Superabrasive machining comes to Europe

Citation

(1998), "Superabrasive machining comes to Europe", Assembly Automation, Vol. 18 No. 2. https://doi.org/10.1108/aa.1998.03318baf.007

Superabrasive machining comes to Europe

Superabrasive machining comes to Europe

Keywords Abrasive, Automation, Jones and Shipman plc, Machining, Production engineering

Following the acquisition of American CBN superabrasive machining pioneer Edgetek Machine Corporation by Jones & Shipman plc, this new production process is now being launched with full technical back-up in Europe (see Plate 7).

Although clearly a form of grinding, the revolutionary superabrasive machining process is better described as being akin to milling in terms of its stock removal rates and overall flexibility, claims Jones & Shipman. Preformed steel-core wheels, electroplated with cubic boron nitride (CBN), are used instead of a milling cutter. With relatively high feed rates and the high rpm involved, the CBN wheels provide a surface finish similar to that of grinding. These factors, combined with the excellent vibration damping characteristics and stiffness of the Edgetek system, make for an extremely effective way of machining components when high volume throughput is required.

Of crucial importance for many potential applications is the fact that the forces induced in the workpiece have been found to be much less than for a milling operation. As a result there is virtually no deformation of the workpiece and this opens up the prospect of being able to machine many components far more effectively than at present, often with simpler fixtures and with fewer operations. With a relatively low cost for the preformed steel core, CBN electroplated wheels users can expect to achieve significant stock removal before stripping and replating.

Plate 7 Jones & Shipman Edgetek CBN superabrasive machining centre

The machines come in two basic forms; the first being a machining system available as a three, four or five axis CNC controlled machine tool while the second is offered as a dedicated superabrasive turning system. Standard to both are GE Fanuc 16M CNC controls and high volume coolant systems.

The multi-axes superabrasive machining system enables users to make complicated parts, through several planes if necessary, e.g. turbine blades, at a single setting. As well as a rotary table providing the B axis movement a trunnion fixture can be used so that full A, B/C five-axes machining is possible.

The turning system can remove stock from the OD of cylindrical parts (slot, groove and forms) in hard and soft materials 40 per cent faster than conventional lathes but with improved surface integrity, greater part-to-part consistency and better size control. A workhead configured for either fixture or chuck is provided and options include auto loading. As a high production automated system, a dual workhead with two 300rpm heads mounted on a 180 degree index table is employed to give load/unload capabilities.

Jones & Shipman say that the new machines will be particularly attractive to production engineers looking to increase throughput of components made from conventional steels, as well as a variety of other materials, such as nickel alloys, ceramics, and composites. This should appeal to engineers in the aerospace, medical and automotive industries to name but a few.

Contact Mark Franckel, Sales Director, Jones & Shipman plc, Narborough Road, South Leicester LE3 2LF, UK. Tel: +44 (0)116 289 6222; Fax: +44 (0)116 289 2945.