Winners of the 2020 Formnext Entrepreneurship Challenge: automated design, new materials and optimized post-processing
In 2022, Stuttgart will host a new trade show: the first new grinding technology trade fair, Grinding Hub, will be held from May 17th to 20th, 2022. In this event, leading manufacturers will showcase the current trends in their solution grinding technology.
Electricity, digitalization and automation are just some of the main trends in the field of grinding technology. Research experts and companies participating in the new grinding center trade show will gain insights into the latest technologies and processes in this fast-growing industry.
Electric cars are changing the entire power system of cars. Gear parts must become lighter, more precise and stronger. Liebherr-Verzahntechnik has been paying close attention to the requirements of electric vehicles. The side line modification method is used to minimize noise and optimize load capacity. Here, the use of dressing-free CBN worms for grinding can represent an economical alternative to corundum worms. The process is reliable, can ensure a long tool life, and significantly reduce the time and effort required for measurement and testing.
The grinding process and clamping equipment used to produce finely machined electric bicycle transmission components must be fast and precise. Using a special clamping solution, even small collision-critical parts can be processed without problems. The exclusive Liebherr machine concept with a single table helps to achieve optimal concentricity and high reproducibility when producing parts with micron-level quality requirements. The choice of process ultimately depends on specific requirements. Liebherr can use its own machines to test all process parameters. “There is usually no right or wrong,” explains Dr. Andreas Mehr, a gear grinding expert. “As a partner and solution provider, we advise our customers and show them alternatives-let them make the best decision. This is exactly what we will do at Grinding Hub 2022.”
Although the design of electric vehicle transmission is simpler than that of a traditional internal combustion engine, it requires much higher gear manufacturing precision. The electric motor must provide constant torque over a wide speed range at speeds up to 16,000 rpm. There is another situation, as Friedrich W?lfel, head of machine sales at Kapp Niles pointed out: “The internal combustion engine masks the transmission noise. On the other hand, the electric motor is almost silent. At speeds of 80 km/h and above, regardless of power The system, rolling and wind noise are the main factors. But below this range, the transmission noise in electric vehicles will become very obvious.” Therefore, the finishing of these parts requires the use of a generative grinding process, which not only produces The efficiency is high, and most importantly, the noise characteristics of the grinding gear teeth are optimized. It is very important to avoid the so-called “ghost frequency” caused by unfavorable machine and process design during parts grinding.
Compared to control measurements, the time required to grind gears is much less: this makes 100% inspection of all components impossible. Therefore, the best method is to detect possible defects in the grinding process. Process monitoring is crucial here. “Many sensors and measurement systems that provide us with a wealth of signals and information are already built into the machine,” explains Achim Stegner, head of pre-development. “We use these to evaluate the machining process of the gear grinder itself and the expected quality level of each gear in real time. This allows order analysis of noise-critical components in a manner similar to the inspection performed on the offline test bench. In the future, gear grinding Sharp will provide significant added value by ensuring that the quality requirements of these components are met. As a Grinding Hub exhibitor, we are very excited about the innovative concept of the show.”
The tool grinding industry must meet greater challenges. On the one hand, more and more special tools are produced in small batches, which means that from an economic point of view, the process design until the first part that meets the specifications becomes more and more important. On the other hand, the robustness and productivity of the existing series of processes must be continuously optimized so that they can maintain their position in international competition even in high-wage countries. The Institute of Production Engineering and Machine Tool (IFW) in Hanover is pursuing several different research avenues. The first step involves simulation mapping of the tool grinding process to support process design. The simulation itself predicts the displacement of the grinding blank related to the machining force before the first cutting tool is produced, so that this can be compensated during the grinding process, thereby avoiding any resulting geometric deviations. In addition, the load on the abrasive tool is also analyzed, so that the process planning can be optimally adapted to the abrasive tool used. This improves processing results and minimizes the amount of scrap.
“Laser-based sensor technology has also been installed in the machine tool to measure the topography of the grinding wheel. This helps to maintain excellent processing quality even at higher throughputs,” explains Managing Director Professor Berend Denkena. He is also a member of the board of directors of WGP (German Association of Production Technology). “This allows continuous assessment of the condition of the abrasive tool. This means that it can be used to determine the dressing interval for a specific process. This helps avoid deviations in the geometry of the workpiece due to wear-and related scrap.”
“The development speed of grinding technology has increased significantly in recent years. The advancement of digitalization is the main reason for this situation,” Dr. Stefan Brand, Managing Director of the Vollmer Group in Biberach, commented on the latest trends in grinding technology Shi said. “We at Vollmer have been using digitization in automation and data analysis for many years. We have developed our own IoT gateway to which we are providing more and more data. The latest trend in grinding technology is the further integration of process data. By The resulting knowledge provides users with useful insights on how to optimize the grinding process. The journey to the digital future is constantly evolving. It is clear that combining classic grinding techniques with digital functions not only affects the grinding process itself, but also changes Grinding technology market. Digitization and automated processes are being used as optimization levers by sharpening services, tool manufacturers, and manufacturing companies operating globally.
This development is one of the reasons why the new grinding center trade show not only focuses on the automation and digitization of grinding technology, but also focuses on the areas of technology/process and productivity. This is why we welcome the opportunity to showcase our grinding technology to a broad international audience at Grinding Hub. ”
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Post time: Oct-18-2021