Cylindrical grinding machines for metal. Purpose and device of cylindrical grinding machines Features of circular grinding machines

Now many important enterprises require the manufacture of precise parts with a fairly smooth surface. This work can be done using various abrasive equipment, including cylindrical grinding equipment. Cylindrical grinding machines can be attributed to the class of metalworking tools. With their help, they make precise grinding of metal blanks on the outside. Structurally, tools of this type are very different from similar equipment.

The purpose of the machines

The main purpose of this equipment is this is the processing of the outer parts of the part, which has different shapes. For example, a cylindrical, straight, or conical shape. Due to the fact that grinding and diamond discs are used in this equipment, a rather high accuracy of size and geometry is ensured, as well as a slight roughness of the machined parts. Most often, cylindrical grinding machines are used after the part has passed the first (thermal or mechanical) processing. Specialists divide cylindrical grinding machines into a couple of types, there are ordinary options and there are universal ones.

A simple cylindrical grinding unit processes parts that have a small taper, no more than six degrees.
Universal aggregates can process parts with a huge taper angle, this is possible due to the design features of these machines. The fact is that on them you can rotate the front and grinding heads. The latest models of cylindrical grinding units have features that help them work with workpieces that have a huge diameter and size. They are fully automatic and semi-automatic.

Characteristics

Circular grinding machine 3m151

This unit has been operating in our country for a very long time. It helps to finish cylindrical, interrupted cylindrical parts, as well as the surface of various cones at the highest level.

Due to its uniqueness, unit 3m151 helps to work with the most complex workpieces. The method of grinding, which is used in such a machine, is called longitudinal or mortise. The devices that are installed on this machine make it possible to fully control both the size of the workpiece and the process of processing itself.

Additionally, you need to take into account the following subtleties that the circular grinding unit has:

The presence of a turntable. Thanks to this table, it is possible to shift the product relative to the abrasive disc in the horizontal and vertical parts;
Feed mechanism device. It can be an automatic complex or its special analogue. In the latter case, units of this type are used for rough grinding.
Possibility of fixing products in centers, chuck. This factor applies only to equipment of the center type.

The unit helps the specialist to quickly work with products with a length of 700 mm and a diameter of 200 mm. The frequency with which the grinding wheel of the unit will begin to rotate will be equal to 1590 min-1. It turns out that the speed of movement of the table (which can be adjusted steplessly) will be 0.05−500 min-1. Recently, a huge number of models of such machines have been produced. Therefore, in addition to choosing according to standard parameters, you need to look at the technical and operational qualities.

Such cylindrical grinding units are of great benefit and now it is very difficult to do without them, they are required almost everywhere.

Often, after finishing a part on a metal-cutting machine (for example, on a lathe), the quality of the resulting surface does not meet the requirements for it. In order to achieve the required indicators of surface roughness, such a type of metal processing with the removal of a layer of material as grinding is used. For grinding parts made in the form of bodies of revolution, circular grinding machines are used.

Cylindrical grinding machines are divided into four groups:

Simple
Universal
Mortise
Special

Universal machines have a design that includes a rotary table, in another version, in addition, they have a rotary front and rotary headstock.

For cylindrical grinding machines of a simple type, all of the listed units have a fixed design.

Plunge grinding machines do not have a longitudinal feed of the workpiece. The grinding wheel, wide enough to cover the surface to be machined, along with the rotational movement, is given a continuous transverse feed to the workpiece and due to which it performs grinding along its entire length.

Special cylindrical grinding machines are technological equipment of a certain profile, designed, for example, for grinding the surfaces of turbine blades, tooth profiles, cam shafts, etc.

The machine has the following main components: bed, rotary table, grinding headstock, front headstock. Inside the frame there is a hydraulic drive of the turntable; in the front headstock there is an electric spindle drive that transmits rotational motion to the workpiece, and inside the grinding headstock there is a grinding wheel drive.

The main controls of the machine are as follows: table speed control handle, table manual movement handwheel, handwheel for manual feed of the grinding headstock, quill retraction handle, table reverse handle, handle for turning off the automatic movement of the table, stops, throttle handles for controlling the feed of the grinding headstock, quick approach handle and removal of the grinding headstock and push-button station.

To improve the quality of processing and simplify the work on the machine, cylindrical grinding machines are equipped with digital display devices.

The full range of grinding machines is in the corresponding section

Cylindrical grinding machine - equipment for roughing and finishing the outer surface of parts. Design features allow you to work with workpieces of various shapes: cylindrical, conical, straight. As a working tool, diamond and grinding wheels are used.

