Sampustensili G400-Masina Rectificat Dantura

7/29/2019 Sampustensili G400-Masina Rectificat Dantura

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G 400

generating and profile grinding machine


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2 G 400

Our aim is simple:to bring an

economic surplus

to your daily

manufacturing

life.

precision

economy


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G 400 3

+ Small footprint, space saving and compact

+ Modular design for cost savings and spare parts availability

+ Thermally stabile and vibraton damped machine structure

+ Optimised direct drives for tool and work spindle

+ Easy service and maintenance with quick access and online support

+ Extended workarea for wider workpiece range

+ Generating grinding with electroplated CBN and dressable tools

+ Dressing with profile dressing rolls or diamond-plated dressing gear

+ Modular dressing unit for tool packages on one spindle

+ Profile grinding with electroplated CBN wheels

+ High speed loading system

+ Quick-change tool clamping for fast tool change

+ Universal workholding

+ Siemens 840 D control

+ Windows-based Samputensili Operator interface for easy operation

+ System solution machine, tool and process out of one hand

Simply efficient. G 400 generating

and profile grinding machines.

The G 400 has been designed for the efficient mass production of gears and shafts with

straight and helical gearings.

This simple-to-operate and reliable machine is equipped with latest drive and tool tech-

nology for the efficiency you demand in today's production and the flexibility you might

need tomorrow.


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4 G 400

Basics first. With

innovative concepts

and attention for the

necessary details.

The common modular platform is the

base for a very compact but stabile

machine with an optimum cost-benefit ratio.

Nevertheless no compromises are

made when it comes to thermal stability

and vibration damping: advanced

cast iron compositions allow tightertolerances while maintaining the

optimum characteristics of rigid and

thermal stabile cast iron bases.The coolant flooded machine structure

supports the rigidity and keeps tem-

perature deviations to a minimum.

The chute is designed with inclined

planes to avoid the buildup of swarf

nests in the workarea. Swarf is evacu-

ated immediately by the integratedflushing system and directly trans-

fered to the filtration unit. With no heat

transfered to the machine structure

thermal stability is maintained even

in the harshest production environ-

ments.

G 400

ingeniously simple Your advantages+ Modular platform for lean

and cost-efficient

manufacturing

+ Cast iron, ribbed structure

for superior vibration

damping

+ Circulation coolant system

for thermal stability of

structure

+ Inclined chute planes and

additional residue flushing

for optimum swarf removal


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G 400 5

A Swivel grinding head

B Rotation grinding spindle

C Rotation workpiece spindle

W Swivel coolant nozzle

X Radial movement grinding column

X1 Radial movement centring unit

Y Tangential movement grinding head

Z Vertical movement grinding head slide

Z1 Vertical movement tailstock

U1 Rotation dressing spindle A

U2 Rotation dressing spindle B

anti-vibration

stability


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6 G 400

Electroplated CBN Dressable corundum

Grinding wheel

Grinding worm

power

flexibility


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G 400 7

The grinding spindle with its spe-

cifically large tool capacity allows the

use of long grinding worms to raise

the tool life of single worms or com-

binations of roughing and finishingtools employing electroplated CBN or

ceramic bound grinding worms and

wheels. So you can always rely on the

most efficient technology or the most

beneficial combination to completeyour grinding task.

Due to the extremely high rota-

tional and linear accelerations with

their appropriate absolute speeds

the machine guarantees excellentcycle times and is perfectly suited

to benefit from future developments

on the grinding tool sector.

Universal quick change clamping

systems for mass production envi-

ronments allow rapid tool changeso valuable grinding time is never

compromised.

Highly productive results

with a future-safe investment

+ Tailored solutions for

each application

+ Grinding of smaller workpieces

and complex geometries

+ Power and speed reserves for

future tool developments

+ Simple, stabile and flexibleworkholding solutions

+ Choice of tool suppliers

+ Reduction of overall cost

Optimised direct drives for tool

and work spindle with indipendent

refrigerating circuits.

Large tool capacity

New enlarged workarea

capacity

Electroplated CBN and

dressable corundum tools

Grinding worms and wheels on one

spindle

Standard tool clamping systems

and workpiece fixtures

Tool usage determination by power

input control

Your advantages

efficiency


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8 G 400

Automatic centering

of workpieces

Portal loader waiting for a wokpiece to be

pre-centered while another workpiece is being

ground. Up front the dressing master standing by.

Time-parallel

centering of work-

pieces

The automation via portal loader

allows the time parallel pre-centering

of workpieces on a separate sta-tion outside the work-area reducing

the actual centering process on the

workspindle.

Your advantages

Centering of workpieces is one of the

key issues when it comes to error-

free and fast production. The G 400

allows you to center your workpieces

automatically and reliably.

