Willkommen bei - Vogelof pinion gears 齿轮双端面平面抛光 MicroStar 200 Series Flat finishing on up to 7 stations with 1 or 2 loading / unloading stations 1或2个上下料工位+至多7个平面超精工位

μ Ra Tpi

Willkommen bei

A division of 25.08.2014 1 本文档来自于2014中国变速器先进制造技术高层论坛未经允许不得转载

About us 梯伦豪斯总览

25.08.2014 2

Waldwick, NJ, USA

Shanghai, PRC

Matzingen, CH

Wuppertal, DE

Detroit, MI, USA

Chennai, IND

Products & Services: 产品和服务

MICROFINISH machines, devices & subcontracting

抛光机，设备和代加工

Gear boxes

齿轮箱

Compressors

压缩机

„Germany‘s1000

Global Market Leaders“

Sales: € 60 Mio. Employees: 230

本文档来自于2014中国变速器先进制造技术高层论坛未经允许不得转载

Divisions 分类

25.08.2014 3

Microfinish machines, devices & tools

抛光机，设备和刀具

Maschines for process combinations

(finishing / grinding / honing)

多工艺结合设备（抛光，磨削和珩磨

结合在一台设备内加工）

Double-disc grinding machines

双端面磨床（如连杆抛光，大众娄塘）

Gear boxes and Compressors

齿轮箱和压缩机

Subcontracting 代加工

420 patents in surface machining technology 表面加工技术涉及420项专利


A division of

Cube, Center- & CrankStar For cylindrical surfaces 圆柱体表面抛光

• Crank shafts曲轴 • Balance shafts平衡轴 • Cam shafts凸轮轴 • Steering racks转向杆 • Drive shafts传动轴

MicroStar For flat surfaces & process combinations – finishing, grinding and honing 平面抛光及多工艺结合-抛光，磨削和珩磨 • Fuel injection components

• 油泵油嘴零件 • Sealing seats密封座 • Fine blanking parts • 精密冲压件 • Gear wheels齿轮 • Sensors感应器

Microfinish solutions for all surface types 满足所有表面的抛光

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BearingStar For raceway finishing • Ball bearings球轴承 • Roller bearings • 滚子轴承

EndoStar For spherical surfaces 球面抛光 • Hip joints髋关节 • Balls and sockets球和球窝 • Spinal discs椎间盘假体 • Ball valves球阀

Thielenhaus also offers 100% customized solutions 梯伦豪斯总能满足客户的抛光需求

SF 125 For roller bearings 滚子轴承 • Roller bearing bodies


A division of

Service from all locations 全方位的服务

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24 hour hotline 全天候在线

Refurbishing 改造

Inspections 检查

Spare parts 备件服务

Training 培训

Consumables 耗材服务

Subcontracting 代加工

Process discovery 工艺研发


A division of

Flat and thrust surfaces:平面和推力面

Synchronous gears, clutch housings, pinion gears 同步齿轮，离合器外壳，齿轮

Surface roughness must be minimized while flatness must be optimized - components must meet tightest tolerances not only for radial but also for tangential surface roughness measurements

改善平面度和表面粗糙度最优化并行-采用极窄的测量公差（直径和表面粗糙度）

Shafts:轴类 Bearing seats on input- / output shafts 输入/输出轴的轴承面

reduced friction and noise development 降低摩擦和噪音的研发

Microfinishing of transmission components变速箱工件的抛光


A division of

TRANSMISSION APPLICATIONS 变速箱领域的运用 Automatic – Manual – Dual-clutch – CVT 自动挡-手动挡-双离合-无极变速

GEAR WHEELS齿轮


A division of

Flat finishing 平面抛光

Synchronous cone grinding/finishing 同步锥面磨削/抛光

Internal grinding &

honing 磨削和珩磨

Grinding 磨削

...on one machine 所有加工工序在一台机床上完成

Intelligent manufacturing via...

