quality and grinding performance during the grinding pro-cess, the design and use of this unit both take on important functions. The coolant unit and corresponding grind-ing wheel guard can be removed from and mounted to the changer with the main spindle.
When wheels are changed that have different contours, the motor-driven coolant nozzles automatically adjust their height to match the current wheel’s contour. As a result of intelli-gent wiring within the unit and the unit’s controller, the nozzles for the front and back chambers can be oper-ated independently. This feature is a world’s first, and it ensures that the grinding wheel is always supplied with the ideal amount of coolant.
Controls
When it comes to the machine’s control unit, Haas uses the Siemens 840D solu-tion line as its hardware platform. The NC and PLC software and the layout of the user interface were all developed internally by Haas and contain all the necessary features. DLLs (direct library links) are used to program the wide va-riety of different grinding cycles and to ensure that the structure of the work-flow is designed in the optimum man-ner. Special grinding cycles are pro-grammed by Haas – even 3-D tracks that can be inserted into the grinding wheel using the dresser unit.
Automation
Out of all the CA and CB machines The A axis can rotate at 2,600 rpm and
as such can be used for cylindrical grinding in conjunction with measure-ment control.
The supply units, such as oil for lu-brication, semifluid grease for the spin-dle, the cooling unit, and the machine’s pneumatic and hydraulic systems, are all installed in a separate enclosure in an extremely orderly fashion. The sys-tematic design of these units, as well as of the entire machine, can be seen quite clearly here. CAD datasets exist for every part of the machine. This can also be easily understood examining the way the electrical cabinet is set up. And one point of interest is the fact that the machine’s electrical wiring is fed through conduits cast as part of the machine’s mineral-composite body. This minimizes the effort needed to wire up the machine and also ensures that the machine’s interior remains free of wire clutter.
Tool Changer
The full flexibility of the Multigrind CA machine is encompassed in the design and configuration of the tool changer. It is designed as a pick-up changer with two segmented wheels that operate in-dependently of one another and can hold a maximum of up to 27 grinding wheels with a diameter of 100 mm. The mounting device for the grinding wheels’ HSK flanges is supported by the base frame using spring-steel packages. These absorb the shock when the grind-ing spindle latches on, and this increas-es the useful life of the main spindle as a result. If the operator’s grinding duties
Haas Schleifmaschinen GmbH, Germany D-78647 Trossingen, Tel.: 07425/3371-0, E-Mail: [email protected]
My Opinion
The■machine■is■constructed■to■be■ rigid■ and■ precise,■ which■ are■ the■ two■most■important■requirements■ for■ grinding.■Thanks■ to■ the■ many■ different■ components■ available,■ the■ machine■ can■ be■ customized■ for■every■customer.■The■tool-changer■and■X■axis■ are■both■extremely■impressive■components■due■to■ the■multifunctional■design■possibilities■they■offer.■ Haas■has■come■up■with■a■unique■and■intelligent■ solution■ with■ the■ automated■ height-adjustable■ coolant■unit.■When■examining■the■CA■machine■and■ also■when■walking■through■the■factory■halls,■one■ repeatedly■ encounters■ ingenious■ solutions■ that■ document■ the■ manufacturer’s■ expertise■ and■ in-ventiveness.
■ Edwin■Neugebauer
The height-adjustable coolant unit is a patented solution from Haas. The spray nozzles adjust auto-matically to match the grinding wheel.
The tool changer is equipped with two segments and can accommodate various tools. It can also be used as a place to store workpieces.
The Haas Newsletter . The latest news fr om the world of grinding
We keep
your world
spinning
*
* spinning like a grinding wheel
At heart, we have always been inquisitive and love to experiment. And, our world has now been re-volving around the wheel for more
than 75 years. To be more precise, around grinding wheels – the grinding wheels that are used in our precision grinding machines.
Our company is based in a country whose engineers are noted for their innate drive for perfection and we happen to employ a fair number of them. It comes as little surprise then that our products are always ahead of the times.
HAAS Schleifmaschinen GmbH · Im Sandbruch 1
