Officials at United Grinding Technologies’ Tool Division announces the Walter Helitronic Micro CNC grinder for the small tools needed for machining the new micro parts and features in medicine, electronics, aerospace, automotive, and more.
The Helitronic Micro features the same linear motor/torque drive technology in all axes resulting in incredible accuracy, acceleration and speed (up to 2,000imp). Further, the Micro has a radically new seven axes layout optimized for grinding micro tools. For example, the Micro has an X2-axis that automatically moves the tool to center during a grind, thereby achieving better accuracy on corner radii and ballnose forms on even the tiniest tools.
The machine also boasts a three-spindle grinding head for up to 12 wheels and the Micro’s new tilting B-axis positions the wheel to grind clearance angles with the same point on the wheel throughout the entire grind.
The result? 30% faster speeds and 50% better surface finishes than machines with conventional ballscrew technology. The optimal range for high precision production is from 0.50mm to12.7mm in diameter, though the machine is capable of handling both smaller and larger tools. The Micro also features a FANUC 6-axis robot loader for fast automatic changes of up to 1,500 tools. Plus the 1,000rpm A-axis workhead can handle precise cylindrical grinds — particularly helpful when making step tool.
The Helitronic Micro uses a mineral casting bed and column that has been especially designed for micro tools. The machine offers optimum vibration damping and insensitivity to temperature fluctuations for the highest grinding precision.Long workpieces are guided on a hydraulic shank steadyrest with fine adjustment, enabling 1µ concentricity during the grinding process. With active Adaptive Control the machine automatically adjusts the feed rate to maintain optimum load on the wheel without sacrificing quality, finish or wheel life. The result is the shortest possible cycle times, maximum wheel life and extended untended operation. FANUC controls and drives have the lowest failure rates in the world. Precision is in the nanometer range. The Heli-Probe automatic positioning and measuring system collects important tool parameters and positions as quickly as possible. This enables grinding down to 2mm in diameter.
With three grinding spindles and up to 12 grinding wheels, the Helitronic Micro has the flexibility needed for micro tools with complex geometries. One spindle produces 6.7hp for fluting while the other two offer 2hp.
Helitronic Tool Studio
This grinding software combines incredible flexibility with great ease of use. Every change appears instantly in a high-resolution 3D graphic and automatically rewrites the grinding program in the background. The simulation is the grinding program. Add any number of grinding operations per tool, mix and match operations and change any individual feature to create geometries of any complexity: variable helix, variable rake, variable core, variable land width, and more. Simply clicking the 3D graphic allows operators to see anything relevant to that part of the tool: grinding parameters, operations, wheel data, a 2D cross section, a profile view and a complete machine view. Measure tool features from this central screen, correct any errors, try new design ideas, and check the results instantly. The Tool Studio’s Automatic Machine Move Optimizer (AMMO) makes lift-offs as small as possible and calculates the shortest path between operations. Thus, all non-grinding moves are minimized for reduced cycle times.
Technical Data
Axes travels: X, 400mm; X2, 110mm; Y, 320mm; Z, 320mm; A, ∞; B, 280°; C rotary table, 200°. Accuracy: linear resolution, 0.0001mm; radial resolution, 0.0001°. 3-spindle grinding head: maximum grinding wheel diameter, 15mm; spindle power, 1 at 6.7hp, 2 at 2hp; spindle speed, 0-10,000rpm; A-axis maximum, 1,000rpm. Tool data: diameter for production, 0.5mm to 12.7mm; diameter for regrinding, 2.5mm to 12.7mm; length, 150mm; cutting length, 70mm.