S40 The Allrounder for complex grinding jobs.
Advantages S40 Dimensions Distance between centres 1000/1600 mm (39.4 /63 ) Height of centres 175/225 mm (6.9 /8.9 ) Maximum workpiece weight 130/150 kg (286/330 lbs) Hardware Turret wheelhead with automatic swivel, 1 deg indexing Complete machining with up to four grinding wheels High-resolution 0.0001-deg B axis for grinding cylindrical and tapered parts in one workpiece program C axis for the workhead enabling form and thread grinding Full enclosure with sliding doors Granitan S103 mineral-cast machine base Software Extremely easy programming with Studer Pictogramming Programming software StuderGRIND for producing grinding and dressing programs on a PC Reduced setup and dressing times with Studer Quick-Set Standardised interfaces for loader and peripheral devices S40
Range of parts for external, internal and form grinding The Allrounder for complex grinding jobs. The S40 CNC universal cylindrical grinding machine is designed for grinding complex workpieces in small and large-batch productions as well as individual components. It is built with a distance between centres of 1000 mm or 1600 mm and centre heights of 175 mm and 225 mm. Due to its modular system design, it can be precisely adapted to individual requirements. The Granitan S103 machine base forms the basis for assembling the high-technology components to build a cylindrical grinding machine that guarantees the highest levels of precision, performance and reliability over many years. The full enclosure with two large sliding doors makes setting up easy and convenient, and also allows the use of emulsion or oils as a cooling lubricant. The defined loader interface enables the fitting of handling devices for automation, which together with our know-how results in high productivity. The S40 s area of application is further enhanced by features like the vertical spindle on the wheelhead or the R axis on the longitudinal table. The practical Studer grinding software with its proven pictogramming allows even less experienced users to quickly optimize the potential of this machine. The StuderGRIND software is also available; this enables efficient programming of special applications, such as form and thread grinding. The systematic development, production, assembly and testing of Studer products are carried out in a process-oriented manner and in strict compliance with the VDA 6.4 and ISO 9001 directives. 3
amplitude conventional machine base machine base produced in Granitan - Vibration-damping - Thermal stability - Non-wearing 1 Vibration characteristics of Granitan compared to cast iron 2 Guideways with patented surface structure 3 Machine base with X and Z guideways 4 Machine base with longitudinal and cross slides 5 Z axis with circulating ball screw and three-phase servomotor oscillation frequency Granitan mineral-casting S103 machine base 1 2 The material structure developed by Studer and which has proved its superb efficiency over many years is produced in the company s own plant using the most modern industrial techniques. The excellent dampening proprieties of the machine base ensures outstanding surface quality of the ground workpieces. The service life of the grinding wheel is also increased, leading to reduced downtimes. Temporary temperature fluctuations are extensively compensated for by the favorable thermal behavior of Granitan, resulting in high dimensional accuracy at all times. The V and flat guideways for the longitudinal and cross slides are moulded directly into the machine base and are provided with a nonabrasive Granitan S200 slideway coating. The patented knobbed structure of the guideways largely eliminates the slip-stick effect or floating of the slides observed on conventional guideways. The guideways offer the highest possible accuracy through the entire speed range with high load capacity and dampening levels. Thanks to the robust and maintenance-free design, these excellent guideway characteristics are more or less completely retained. 3 4
