Topics & News Release
2014/10/16
Toyo Advanced Technologies Develops New Horizontal Internal Grinding and Vertical Profile Grinding Machines.
- Three New Grinding Machine Products Displayed at "27th Japan International Machine Tool Fair" -
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Toyo Advanced Technologies Co., Ltd. (Head office: Minami-ku, Hiroshima City, President: Yoshiaki Hongo) has newly developed the "THG-10C" horizontal internal grinding machine and "TVG-10PG" vertical profile grinding machine, and will display these models at the "27th Japan International Machine Tool Fair" to be held in Tokyo from Oct. 30 at the Tokyo Big Sight. Under the theme for this exhibition of "The Next Grinding Solution - Insistence on Precision Without Limit -", Toyo will display the "TGG-26-2W", a new gear grinding machine that is available for purchase starting this month, as well as wheelheads having elemental grinding machine technology, and other Toyo products.
As a successor to the "T-11L" that has received high praise as an automated processing machine for mass production, the newly developed "THG-10C" is a compact horizontal internal grinding machine that provides even greater high-precision, high-efficiency machining, and is compatible with variable-type/quantity production.
In addition to having a more compact size than existing models and being equipped with a newly developed chuck that reduces workpiece strain at clamping, the THG-10C has a high-speed workpiece main spindle with a maximum rotation speed of 3,000 min.-1, high-resolution servo motor, newly developed single arm loader, and other features to provide even more high-precision, high productivity machining. Conveyors connected to previous and subsequent processes are arranged along a straight line in order to provide simple production line layout. Additionally, reducing the amount of setup change parts required when changing workpieces by 30% and similar innovations have greatly reduced the time required for setup change. This machine provides flexible compatibility with variable-type/quantity production.
Newly developed functions have been added to the TOYOMATIC interactive CNC control system. These consist of the "Grinding Navigation" function that can automatically set grinding conditions and adjust the machining precision, "Offline Editing" function that allows you to set the machining conditions for the workpiece following the one currently being machined, and the simple "Remote Maintenance" function for responding to faults when they occur. These functions not only allow the customer to easily establish the machining conditions but also ensure that setup change procedures can be smoothly performed.
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The "TVG-10PG" vertical profile grinding machine was developed as a successor to the "T-182PG" that machines parts that are not perfectly round such as cam rings. The highly praised TVG Series of vertical grinding machines feature independent spindles for cutting (X-axis) and the table (Z-axis), and a structure that situates the workpiece main spindle on the X-axis. This enables even higher precision machining because Z-axis torsion due to machining load is reduced, and it also provides a compact size with a width of 1,300 mm.
A linear motor has been adopted for the X-axis to provide 2G acceleration that is 2.5 times that of existing models, as well as to improve tracking in relation to workpiece main spindle rotation. Additionally, this workpiece main spindle is equipped with a high-torque direct-drive motor that increases the rotation speed during machining to three times that of existing models. A wheelhead has been adopted for the grinding wheel spindle that provides a maximum rotation speed of 60,000 min.-1, twice that of existing models. In addition to these features, this new machine has various types of compensation control, developed in-house, that provide high-precision machining with a profile precision of less than 10 μm, as well as high-speed grinding that greatly reduces cycle times.
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The "TGG-26-2W" that will be first time on display at the "27th Japan International Machine Tool Fair" is a gear grinding machine capable of high-efficiency production of JIS Grade 1 precision gears. It is newly equipped with a tooth-surface modification function developed uniquely by Toyo that allows teeth to be easily modified to achieve the customer's desired tooth surface profile, even if machining the gear for the first time, and this makes it possible to start up production of high-precision gears in a short period. Additionally, the use of dual heads greatly reduces the non-machining time, making it an optimal model for mass-production machining.
Additional models on display include the lineup of high-rigidity, high-efficiency wheelheads for the TVG Series lineup of composite vertical grinding machine, and interactive CNC control system equipped to the THG-10C.
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[Overview of New Models]
Horizontal Internal Grinding Machine "THG-10C".
- Installation dimensions (W x D x H): 2,390 x 2,110 x 1,980 mm
- Max. grindable work inner diameter: φ 100 mm
- Max. chuckable work outer diameter: φ 200 mm
- Max. chuckable work width: 80 mm
High-Precision Machining
- The table guide span has been increased to improve machine rigidity.
- A coolant pan has been newly installed on the bed to prevent thermal deformation of the bed from the coolant.
- A new chuck that prevents clamping strain has been developed and adopted. The structure has been changed to enable independent control of the holding and pushing claws of the chuck, which had previously been controlled in unison. This allows for the clamping forces of holding and pushing claws to be adjusted independently to match the workpiece, and functions to reduce workpiece deformation (clamp strain) at clamping to the minimum degree.
- A high-speed workpiece main spindle with a maximum rotation speed of 3,000 min.-1 and a wheelhead with a maximum rotation speed of 60,000 min.-1 have been adopted. High peripheral grinding speed provides high-precision machining.
- A high-resolution servo motor has been adopted for the X and Z-axises. This has improved machining precision of biaxial interpolation.
High Productivity
- High peripheral grinding speed serves to also greatly increase the metal removal speed and reduce cycle times.
- The standard double-arm loader has been changed to a newly developed single arm loader. This allows the arm loading time to be greatly reduced, because the arm standby position is optimally set and arm movement at loading has been reduced to the minimum amount.
- Layout of conveyors connected to previous and subsequent processes has been redesigned to place them in the line. This facilitates automation, and the linking of previous and subsequent processes, thereby improving the freedom of customers in designing their production lines.
- Setup change of chucks, tooling, transfer equipment and other components enables variable-type/quantity production. The components structure of the THG-10C was revised to reduce the amount of setup change parts required when changing workpieces by 30%. Setup change time has also been greatly reduced, for example, by adopting a layout that provides for easy setup changes.
Vertical Profile Grinding Machine "TVG-10PG".
- Installation dimensions (W x D x H): 1,300 x 2,400 x 2,200 mm
- Max. grindable work inner diameter: φ 80 mm
- Max. chuckable work outer diameter: φ 100 mm
- Max. chuckable work width: 50 mm
High-Precision Machining
- Column thermal deformation has been prevented by installing a discharge path for coolant to the outer periphery of the bed in order to provide stable machining precision.
- The structure has been changed from the Z-axis above the X-axis (fixed workpiece main spindle and grinding wheel spindle along the Z-axis) to a structure that separates them (workpiece main spindle along the X-axis and grinding wheel spindle along the Z-axis) so that torsion and Z-axis vertical movement is reduced when the machining load is applied.
- A highly rigid linear guide has been adopted for the Z-axis in order to provide high linearity even when a high machining load is applied.
- The workpiece main spindle can achieve high speed in order to increase the rotation speed during machining to three times that of existing models. - A linear motor has been adopted for the X-axis in order to provide 2G acceleration and improve tracking in relation to rotation of the workpiece main spindle.
- A wheelhead has been adopted for the grinding wheel spindle that provides a maximum rotation speed of 60,000 min.-1. The high-speed capability of the workpiece main spindle and high peripheral grinding speed provide high-precision machining.
- This makes it possible to achieve stable high-precision machining with a profile precision of less than 10 μm.
High Productivity
- High peripheral grinding speed serves to also greatly increase the metal removal speed and reduce cycle times.
- The 2G acceleration of the X-axis greatly reduces non-grinding and grinding time.