What is a grinding machine?

Grinding machines use rotating, abrasive wheels that take light cuts — not so much for high material removal, but to create a better surface finish than can be achieved by milling or turning operations. Grinding is commonly one of the last machining operations performed to complete a part. Cylindrical and centerless grinders are used for cylindrical parts. Grinding machines for flat surfaces are called surface grinders. Form grinders move the work and/or the wheel in various axes to grind surfaces that are precisely contoured. Grinding machines are also used to create and sharpen cutting tools. Advances in grinding wheel technology continue to improve grinding speed, part surface finish and wheel life.

Automation in the Alps: Studer AG Unveils New Grinding Concepts

Motion Meeting Expedition 2023

Thun, Switzerland, was buzzing with excitement on Friday, Feb. 10, 2023, as members of the press from across the world traveled to the headquarters of Fritz Studer AG, member company of United Grinding. I was fortunate enough to attend representing Production Machining. That morning, our diverse group of journalists gathered to learn about the latest grinding equipment offerings at the international OEM’s press conference and event in the Swiss Alps titled Motion Meeting Expedition 2023.

Several company executives kicked off the annual event by presenting about the state of the business prior to revealing the company’s newest innovations, most of which include automation. After the presentations, we were led to a different building on the campus where the OEM’s new machines were displayed. Automation appeared to be the theme of the new equipment shown to us.

“There are still a lot of prejudices about automation in grinding," says Daniel Schafroth, systems division manager at Studer. There are frequently concerns that people or jobs could become redundant. “However, the opposite holds true: Automation should enable the human operators to do their work more easily, efficiently, and safely," he says.

The new Studer S100 internal cylindrical grinding machine was introduced, which is the entry-level system designed for simplicity and efficiency, and is said to make operation and maintenance easier for the operator. The machine can be equipped with up to two internal grinding spindles or one internal and one external spindle. In addition to a fixed wheelhead, it can be equipped with a manual with a 2.5-degree hirth and, in its optimum configuration, with an automatic wheelhead with 1-degree hirth. On request, the machine can be equipped with a loading interface and an automatic sliding door, enabling automatic operation and high-volume production.

Several new loading equipment options were also presented, including easyLoad for external and universal cylindrical grinding machines on Studer cylindrical grinders models S31, S33, S22, and S41. The loading process is suitable for use as a gantry loading system for shaft parts with a workpiece length of up to 300 mm (11.8”), a diameter of up to 30 mm (1.18”), and interfering contour diameters of 50 mm (1.97”) maximum. The adjustable synchronized conveyor enables autonomous processing of 50 workpieces, maximum.

The ecoLoad for high-volume production is a cost-efficient and compact automated loader. It can load workpieces with a diameter of up to 50 mm (1.97”) and a length of 250 mm (9.85”). This is either done using a carousel magazine or an insertion prism, which can also be used as the interface for standalone tool magazines. The programming is integrated into the grinding machine control systems, which ensures short retooling times.

The uniLoad automatic loading system makes it possible for operators of the Studer S31 and S33 external cylindrical grinding machines to significantly increase productivity without any loss of quality. It is suitable for workpieces with a length of up to 350 mm (13.8”) and 100 mm (3.94”) diameter and thus covers a range of parts normally produced on these machines.

For automation when space is tight on the shop floor, smartLoad is a loading option for the company’s S11 production cylindrical grinding machine for small workpieces. With a footprint of only 1.8 square meters (19.4 sq. ft), the unit is compact and can feed in workpieces from outside the machine, using either a conveyor or a swiveling unit.