Precise, compact and cost-effective – these are the criteria that have made the WPG 7 external cylindrical grinding machine from EMAG WEISS a great success on the market. It requires minimal floor space and can also be installed quickly, but at the same time features a whole range of high-tech components for flexibility and productivity. What characterizes the machine in detail? Our grinding expert Andreas Holstein provides the answers in this interview.
Mr. Holstein, which applications suit the WPG 7 external cylindrical grinding machine from EMAG WEISS?
Andreas Holstein, Plant Manager at EMAG Weiss
Many users machining smaller components, such as shafts or pinions in medium quantities, may find this solution interesting. The maximum workpiece length here is 250 millimeters. In this situation, companies often rely on oversized universal cylindrical grinding machines, which take up an enormous amount of space and are also very expensive in the end, even though their functionality is not actually fully used. Instead, we offer a highly compact, high-tech solution with a footprint of only around four-square meters, with everything inside the housing – including the electrical cabinet, cooling system, lubrication and more.
The cylindrical grinding machine has a footprint of just 1.8 x 2.4 m.
What characterizes the technology in the work area?
The WPG 7 is basically available in two different versions – for straight grinding or angled plunge grinding with a 30-degree angle. Users must, therefore, decide between these options in advance. In both cases, they benefit from a powerful grinding wheel drive with speeds of up to 50 m/s and a large grinding wheel with a maximum diameter of 500 millimeters. As a result, the grinding process is very fast and productive. It also takes a relatively long time to dress the wheel, which of course also increases productivity.
The WPG 7 ensures rapid processes during cylindrical grinding.
What kind of grinding wheels are used and how is the cooling system used?
Users have the option of employing either CBN or corundum wheels, with cooling systems using water or oil – both provide good heat dissipation and reliably prevent the workpiece from overheating. It also improves the surface quality and increases the service life of the grinding wheel.
Is loading manual or automated?
Both are possible. For the automation of cylindrical grinding, we have developed a linear gantry that can be integrated into the enclosure of the cylindrical grinding machine at the customer’s request. On this basis, the WPG 7 can be linked-up with chain conveyor belts, a pallet circulation system or by robot, for example. The gantry removes the raw parts from these solutions and then feeds them into the work area at high speed. Once the process is complete, the finished parts land back on the conveyor belt. The whole process is controlled by a machine panel. The operator can still load and unload smaller batches by hand. It is also possible to order the machine without our gantry solution for manual loading only.
The interior of the external cylindrical grinding machine is easily accessible after opening the large front door.
How demanding is the operation of WPG 7?
This is a very important point for us. We have attached great importance to simple operation with intuitive interfaces and dialogs. This is why a Windows-based dialog interface is available, whereby users can call up certain tasks directly via “touch” – such as setup processes, approaching the zero point or exhibitions. In addition, the basic version of the software already contains all common cycles for cylindrical grinding. The operator only must enter a few parameters.
How do you guarantee process reliability and quality?
The WPG 7 has a very rigid design and optimum heat transfer, which ultimately ensures special quality and process reliability during grinding. In addition, the component diameter is continuously measured in-process using Marposs technology. Overall, the cylindrical grinding machine achieves a circular accuracy with deviations of less than one micrometer. Further benefits include passive longitudinal positioning, an automatic balancing system and GAP and crash control.
At the end of the day, the question of installation and footprint remains: What steps should users expect?
We already talked about the size of the cylindrical grinding machine at the beginning. Thanks to its footprint of just 1,800 x 2,400 millimetres, it fits easily on two Euro pallets and can be transported to its location by crane as a hook machine. The initial machine setter is then set up at the customer’s premises quickly. Simply connect the power and compressed air and off you go! This process usually takes less than four hours. No major adjustments or new settings inside the machine are necessary. There is no quicker or easier way to get a new production solution.