+ Completely automatic

centering

+ Stabile and reliable solution

+ Protected from swarf and

heat

+ Optional time-paralllel pre-

centering of workpieces

The centering unit is mounted on

a stabile arm which is swivelled

into the workarea when required.

During grinding it is stored safely

out of the way so centering results arenot influenced by swarf and heat.

speed


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G 400 9

reliability

control


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10 G 400

Your advantages

+ Flexible dressing,

no special dressing toolsrequired, no sourcing

problems, less costly supply

+ Very precise, high quality

dressing results

+ Automatic applicaton,

completely integrated intow

CNC

Dressing for flexible efficiency

via standard profile dressing rolls

The profile dressing unit consists ofa standard profile dressing roll and

an OD dressing stick mounted on a

stabile arm which can be swivelled

into the workarea. If the tooth rot

diameter must be ground as well a

tip radius dressing roll is applied tocreate the required tip radius on the

grinding tool.

When required the dressing unit isautomatically brought into working

position. The dressing movements are

actuated by interpolation of the axesB and Y.

The application of generic profiledressing rolls saves you costs and

grants fast supply of dressing tools.

You may deploy single or double flank

dressing rolls without inclination.

Optionally you can mount a doubledressing unit which allows you to dress

two grinding worm packages on one

spindle without dressing tool change.If not required the second dressing

unit is stored orderly away, protected

from swarf within the workarea.

Additional dressing spindle

stored away readily availableflexibility


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G 400 11

Option

+ Dressing unit for the dressing

of tool packages on one spindle

+ No tool or format changes for

the grinding of 2 gearings on

one workpiece

+ Cutting down of non-productive auxiliary times

efficiency


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12 G 400

+ Faster dressing and less tool

wear with larger contact

surface between dressing

and grinding tool

+ Simple error-free process

with all necessary data already

included in the master geometry

+ Dressing process controlledby the generating grinding

software. No additional soft-

ware, programming or special

dressing cycle setup necessary

+ Clean and protected storage

of the dressing master outside

the workarea

Diamond plated dressing master gear

Non-productive dressing times canbe reduced considerably by dressing

via a diamond-plated dressing gear.

With its total length in contact and

its ten times larger diamond-plated

surface, the dressing gear dresses

a lot faster and with less wear, thusmuch more productively than a single

dressing roll. Additionally dressing

tool changes are reduced as well.

For further cost reductions positiveplated dressing masters are up

to three times replatable. Double-

reversed plated dressing masters willraise your productivity even more.

For the dressing cycle, the dressing

master is transferred like a work-

piece from an external station into

the workarea. Consequently it alwaysstays clean and is not affected by

swarf and heat.

Fast and simple profile dressing

via dressing gear

Your advantages

productivity


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G 400 13

Optimum results with less energy saving

cost in the long run

The coolant nozzle automatically fol-

lows the movement of the tool head.

For different wheel sizes it can be

adjusted modularly to apply the cool-ant fluids exactly to the contact point

between tool and workpiece. The

adjustable output angle and the flatbut wide coolant jet secure the opti-

mum application of a coolant film on

the grinding wheel. The risk of grind-ing bur is significantly reduced with-

out wasting coolant and energy.

+ Positioning towards

point of grinding action

+ Adjustable to different wheel

sizes

+ Special nozzle outlet for

efficient application

+ Coolant pressure and volume

adjustable

+ Long-term savings of operation

cost

Your advantages

savings


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14 G 400

from the workarea during the grinding

process it is protected from swarf,

oil and heat. In the long run it proofs

itself very reliable.

Especially advantageous is the pos-

sibility to load ring gears or shaft-type

workieces alike. With its rotary gripper

joint and various gripper jaw options

the standard portal loader can pick

and place vertically or horizontallydepending on the requirements of

your automised workflows.

The G 400 is available with several

standard automation solutions. The

modular pick-and-place portal loader

allows the easy linking and integra-tion in existing production processes.

It hands workpieces to an integrated

workpiece magazine or directly to

your existing workpiece conveyor

band. Optionally a pallet storagesolution can be integrated seamlessly.

The light but stable construction of

the portal loader with its low masses

allows high acceleration rates and

fast change times.

The setup of the loader is problem-

free since all axes are CNC control-

led. Since the loader is retracted

Automation options: Maximum productivity

with minimum auxiliary times.

Your advantages

+ Direct and fast auto-

mation options withminimum change time

+ Automation systems

protected against

swarf and heat

+ Universal and flexible to fit

all workpiece requirements

+ Easy integration into

existing manufacturing

lines

Portal loader waiting outside the workarea for a

shaft to be ground, the next workpiece readily

in its gripper.

speed

universality


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G 400 15

Q

Flexibility for the

tasks of tomorrow

The G 400 is also available with a fast,

two- or four-station ring loader. Work-pieces are precentred time-parallel tothe grinding process.