The low grain size of the machining tool provides a slight roughness of the contact zone and high work accuracy. When using machines for industrial purposes, workpieces undergo primary thermal and mechanical processing, so the allowance is minimal.

The capabilities of machines are limited by performance. On standard equipment, it is impossible to work with parts whose taper exceeds 6º. The design of modern devices allows you to process the outer surface of any workpiece due to the device of the front and grinding heads, capable of rotating around its axis.

As a rule, cylindrical grinding machines are used at the finishing stage of processing.

Types of cylindrical grinding equipment

In the process of developing metalworking technology, the production of the following types of cylindrical grinding machines was launched:

The classic type involves the installation of the workpiece in the centers. The role of the clamps is performed by the front and rear headstock. With the start of work, the part begins to rotate due to the drive of the apparatus. Removal of metal occurs upon contact with the surface. The method of removing metal chips depends on the model of the machine.

Similar models are popular with various repair shops. For example, this equipment is used to grind the crankshafts of internal combustion engines.

The centerless design is considered universal, since the workpiece is mounted on a special carriage. On the one hand, it is fixed in order to avoid displacement of the part during processing. An auxiliary circle is used as a fastener. Grinding is performed on the reverse side of the part. This allows you to work with hollow cone-shaped products.

CNC cylindrical grinding machines deserve a separate description. Process automation increases work productivity by reducing the role of the equipment operator. In addition, the quality of processing increases significantly, since automatic feed increases the accuracy of work - the indicator of permissible error does not exceed hundredths of a millimeter. Software control reduces the likelihood of marriage.

Device and design features

The device of cylindrical grinding machines depends on the working materials and quality requirements for finished products. The following accuracy classes of devices are distinguished:

increased accuracy;
high precision;
especially high precision.

Machine tools are used for processing various materials: from cast iron, steel and alloys based on them to high-strength materials - polycrystalline diamonds and cubic nitrides.

Consider the design features of various devices and the most common layout options.

Working nodes

Regardless of the type of execution, the main elements of cylindrical grinding machines are:

bed;
Desktop;
grinding and headstock;
control mechanisms.

The drive to the spindle is mounted in the headstock, and to the wheel in the grinding headstock.

The main element of the control mechanism is a push-button station. Flywheels are responsible for the manual movement of the desktop and the headstock, which are controlled using the following handles and stops:

fast feed of the headstock;
movement of the quill;
desktop speed adjustment;
disabling the automatic movement and reverse of the table.

In addition to the above components and parts, the following elements play an important role:

Grinding grandma. Differs in rigidity of a design. Depending on the layout of the machine, it can be a fixed or movable element. It contains a spindle mounted on hydrodynamic or other supports.
balancing mechanism. Reduces oscillatory processes during the working cycle. There are models with both manual and automatic balancing of the machine.

Automatic balancing is carried out using a switchable spindle stiffness or additional balancing weights.

Tool editing mechanism. Adjusts the shape of the contact tool and maintains its functionality.
Feed unit. Responsible for the movement of the grinding wheel.
Rear grandma. It is one of the design elements of machine tools for which the working location of the workpiece is the installation in the centers.
Lunettes. Special supports for working with long parts.

Possible layout options

The most common layout methods for cylindrical grinding machines are:

cartridge;
center;
centerless.

An important factor is the presence of a second table. In centerless models, the shoe is a fixed element.

In some devices, the support knife is mounted on the slide of the headstock. In this case, it moves simultaneously with the grinding tool relative to its axis.

Fixed knife models have found their way into automatic assembly lines. They are valued for their high quality characteristics, because such an arrangement ensures the stability of the axis of the workpiece, regardless of the state of the grinding tool of the machine. The design of such equipment is characterized by high technological complexity due to the movable headstock and the mechanism for moving it.

Principle of operation

There are several ways of external processing, which depend on the technical parameters of the metalworking equipment.

In repair shops, the longitudinal grinding method is most often used. In this case, the workpiece must be fixed in the centers of the machine. The electric motor drives the headstock together with the fixed object. Longitudinal movement is performed by the feed mechanism, changing the position of the workpiece relative to the grinding wheel.

In addition to longitudinal grinding, the following processing methods can be performed on modern devices:

Deep. The amount of allowance in one pass can reach 0.4 mm of metal. The impact on the surface is carried out by the conical part of the tool.
Mortise. This technology involves the use of wide grinding wheels for roughing or finishing work. During processing, the position of the workpiece relative to the circle does not change.
ledges. The method combines deep and plunge grinding. This allows you to process products of complex shape.

