“This type of project, that is to say a lot of changes in the functional process, must require an in-depth process along with the process,†says Edgar Meyer. “We need to negotiate with our customers regarding the setting of the process. In order to be able to submit a qualified gearbox, we have done a lot of high-cost testing processes in our factory and our customers. We have to decide where to focus more. In order to ensure the process safety that must be achieved in daily processing. Finally, we interpret the principle of 'Total Quality Management (TQM)' as 'Daily Quality Manufacturing'. To do this we must work with the machine tool and equipment supplier. Work hard."
Quick potential is released with the Quickpoint grinding process
At the beginning of the project plan, the process safety and rationality of the external and external shaft grinding must be planned. These load-bearing units made of carburized steel can be used as a standard for gearbox life and function. Therefore, there must be particularly stringent requirements for the dimensional accuracy of the machining (see heading photo and picture 2): the diameter of the shaft seat is IT 5, the static runout accuracy is 0.02 mm, the cylindricity is 3 μm, and the roundness is 2 μm. And the linearity can reach 1.5 μm. Until 1998, the outer circle of these shafts was ground by a slanting cut-in method using conventional techniques, namely a combination-pack grinding method. To do this, three processes were required at the time—three clampings were performed on three machines. In addition to a net processing time of 5.7 minutes, it takes of course a lot of time to unload, clamp and center between the two tops. Moreover, it is very cumbersome to prepare, because the grinding wheel combination package must be strictly graded to avoid grinding and burning.
figure 2
“After market research, we are targeting high-speed grinding, especially JUNKER’s Quickpoint process,†recalls Mr. Edgar Meyer. “Before, we had very little experience with CBN wheels. My knowledge of JUNKER comes from a previous project. I have seen the machine tool that uses this process to grind the crankshaft during the on-site inspection of the machine.†As early as 1995, ZF was in Hartmut. Under the leadership of Mr. Grossman, Director of Process Technology/Processing Control, the Quickpoint project was included in the shop floor planning.
The basis for grinding with the Quickpoint process is to form only one point of large grinding contact on the machined grinding area. For this purpose, a highly wear-resistant CBN or diamond grinding tool of only a few millimeters is required. By the inclination between the abrasive shaft and the horizontal axis of the workpiece, a relief angle is formed, by means of which the contact zone is reduced from a line contact to a point contact (see picture 3).
image 3
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