6 T groove and clamping surface for fitting dressing tool holders, etc. 7 Setup scale 4 5 6 - High-accuracy axis movements - Auxiliary scale for setup and resetting - Effective covering of the guideways Longitudinal and cross slides 7 The longitudinal and cross slides are manufactured from high-quality gray cast iron and have highly precise, ground V and flat guideways, with the distance between the guideways optimally suited to the machine s overall rigidity. The slides rest completely on the guideways of the machine bed through the entire travel range. This provides the cornerstone for the excellent inherant grinding straightness of 0.0035 mm (0.000,14 ) over 950 mm (37.4 ) measured length. The slides are advanced by 40 mm (1.57 ) diameter circulating ball screws connected to a three-phase servomotor via torsion-resistant, bellow-type couplings. These axes achieve high process speeds, on the one hand, while on the other hand the short auxiliary times also guarantee maximum precision with in-feed movements of 0.0001 mm (0.000,004 ). These axes can be equipped with rotative or linear measuring systems, depending on requirements. The top of the longitudinal slide has a surface that is ground over its entire length and acts as a support for the workhead, the tailstock, as well as accessories and devices. A setup scale, recessed in the table, makes it easy to set up and reset the position of workhead, tailstock and ancillary equipment. An additional T-slot with ground surface enables optimal utilization of dressing devices. 5
* * 1 2 * test result ** guaranteed range 3 4 1 High-precision B axis assembly 2 Evaluation of repetition precision of the B axis 3/4 Turret wheelhead left/right/ internal 5-10 Wheelhead examples Turret wheelhead The most important component for complete machining is the wheelhead with its integrated B axis. This swivels automatically, making it possible to use up to four grinding wheels. This means that workpieces can be completely machined in the same clamping. And all of this, with minimal idle times while ensuring greater precision. The basic position of the B axis is set by the 1- deg Hirth gear, and the simultaneous fine-positioning via a special cam adjustment device. The 0.0001-deg resolution guarantees outstanding values for positional stray (repetition) and positional deviation (angular deviation). 6
- Customised configuration - Complete machining - Grinding of cylindrical and tapered parts with the same grinding wheel Combinations of up to four external grinding wheels and three internal grinding wheels produce 30 basic configurations, with the option of using belt-driven internal grinding spindles at speeds up to 60 000 rpm or high-frequency internal grinding spindles up to 120 000 rpm. Dynamic or automatic balancing systems and frequency converters for the individual external grinding spindles enable the wheelhead variants to be attuned even more to optimize the grinding process. A vertical spindle for grinding longitudinal keyways can also be fitted to the wheelhead as a special solution. 5 6 7 8 9 10 7
Workhead The versatile universal workhead enables both live spindle grinding and grinding between centers. The machine can also be fitted with a specially designed chuck workhead for chuck applications. The workheads are equipped with roller bearings, are low-maintenance and have an excellent roundness accuracy of under 0.0004 mm (0.000,016 ), which can be optionally improved to under 0.0002 mm (0.000,008 ) during live spindle operations. The fine adjustment allows for taper corrections in the 1 µm range during live spindle operations. Like the tailstock, the work- head is also equipped with a pneumatic lifting device to facilitate movement during setup and resetting. Option: Roundness of < 0.0002 mm (0.000,008 ) during live spindle grinding operations. With the hydrodynamic bearing up to < 0.0001 mm (0.000,004 ). - High roundness accuracy - Low maintenance - Air cushion under workhead 1 2 3 8
1 Chuck workhead 2 Roundness value (test certificate) 3 Fine adjustment for taper corrections 4 External and internal thread grinding 5 Form and die grinding 6 Wheel contact situation during form grinding 5 4 6 C-axis for form and thread grinding Complete machining also entails form and thread grinding operations to an ever increasing extent. These processes are made possible by the position and speed-controlled C-axis. The standard C-axis with measuring system on the drive motor is suitable for thread grinding. A direct measuring system is mounted on the workhead spindle for maximum form accuracy (high-precision C-axis). Acceleration and grinding forces are absorbed without difficulty through the high dynamic rigidity of the axis drives. Form and thread grinding The Studer S40 enables axis-parallel grinding of conventional to high accuracy threads. Polygons, eccentrics, control cams, cams etc. can be manufactured cost-effectively and in the highest precision with High Speed Machining (HSM). 9