Important equipment parameters and specifications

The main parameters are indicated in the manufacturer's passport. These include:

Electric drive power. The performance of the device depends on the value of this parameter. The unit of measure is kW.
Voltage. Defines the scope of use. Compact models for household work operate from a 220 V home network. Machines for industrial use operate on 380 V.
Desktop dimensions. Limit the dimensions of the processed workpieces.
The maximum diameter of the grinding wheel. Its dimensions are determined by the interstate standard.
Nominal number of revolutions. The speed of rotation of the tool depends on this indicator.
Availability of CNC and precision processing. Numerical control allows you to increase the accuracy of the work performed, but the cost of such devices is quite high.

What to look for when choosing a circular grinding machine

At the stage of equipment selection, it is necessary to pay attention to the standard equipment and the possibility of its modification.

As an example, consider the R-grind 1660 CNC cylindrical grinder. The standard package includes:

linear scales of the X axis;
grinding wheel with flange;
diamond pencil for editing a circle;
a set of auxiliary tools;
carbide center;
hydrostatic bearings on the spindle;
coolant supply system;
hydraulic oil cooling system;
work area lighting.

The supplier offers the following items as additional equipment for the machine:

device for internal grinding work;
set of driving mandrels;
lunettes;
self-centering chuck;
stand for balancing the grinding wheel;
device for automatic wheel balancing;
control measuring sensor;
coolant filtration system.

Modification of a cylindrical grinding machine can increase the final cost by 20-30%.

External surface grinding machines are a sought-after product in the metalworking market. The presence of CNC allows you to increase the accuracy and productivity of work, but increases the cost of production. Do you think it makes sense to buy a CNC machine for a small workshop or would such a purchase be inappropriate? Write your opinion in the comments.

Cylindrical grinding machines for metal with CNC from the Swiss company STUDER in the warehouse of GALIKA AG in Moscow - in stock and on order. STUDER stands for hardware, software, system integration and service of the highest Swiss quality. The company has 100 years of experience in the development and production of grinding equipment.

The manual machines STUDER S20 and STUDER S30 are designed for grinding workpieces in single and small batch production. They are suitable for applications in any industry that manufactures precision small parts. The operation is very simple and changeover is possible within a short time.

Universal cylindrical grinding machines

CNC universal cylindrical grinding machines are designed for grinding small, medium, large parts in piece and batch production.

Features and Specifications	Movement along the X, Z axis	Grinding wheel	Price in rubles: on request	Availability of equipment
STUDER favoritCNC	285 x 800 mm	500 x 63 (80) mm		On order
STUDER S31	280 x 850/1150 mm	500 x 63 (80) mm		On order
STUDER S33	285 x 800/1150 mm	500 x 63 (80) mm		On order
STUDER S41	350 x 1150/1750 mm	500 x 50 (80) mm		On order

Industrial cylindrical grinding machines

The STUDER S11 model is designed for those customers who are focused on the serial production of small shafts and bushings, external machining with high speed and high accuracy.
STUDER S22 is a production platform. Its main purpose is the mass production of medium-sized customer parts. Combined machining STUDER S242 perfectly combines the technologies of cylindrical grinding and turning.

Cylindrical grinding machines SCHAUDT

SCHAUDT is a German manufacturer of high quality grinding machines. The company sets global standards in technology, precision and quality for center grinding of round and non-round workpieces. The SCHAUDT FlexGrind M is designed for grinding long and heavy workpieces.

Features and Specifications	Grinding length	Price in rubles: on request	Availability of equipment

In order to make products of different sizes from metal, masters of metallurgy carry out various technological processes that are carried out using hand tools and industrial equipment. Among the craftsmen, a circular grinding machine is in demand. It is used to remove the metal layer.

Cylindrical grinder

It is easier to understand the principle of operation when the key components of the machine are known. These include:

Fixed bed. The base that holds the rest of the equipment. It has stable legs. Compact models can be equipped with wheels for moving around the workshop.
The headstock on which the spindle with the grinding wheel is fixed.
Supports, knives.
Gearbox.
Device for changing the position of the snap.
Vice for holding the workpiece.
Control Panel.
Guides along which the table moves.
Work surface for placing parts.

Modern equipment is equipped with numerical control. It allows you to more accurately carry out the technological process. The abrasive material removes the material from the workpiece in an even layer, leaving no recesses or bumps. It is important to set up the program correctly in order to get the best result.

