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Transcript of 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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