Software for process planning

New software solutions also enable simplified process design and planning. Therefore, in addition to tool grinding machines, numerous software developments for process planning and design were also presented. Software can be used to examine and evaluate tool geometries and machining processes. In addition to forecasts of process forces, torque and power, critical engagement conditions can also be identified and workpiece quality predicted. Among other things, this offers the potential to shorten development times and save costs. Another way to minimize expenditure in the manufacturing process is to ensure a stable manufacturing process and avoid machine failures.

Holistic view of the grinding machine

A capable sanding machine is not the only decisive factor in the productive manufacture of high-quality workpieces. The design of an efficient and resource-optimized grinding process requires a holistic view of the grinding machine in conjunction with its peripherals. When it comes to lubricant supply, for example, a distinction can be made between the lubricant itself, corresponding supply strategies and the filtering and recycling of lubricants after the grinding process. Numerous companies presented their products from these areas at the Grinding Hub.

The spindle is an important component of all machine tools and grinding machines. With a view to increasing power density while reducing power consumption, the design of the spindle plays a major role. Larger axle holes, ball bearings and shaft diameters in conjunction with shorter shafts lead to smoother running. In addition, the potential resulting from the improved dynamic rigidity and load capacity can be exploited either through larger tool interfaces or higher maximum speeds.

Additive manufacturing of abrasives

Additive manufacturing processes open up new design possibilities for abrasives. In addition to machine concepts and integrated spindle and supply systems, the grinding wheel is the decisive element in grinding processes. It is in direct contact with the workpiece and has a major influence on the machining result and process productivity. For this reason, developments in the field of grinding wheels and their preparation for the grinding process are constantly being driven forward. Additive manufacturing of abrasives is currently a hot topic. The basic tool body, the grinding wheel or both can be produced using additive manufacturing processes. Compared to conventional manufacturing processes, additive manufacturing processes allow significantly greater design freedom for the components produced. In contrast to manufacturing processes with a geometrically defined cutting edge, where it is possible to feed cooling lubricant through the tool at close range, this is usually associated with major challenges in grinding processes. Here, additive manufacturing processes offer the possibility of designing grinding wheel systems with an internal cooling lubricant supply.

Grinding wheel preparation is also an important factor. On the one hand, grinding wheel preparation gives the grinding wheel its final contour; on the other hand, breaking the abrasive grains out of the bond exposes new abrasive particles and thus creates the basis for grinding wheel topography. At Grinding Hub, many manufacturers presented different approaches to dressing grinding wheels.

Automation increases productivity

Various manufacturers presented automation approaches for a wide range of processes. They are also an approach to counter the shortage of skilled workers and increase productivity. Particularly in the areas of workpiece handling within the processing machine, the loading and unloading of machines and their loading, the automation of processes offers the potential to maintain and scale manufacturing processes more independently of the available workforce.

In the context of the mobility transition towards emission-neutral mobility, grinding technology processes are of great importance. In addition to new drive concepts, the focus is also on emission-reduced brake systems and their production. The grinding of hard-coated brake discs is a growing sector that requires comprehensive innovations in grinding machines, grinding tools and process control.