Characteristics

You can evaluate the capabilities of the machine according to the declared characteristics from the manufacturer. It is necessary to understand the main parameters that are noted in the technical passport:

The power of the machine for metal is indicated in kW. The performance of the machine depends on this indicator.
The power supply of the device depends on the dimensions of the equipment, the number of working spindles, the power of the engines. It can be powered by 220 volts (workshop models) or 380 volts (industrial models).
Desktop dimensions. The allowable size of the processed workpieces depends on them.
Tooling diameter (grinding wheel). Its dimensions are indicated according to GOSTs.
The number of spindle revolutions per minute.

In addition to the main characteristics, the dimensions of the machine itself can be attributed.

Classification

Depending on the dimensions, performance, type of installation, two groups of CNC cylindrical grinding machines are distinguished:

Desktop models. Compact equipment that is used in private workshops. Differ in low productivity, small dimensions, a small number of additional functions. They are powered by 220 volts. Most desktop machines come with manual control without CNC.
industrial models. Large-sized machines that are equipped with a powerful engine, a large work table, guides, stepper motors. There are machines with two or more working parts. Industrial equipment has a high productivity index and is therefore suitable for series production. Most models are powered by 380 volts.

Depending on the functionality, there are two groups of cylindrical grinding machines:

Simple machines. Are intended for carrying out one technological process. Such devices can be assembled with your own hands by looking at the finished drawings, preparing consumables, tools.
Universal models. Multifunctional machines with many customization options. Thanks to this, it becomes possible to process workpieces of complex shape, different sizes.

CNC Cylindrical Grinding Machine

The purpose of the machines

With the help of a grinding machine, you can process wood, stone, plastic, metal. It is designed to perform various technological operations:

Processing of cylindrical, rectangular, triangular, square blanks. Removal of a different layer of metal.
Creating a rough surface. For this, a special type of abrasive is selected.
Sharpening of cutting tools, accessories. In order not to spoil the cutting edge, water cooling is used.

For processing cylindrical parts, it is necessary to select the grain size of the abrasive material. The layer of removed metal, wood, plastic, stone depends on this. The smaller the particles, the more precise grinding occurs.

Selection principles

To choose a reliable machine, you need to consider a number of features:

The speed of movement of the desktop along the guides. Depends on the power of stepper motors that are installed with CNC systems.
Grinding wheel rotation speed.
Engine power. The performance of the equipment depends on this, the ability to work on it for a long time without interruption.
Construction dimensions. They are selected depending on the availability of free space in the room.
Desktop dimensions.
Processing accuracy. Depends on the size of the abrasive grains.
Control type. If the machine will be used rarely, it is not necessary to buy expensive computer-controlled equipment.

Different models of cylindrical grinding machines are equipped with various additional functions. The cost depends on their quantity.

Making a machine with your own hands

To sharpen tools, process small-sized workpieces, you can make a machine with your own hands. To do this, prepare consumables, tools:

Metal corners to create the base.
Washing machine engine.
Grinding wheel.
Wires, switches, buttons for the manufacture of control panels.
Welding machine, drill with drills for metal, grinder.

The process of creating a homemade device:

Initially, you need to study the finished schemes of the circular grinding machine.
Assemble the base with a desktop, a drive, a headstock for a desktop machine. It is made from metal corners. Individual parts are connected by a welding machine. The seams must be cleaned, coated with an anti-corrosion compound.
Fasten the engine to the frame. Install a grinding wheel on it.
Run wires, make a control panel. It is desirable to use a motor with the ability to change the spindle speed. Thanks to this, a separate regulator will appear.

The grinding wheel is installed vertically. It is desirable to make its lower part so that it is one part in a container of water. Additionally, you can make a massive desktop, on which a vice will be installed to clamp parts.

DIY manufacturing

Equipment operation

Cylindrical grinding machines for metal must be able to operate in order to achieve the maximum effect from their work, without injuring yourself. Rules:

Before starting work, check the reliability of the fastening of the grinding wheel, assess its condition. Do not use abrasive with cracks, chips, bumps.
Check network connection. Set the machine settings in advance.
Wear safety goggles to keep chips out of your eyes.
Allow the workpieces to cool if the equipment is not water-cooled.
Change the abrasive depending on the required quality of processing.
Lubricate the moving parts of the equipment with engine oil so that it lasts longer.
Clean work surfaces from accumulated waste after processing.
Securely fix the parts with clamps so that they do not move during operation.

Do not attempt to sand hard surfaces with fine abrasive at low power.

Cylindrical grinding machines are used in various enterprises. They process wood, plastic, stone, metal. Depending on the chosen type of abrasive material, different types of grinding are carried out (rough, finishing). You can make the device yourself. It is suitable for grinding small parts, sharpening tools.