For ultimate flexibility of your manu-

facturing cell you may add a robotic

loader.

C1 Rotation pre-centring unit

Q Ring loader

Vertical gripper movement

hydraulically activated

flexibilityintegration


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16 G 400

Simple maintenance

and fast servicing

Self sufficient units, like automatically

lubricated parts and automatic main-

tence intervals, bring down the overalltime spent for regular maintenance.

With all service components located

in clearly visible and easily accessible

spots servicing itself is much easier

and less time consuming than everbefore.

Integration of most auxiliary units in

machine hull

Self-sufficient auxilary units

Convenient access for mainte-nance and service

Automatic maintenance

intervalls

+ Fast and simple

installation and setup

+ Less maintenance

+ Simplified and more

efficient maintenance

+ Less machine downtime

due to service

interventions

+ Fast and simple

servicing

Your advantages

prevention


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G 400 17

access

safety


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18 G 400

Power requirescontrol.

Latest Siemens drive

technology and

Samputensili menu

guidance guarantee

you maximum

process security

Latest control technology ready for

direct networking, USB interface

included

Modular software packages inclu-ding profile correction modules

Samputensili menu-guided opera-

tor interface

True Windows environment

Your advantages

+ Faster data transfer to

machine

+ Easy and intuitive operation

+ Fast data validation and error

correction

+ Safe operation

+ Fast and efficient online up-

dating and trouble-shooting

simplicity

control


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2

3

1

4

G 400 19

We build machines for efficient, error-free

and safe manufacturing, for daily use andfor people

The vertical G-series is equipped with the latest Siemens CNC Sinumerik840 D. With the comfortable Samputensili menu-guided operator inter-

face running in a true Windows enviroment the user is guided through

the manufacturing process via easy and intuitive entry and demon-

stration screens, supported by validation and error correction software. In case

of unlikely emergency situations, improved safety features protect operator andexpensive tools alike.

The machine is already prepared for network or internet connection giving you

direct access to our online service supporting remote diagnostics and easy soft-ware upgrades.

1) Gear data input for worm grinding grinding cycle

2) Worm wheel input data page

3) Worm wheel grinding cycle input data page

4) Profile wheel grinding cycle input data page


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20 G 400

Layouts & dimensions G 400


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G 400 21

Workholding solutions

Hydraulic clamping

(samples shown for Knig and Mitec)

Mechanical clamping (samples shown for Emuge

and Hainbuch).

The G 400 is already prepared forthe clamping of workpieceseitherin hydraulic or mechanic execu-tion. Changing from hydraulic to

mechanic clamping and vice ver-sa is actuated by a simple switch

and the exchange of the appro-

priate workholding system.

Various standard clamping sys-tems of renowned workholding

specialist can be used to avoid

costly specifics and secure the

maximum efficiency when apply-

ing changes.

A pneumatic tailstock arbor allows

the machine to clamp workpieces

with almost no vibration for im-

proved grinding quality results.


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22 G 400

Technical data G 400

Workpiece diameter, max. mm 380

Module with generating grinding worms mm 0.7 - 8.0

Profile depth with electroplated CBN weels mm 1.0 - 25

Workpiece length, max. mm 450

Workpiece weight, max. kg 200

Centre distance work spindle - tool spindle mm 43 - 308

Tangential travel, max. mm 220

Axial travel, max. mm 400

Tailstock stroke, max. mm 550

Tool spindle speed, range min-1 0 - 20,000

Tool spindle swivel range degree +/- 45

Grinding tool diameter mm 140 - 220*

Usable tool length, max. mm 180

Work spindle speed, range min-1 0 - 800

Radial feed mm/min 0 - 7,000

Axial feed mm/min 0 - 7,000

Tangential feed mm/min 0 - 7,000

Motor power tool spindle drive kW 48

Total connected load of machine/with filtration unit kVA 110 / 140

Control - Siemens 840 D

CNC axes no. 6

Machine weight with/without peripherals, approx. kg 11,000 / 15,000

Machine dimensions, L x W x H (without automation) mm 3,850 x 2,400 x 2,750

* Smaller grinding tool bore diameters require specific clamping devices.

Technical data is subject to change.


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45

99

571

15

380

345

111

140

460

200

310

5

50

G 400 23

135

Distance between

Table-Dressing unit

265

Stroke X

400S

trokeZ

Stroke

Tailstoke


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Sampustensili G400-Masina Rectificat Dantura