智能化加工的实现

MicroStar FGH MicroStar evo 12

Brush-deburring

去毛刺


A division of

MicroStar FGH series Finishing, grinding & honing in one clamping 一次装夹完成抛光，磨削和珩磨

Elimination of clamping errors through back-to-back process combination

消除多种工艺夹紧产生的误差

Up to 7 simultaneous machining operations + 1 loading / unloading station

至多7个加工工艺同时进行+1个上下料工位

Very short cycle times – loading / unloading during main machining process

加工节拍极短-上下料和加工并行

Market-leading MicroSens technology for process stabilization

领先于市场的MicroSens技术保证加工工艺的稳定性

Double-loading: machining of 2 workpieces simultaneously

双上料：同时加工2个工件

Ergonomic and compact design, all assemblies within arm‘s length, diameter of 1.5 m.

符合人体工程学和紧凑的设计，操作者可轻易接近设备，设备直径1.5m

Sample configuration for pinion gears齿轮加工配置示例

Flexible automation 自动化

High reuseability due to modular concept 模块化结构，高柔性设备

Click here for video (online)


http://www.thielenhaus.com/en/solutions/grinding-honing/







A division of

Effective process-combination enabled by indexing table concept 分度回转工作台实现工件高效多工艺的加工


A division of

MicroStar evo(lution) 12 More processes, more productivity 更多的工艺更高效的产能

Up to 11 machining processes parallel to loading / unloading on 1 station

至多11种加工工艺同时进行，1个工位上下料

Optional multiple-part loading for increased productivity

可选多工件上料，提高产能

Flat finishing平面抛光

Taper grinding锥面磨削

Internal grinding & honing

磨削和珩磨

Sample Part

Taper grinding锥面磨削

Bore gauging 测孔


A division of

MS evo process combinations

Loading / unloading 上下料

MICROFINISH-station flat finishing 平面抛光工位 MICROFINISH-station

cone finishing 锥面抛光

Internal grinding Station 1 磨削工位1

Internal grinding Station 2 磨削工位2

Honing Station 1 珩磨工位1

Honing Station 2 珩磨工位2 Bore gauging 1

测孔工位1

Bore gauging Station 2 测孔工位2

Brush deburring 去毛刺工位

Flip over / Rotation (optional) 翻转/旋转工位（可选）

Spin-off 甩干


A division of

Case study – double sided flat finishing of pinion gears齿轮双端面平面抛光

MicroStar 200 Series

Flat finishing on up to 7 stations with 1 or 2 loading / unloading stations

1或2个上下料工位+至多7个平面超精工位

Force-control technology for top work piece quality

切削力控制技术保证工件加工精度

Optional gauging stations and flip-over stations for machining of both sides

抛光双端面时可选测量工位和翻转工位

Uniform temperature balance throughout working area guaranteed by oil mist suction through column adjacent to machining site

通过立柱上的吸油雾器保证设备加工区域内的恒定温度

Sample configuration Loading & unloading

MICROFINISH-station Side 1

MICROFINISH-station Side 2

Rotating / Flip over

Work piece specifications工件参数

FLAT FINISHING 平面抛光

Before Microfinish

After Microfinish

Roughness (Rz) 粗糙度

-- 1.6µm

Axial runout to bore hole 轴向跳动

Max. half of stock removal

per side

最大为单面余量的一半

0.02mm

Stock per side 每个端面抛光余量

0.03-0.05mm -

Cycle time 节拍

7 seconds


A division of

Honing results珩磨结果

Work piece specifications

Grinding & Honing 磨削和珩磨

Before After

Cylindricity 圆柱度

-- ≤0.5µm

Roundness 圆度

-- ≤0.3µm

Total stock removal (grinding + honing)

总去余量（磨削和珩磨）

80µm


A division of

Flat finish results平面抛光结果

Flatness

Microfinishing can be used to generate concave or convex surfaces depending on customers’ wishes 可满足客户要求-抛光成凸面或凹面


