Superabrasive machining comes to Europe

Citation

(1998), "Superabrasive machining comes to Europe", Aircraft Engineering and Aerospace Technology, Vol. 70 No. 4. https://doi.org/10.1108/aeat.1998.12770dab.006

Superabrasive machining comes to Europe

Superabrasive machining comes to Europe

Keywords Abrasive, Jones & Shipman, Machining

Although clearly a form of grinding, the superabrasive machining process is better described as being akin to milling in terms of its stock removal rates and overall flexibility. Preformed steel-core wheels, electroplated with CBN (cubic boron nitride), 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, are thought to make for an extremely effective way of machining components when high volume throughput is required (Plate 4).

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 said to be 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 wheel users can expect to achieve significant stock removal before stripping and replating.

The machines come in two basic forms; the first being a machining system available as a three-, four- or five-axis CNC 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.

Plate 4 Jones & Shipman Edgetek CBN superabrasive machining centre

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.

Indeed, once the merits of the Edgetek Superabrasive process are fully understood it could well open up a whole new vista of opportunities for production engineering in general. Jones & Shipman believe that it is likely to be seen as one of the most effective and significant technological advances in material removal of this decade.

Further details are available from Jones & Shipman plc. Tel: +44 (0) 116 289 6222; Fax: +44 (0) 116 289 2945.