CRANKSHAFTS | Crankshafts are typically ground between centres, a process which lacks the speed and precision offered by adopting a utilising modern centreless techniques.

Although there has been an industry reluctance in moving to centreless grinding for crankshaft production, the dimensional accuracy of concentric journals has been demonstrated to be almost doubled since first demonstrated against between centre grinding in 1985. Cycle time is also dramatically reduced as concentric diameters can be ground simultaneously with support on almost every ground diameter.

CAMSHAFTS | Of a similar nature to crankshafts, camshafts are also usually ground between centres due to the performance benefits offered decades ago by the use of external grinders.

With the advances seen in centreless grinding automation and control, it has been shown that the centreless approach is now not only almost twice as accurate, but more far quicker and more reliable. The flexibility of a centreless grinding machine also allows rapid changeover between crankshaft and camshaft grinding, to make best use of the increased productivity migrating to this method offers.

TRANSMISSION COMPONENTS | Centreless grinding has become an increasingly integral process in the production of geared shafts, with the market being pushed continually by the development of new components for electric engines, as well as historic demand on combustion engines.

Through utilising a plunge grinding centreless process, part cycle times are reduced dramatically when compared to external grinding of multi-diameter shafts. All shaft diameters can be ground at the same time while still maintaining high tolerance diameters and surface finishes, instead of passing over each surface with an external wheel.

UNIVERSAL JOINTS | Centreless plunge grinding of universal joints is particularly advantageous when incorporated with a rotational loading mechanism, to automatically rotate the part once the first pair of stems have been ground to present the second pair to the wheels.

The same mechanism can be used to load and unload finished components, and when combined with blank variance detection systems, the user can enjoy vastly reduced cycle times when compared to other techniques used to grind these parts.

TURBO ROTOR SHAFTS | Also ground on a plunge cycle, turbo rotor shafts can be produced in high volumes with great accuracy and repeatability, despite their typically complex shaft profiles and more demanding material properties.

Available again with a range of automation options to further optimise the grinding process, tooling options to cover the production of other plunge ground components, as well as throughfeed grinding setups for further expandability and system ultilisation on other components.

REAR AXLE CASINGS | The main problem posed by grinding rear axle casings is correct support of the non-grind end of the axle, to ensure it runs concentrically to the grind end. This ensures dimensional accuracy is maintained during the grind cycle.

While outboard support is a vital factor in the plunge grind setup for rear axle casings, it has to be provisioned in a manner which allows for simple and effective adjustment and changeover for the operator to prevent excessive downtime. We have a range of automation equipment suitable for use on axle grinding applications, and can talior a package to suit your component size ranges.

STUB AXLES | These components can be notoriously difficult to grind due to the comparative mass of the component which sits outside the wheels. This results in the part being out of balance between the wheels, and if not addressed can result in dimensional errors, surface finish problems and even wheel breakage if the shaft hits the wheel when ejected post grind.

By utilising either an overhead support integrated into the machine control, or a static part support infront of the workrest if the component form allows, this problem can be eliminated to offer high volume, high accuracy production.

VALVE TAPPETS | Spring loaded valve tappets, or cam followers, can be ground on either plunge or throughfeed cycles depending on the form of the component. Both operations offer superb rounding and sizing in the production of tappets, which are often their most critical attributes, but will be recommended based on the stock removal requirement on components, as well as whether the part is headed or parallel.

Which ever production technique is used, the integration of automation equipment into the machine control can greatly increase production volumes.

ENGINE VALVES | Covering a wide range of materials, valve types and grinding processes, our valve grinding machines combine the latest in process automation with sound machine structure to ensure high volume, high accuracy production is available on even the most demanding of valve grinding applications.

Our valve grinding machines are perfectly capable of grinding the chamfered head and either a straight or profiled stem in a single process, as well as dressing complex profiles into the grinding wheel through either CNC profiling or crush dressing dependent on volumes required.

VALVE GUIDES | Throughfeed grinding valve guides to high dimensional tolerances is a process we are very familiar with, and lends itself well to incorporation of an advanced automatation control package into the machine to keep production volumes high and operator intervention low.

We typically advise that these components are bowl fed onto a load conveyor to maximise the throughput capacity of the machine, and can integrate laser gauging for component diameter and surface finish into the machine to further enhance performance.

VALVE SEATS | Critical features for consideration when grinding valve seats on a throughfeed centreless application are tolerances on ground diameter and roundness of the ground component, which can be particularly difficult to achieve due to the thin wall section of the part in comparison to diameter.

Through ensuring high quality infeed slide construction, the stability and production capabilities of a CNC centreless grinder dramatically outperform those of hydraulic or manual slide advance mechanisms offered on older machines. We are able to retrofit to this specification as part of the refurbishment.

FUEL INJECTION NOZZLES | These components lend themselves perfectly to the plunge grinding process, which allows multiple part diameters to be ground concentrically to high levels of accuracy with typical cycle times of a matter of seconds. The inclusion of CNC profile dressing on a machine will also help to increase production rates, component accuracy and the efficiency of part changeover.

By utilising the increased efficiency offered by a magazine or pneumatic plunge loader, manufacturing volumes can remain at consistently high levels without relying heavily on operator skill or intervention.

PISTONS | Ground to high quality surface finishes and dimensional tolerances, we have built machines for throughfeed grinding piston outers as well as plunge grinding the outer and profiled faces simultaneously.

We are also able to offer a wide range of automation options, such as walking beams, pneumatic plunge loaders and ejectors or feed conveyors or rollers, to accommodate your chosen grinding technique, as well as advanced control packages to ensure component quality remains high while keeping the your machines producing efficiently.

PISTON PINS | Key factors for consideration when grinding piston pins (or gudgeon or wrist pins) are material selection, dimensional accuracy and ground surface finish. This typically leads to these components being rough ground prior to finish grinding, either on one machine with a changeable setup, or two machines configured in an automated production line.

Through our experience gained on building centreless grinding machines, and even entire grinding lines, for producing these components, we are able to advise suitable abrasive grades for optimum stock removal and surface finish.