A division of

Case Study – clutch housing 离合器外壳

Work piece specifications工件参数

FLAT FINISHING 平面抛光

Before Microfinish

After Microfinish Rating before &

after

Roughness (Rz) 4.0µm

1 µm circumferential

（圆周） 2.5µm radial

（径向）

cmk> 1.4

Ring height 环高

22.15 +/- 0.5 22.05 +/- 0.03mm cmk> 1.67

INTERIOR GRINDING 内面磨削

Before Microfinish

After Microfinish Rating before &

after

Inside diameter 内径

153.4 - 0,1 153.25 +/- 0.05

mm cmk> 1.67

Runout to reference face 至参考面的跳动

within 70% of stock

≤0.08 mm cmk> 1.4

Surface to be finished 抛光面

Task: grinding and finishing of clutch housings 任务：磨削和抛光

Surface to be ground 磨削面

Finishing station 抛光

Loading / unloading 上下料

Grinding station 磨削


A division of

Case Study – CVT component


Before Microfinish After Microfinish

Roughness (Rz) 3–7µm 2-3.5µm

Contact area ratio 接触面积支撑率

35% (C Ref. 5%) ≥ 75%

Task: improve surface roughness and contact area on conical surface of CVT component 任务：改善CVT工件表面粗糙度和锥面接触面积

Surface to be finished


A division of

MicroStar 300 series

Work piece diameter up to

500 mm 最大加工工件直径500mm Up to three machining

stations 最多3个工位 Highly flexible: ideal for

prototyping and smaller batches

高柔性：样件加工和小批量


A division of

TRANSMISSION APPLICATIONS Automatic – Manual – Dual-clutch – CVT

SHAFTS轴类


A division of

MICROFINISH of shaft components 轴类工件的抛光

Task

25.08.2014 20

Surface 表面

Bearing ratio

支撑率

Roundness 圆度

Cylindricity 圆柱度

Roughness after MF Rz 0.05 µm

Roughness before MF Rz 1µm

Roundness before MF Roundness after MF

Scale: 0.5µm


A division of

Stable process for top component results

稳定工艺

1- or 2- stations for short cycle times 短加工节拍，单/双工位

Flexible tool configuration – tape, stone, CAB, brush-deburring

灵活的刀具选择-砂带，油石，CAB,去毛刺刷

Quick and easy process changeover 快速便捷的程序换型

Easy integration in new & existing production lines (shuttle / gantry/ indexed conveyor/ robot)

无论是新线还是旧线，设备入线方便（滑台、桁架，输送带，机械手）

Horizontal or vertical configuration 卧式或立式

Shaft finishing machines

25.08.2014 21

CLF (centerless) 无心式夹紧

CenterStar (vertical)

CenterStar (horizontal)

Cube


A division of

Tape finishing 砂带抛光

- Long intervals between tool change

- 砂带更换间隔长

- Consistent tool

quality - 恒定的砂带质量

Continuous Abrasive Band (CAB) 连续砂带抛光 - Higher cutting

speeds - 高切削速度

Stone finishing 油石抛光

- Simultaneously

optimizes geometry, surface roughness and waviness

- 同时优化几何参数，表面质量，圆度和波纹度

Tape finishing with shoe system 配备砂带靴的抛光

- Optimizes geometry

(in addition to other advantages of tape)

- 几何尺寸的优化

- Simultaneous machining of multiple journals on compact components

- 同时加工紧凑型轴类的多个轴颈

Tool options刀具选择


A division of

Machine configurations设备配置

Vertical (tape & shoe system) 立式（砂带和靴单元）

Narrow distances between finishing units permit machining of compact components + more compact machine

适用于紧凑型工件的抛光+紧凑的设备

Longer intervals between tool changes 刀具更换间隔更长

Horizontal (tape, stone or CAB) 卧式（砂带，油石或CAB） Easy access / tool change 刀具安装和更换便捷

Direct loading / unloading 直接上下料

Continuous tape feed (pre- & final finish in one step)

砂带持续进给（一步完成粗抛和精抛）

Optional combination of stone and tape 油石和砂带抛光的结合


A division of

Sample configurations配置示例


A division of

Loading / Unloading

25.08.2014 25

Pick & place

Robot

Shuttle

Gantry

Manual


A division of

Case Study – centerless finishing of pin bearing journals on drive shafts 无心驱动轴支撑轴颈的抛光


