The SpheroStar has two tool spindle slides that can automatically rotate to 90 degrees so that the optimal machining position for the chosen process is set up automatically or by the push of a button, thus enabling the production of flat surfaces as well – with optional cross slides – instead of only spherical surfaces. The units are mounted vertically and are easily accessible for fast changeover. The machine is loaded at the first station by a handling robot parallel to the machining cycle and later again unloaded while the other stations are machining. The indexing table then moves to station 2 where the workpiece is aligned axially. Pre-finishing is in-process gauging controlled in station 3 under size-controlled conditions, and the end-finishing with a flexible stone is done in station 4. This operation is in-process gauging controlled too. A MicroSens force sensor is used for both work steps with workpiece contact detection and stone wear compensation.
The clamped workpiece rotates at up to 4,500 revolutions per minute during machining. The spherical surface is created using a defined process and specially preformed finishing tools. Depending on pre-machining, the cycle time is only 12 to 13 seconds, so that the machine can be properly integrated into efficient production lines.
Since the main assemblies are from proven platforms that have already been on the market for years, the new machine also features the same reliability as other machines of Thielenhaus. For example the indexing table comes from Nano-Star, the swing slide and tool spindle from Sphero and the clamping and main spindle are from MicroStar.
This new SpheroStar enables machining of surface topography, spherical roundness, spherical diameter and sealing surfaces. Furthermore, it can be used to improve the contact ratio and to meet tribological requirements. In just a few installation steps that take only a very short time, the operator can convert the machine from outer machining to inner machining, i.e., from a ball valve to a sealing ring or a socket. Since the workpiece remains in the collet chuck until it is completely finished, the operator interference is reduced and clamping errors are ruled out. This increases process repeatability considerably.
Workpieces can be machined up to a diameter of 75 mm on the ergonomically designed machine. It is typically used for machining the axial piston pumps found in all fields of hydraulics. The axial piston has a spherical sliding surface at the end, and the dimensions of this component must be accurate to 1 µm or less in order to guarantee safe operation at great strain – such as in aviation. Another instance are the metallically-sealing valve balls and seating rings for valves in the chemical industry, through which aggressive or very hot media travel. These workpieces can be machined with a high degree of geometric and surface accuracy. Furthermore, the new SpheroStar is used in the automotive industry for machining the joint heads of wheel suspension and steering components that require a high level of freedom and movement for the associated assembly units.
More information can be found at: Thielenhaus Technologies GmbH, P.O.B. 201855, 42218 Wuppertal / Germany, Telephone + 49 (0)2 02 481-0, Fax + 49 (0)2 02 45 04 45, or on the Internet at www.thielenhaus.com
Thielenhaus Microfinish
Thielenhaus Microfinish, a division of the German Thielenhaus Technologies GmbH, has been building high-precision, high-productivity machine tools for over 110 years. In the last 70 years, Thielenhaus Microfinish has become the leading manufacturer of extreme-precision machine tools for Microfinish/Superfinish and double-disc grinding applications.
Microfinishing, also known as superfinishing or short-stroke honing, is the ideal machining process for achieving extreme precision surfaces and component geometries, and removing amorphous surface layers in the magnitude of 2 µm. Honing stones, cup wheels and microfinishing tape or film can be used to generate surface roughness or geometrical accuracy within a previously defined window that often spans a few tenths of a micron. Indicated below are a number of parameters which can be optimized using Microfinish:
With facilities in Europe, America and Asia and a worldwide service network, Thielenhaus has adapted itself to the market conditions and to the customer needs all over the world.
Commitment to quality: Thielenhaus machines are employed by leading manufacturers across the world for a good reason – their high reliability, productivity and production quality. Thielenhaus continuously pushes the limits of precision machining, enabling its customers to achieve workpiece qualities that were previously impossible.
All solutions from a single source: Extreme precision is the specialty of Thielenhaus, and over the years the manufacturer has built the world’s largest portfolio of Microfinish solutions, ranging from industrial equipment for large and small manufacturers to just-in-time tool delivery and other services. When it comes to Microfinish Thielenhaus is the one-stop shop.
The flexibility of Thielenhaus is its customer’s advantage: The manufacturer adapts the machine solutions to the customer’s component, loading/unloading preferences, cycle time requirements and other specific needs. The modular design of the machine platforms accommodates even tricky components.
New challenges and innovation are the passion of Thielenhaus: They are proud of their 430+ patents in surface finishing technology as well as of numerous market-leading platforms and pioneering innovations. Thielenhaus constantly seeks to improve the machining concepts, always keeping in mind the challenges of tomorrow.
Customer support all over the world: With customer service locations in six countries and service agreements with a network of agents and distributors, Thielenhaus is able to provide quick service on short notice practically anywhere in the world. The customers also benefit from a 24/7 hotline and Online Direct Service.
Thielenhaus is known as a highly experienced problem solver: Anyone can be a problem solver, but with more than 70 years of developing Microfinish solutions, the Thielenhaus staff have probably seen and solved more Microfinish problems than anyone else in the industry. When it comes to splitting microns, the Thielenhaus in-depth knowledge of the microfinishing process is unsurpassed.
Thielenhaus Technologies GmbH
Schwesterstr. 50
42285 Wuppertal
Telefon: +49 (202) 481-0
Telefax: +49 (202) 4504-45
http://www.thielenhaus.com
E-Mail: riedel@technopress.de