Length长度 50 - 650mm

Swing diameter回转直径 max 220mm

Finishing diameter抛光直径 max 200mm

Before Microfinish After Microfinish

Roughness (Rz)粗糙度 2.5–4.0µm 1.3µm

Bearing ratio支撑率

Ground or hard-turned

磨削后或硬车后

Rmr 0.2 (C Ref. 5%) ≥ 70%

Amplitude for waviness from 5-500th level (Fourier -Analysis)

傅里叶分析波纹度

max 1µm max 0.25µm

Task: centerless microfinish for improved surface and geometry of multiple journals on various drive shaft types 任务：改善驱动轴轴颈表面和几何参数的无心抛光

Loading: work pieces on individual coded palettes; linear conveyor with queue effect, i.e. independent timing; gantry loader with double-gripper (wet / dry separation) 上料：工件位于相应的托盘上；输送料道上顺序放置；桁架双爪机械手（干湿分离）


A division of

Overview

Fully automatic machining center returns work pieces to production line drip-free 工件表面从全自动设备输出无油滴

Cleaning station removes flushing liquid residue parallel to main machining cycle 工件进入设备加工前，在清洁工位去除工件上的残余物

Gantry loader moves work piece from vertical to horizontal position 桁架机械手将工件从立式改为卧式放置


A division of

Case study – needle bearing on drive shaft 传动轴的滚针轴颈抛光

Task: 1 journal seat for needle bearing (set-up for up to 8 journals) 任务：滚针轴颈1（至多可抛光8个轴颈） Before Microfinish: Rz 1.5 μm via whirling 抛光前： Rz 1.5 μm ，铣加工 Cycle time: < 25 seconds 节拍< 25 秒

Driveshaft传动轴

CS LC 11 with stone finishing unit油石抛光单元

Results抛光后参数


A division of

Case study – combination flat surface & cylindrical surface on shaft 改善轴类零件的平面度和圆柱度

Task:任务 Shaft 1: 1 journal, 1 sealing seat (non-twisting) 轴1：轴颈1，密封座1（无纹路） Shaft 2: ring surface axial journal 轴2：轴向轴颈环形表面 Cycle time: < 20 seconds Random mixed loading随机混装

Camshaft 凸轮轴

Before Microfinish

After Microfinish

Tolerance limits

Roughness (thrust surface) 推力面的粗糙度

Rz < 6.0 μm Rz 2.5 μm Cmk > 1.4

Roughness (cylindrical surface) 圆柱面的粗糙度

Rz < 6.3 μm Rz 2.5 μm Rt max 6.3

Cmk > 1.4

Roundness 圆度

0.005 0.005 Cmk > 1.67

Parallelism 平行度

0.005 0.005 Cmk >

Stock removal 余量

- 10-12 μm -

Cup wheel finishing unit

杯形砂轮抛光单元

Tape finishing unit 砂带抛光单元


A division of

PowerCube - NEW

25.08.2014 30

For cylindrical work pieces up to 400mm 最大加工圆柱体工件直径400mm

3 machining stations 3个抛光工位

1 station for loading / unloading parallel to main machining cycle (fully automatic)

1个工位用于上下料，与加工同时进行

Cycle time approx. 8 seconds 节拍约8秒

Machining Station 2

Machining Station 3

Machining Station 4

Station 1 loading / unloading


A division of

THANK YOU FOR YOUR ATTENTION


A division of

Derya Lenbet Product Manager Email: [email protected] Tel.: +49(0)202 / 481-186 Fax: +49(0)202 / 45 04 45

Thielenhaus Technologies GmbH Schwesterstraße 50 40228 Wuppertal Germany Visit us at: www.thielenhaus.com

Your contact:

谢媛媛产品经理 Email: [email protected] Tel.: 021-67753157 Mobile: 18116225451 Fax: 021- 33528766 梯伦豪斯机械（上海）有限公司上海松江区江田东路212号 7栋


http://www.thielenhaus.com/

Documents

Willkommen bei - Vogelof pinion gears 齿轮双端面平面抛光 MicroStar 200 Series Flat finishing on up to 7 stations with 1 or 2 loading / unloading stations 1或2个上下料工位+至多7个平面超精工位