Tailstock The generously dimensioned barrel, designed for the use of Morse 3 taper centers, glides in the tailstock housing. The center pressure can be adjusted with the delicate precision required for grinding high-precision workpieces. The tailstock can be equipped with a hydraulically actuated barrel retraction for workpiece changeover The fine adjustment enables taper corrections in the range below 1 µm when grinding between centers. A pneumatic lifting process facilitates movement during setup and resetting. In order to guarantee optimum thermal stability, the tailstock is flooded with cooling lubricant, as are the barrel and the diamond holder. The machine is also equipped with an optional synchronous tailstock for direct driving of workpieces between centers. 1 - Taper corrections 2 3 - Barrel flooding 10
Dressing 1 Tailstock 2 Dressing tool holder 3 Fine adjustment for taper corrections 4 Rotary dressing device 5 Diamond holder behind the tailstock on the table (225 mm centre height only) 6 Dressing parameter dialogue image 7 Swivel dressing device A sharpened grinding wheel is a prerequisite for economical and high grinding quality. Studer offers a large selection of dressing devices for attaining the dressing process optimally and flexibly to the specific workpiece, tool and material properties. The grinding wheel profile and dressing parameters are easily defined via macros. Another Studer speciality are the grinding wheel reference points (T numbers). These permit programming with nominal dimensions, which makes it much easier to create grinding programs. A software package with extended dressing functions is available for fine-tuning the dressing process. 4 5 6 7 11
Machine control and operation The S40 is equipped with the extremely reliable Fanuc 16i-TA, which is optimally attuned to the drive elements. The control cabinet is bolted to the machine bed at the rear of the machine and contains separate power and control compartments. The layout of the elements complies with the relevant safety norms and is EMV-tested. - PCU manual control - Control cabinet EMV-tested - Ergonomically arranged controls All controls are clearly and ergonomically arranged. An important role is played by the manual control unit, which facilitates setup close to the grinding process. A special function the Sensitron electronic contact detection device reduces downtimes to a minimum. 1 2 3 1 PCU process control unit 2 Machine control with accessories such as the Sensitron air-gap bridging device, balancing device and external measurement controls 3 Internal view of the control cabinet 4 Pictogramming 5 Quick-set 6 Programming software StuderGRIND 12
4 - Modern technology - Pictogramming - Programming software StuderGRIND 5 Programming 6 The sophisticated mechanical engineering concept of the S40 is completed by a grinding software program developed in-house by Studer and continuously further optimized in collaboration with customers. This software offers: Pictogramming: The operator strings the individual grinding cycles together the control unit generates the ISO code. Quick-Set: The software for grinding wheel alignment reduces resetting times by up to 90%. Microfunctions: Free programming of grinding and dressing process sequences for optimization of the grinding process. StuderGRIND: Programming software for special applications such as form and thread grinding and profiling the grinding wheel for complex workpiece forms; the program is created on the PC and transferred directly to the machine control. 13
- Automatic production processes - Integrated quality control Process-optimized complete solutions guarantee greater efficiency and reliability throughout. - Standardised loader interfaces Comprehensive quality control is possible during Loading systems are available for the Studer S40, which can be precisely adapted to the machine application and the machining processes thanks to their modular design. The corresponding peripherals ensure seamless integration into the respective production process. The handling systems used communicate with the machine via the standardized loader interface and enable even complex handling tasks to be solved. the grinding process. This entails: in-process, post-process, recording, evaluation and correction. This type of quality assurance is crucial during grinding, but especially match grinding. 1 2 3 1 Customised system machine 2 Work area with workpiece handling 3 Post-process measuring station 4 Teleservice 5 Deployment of engineers on the customer s premises 6 Operating worldwide 7 Training on simulators 14
5 4 6 Accessories and services There is an extensive range of accessory equipment available for all Studer cylindrical grinding machines, including centers, dressing tools, grinding wheels, clamping devices, internal grinding spindles, in-process gauging devices, etc. The Studer Training Department organizes courses for hundreds of customers every year specializing in programming and machine use a sound basis for optimum use of your Studer machines. 7 Maintenance courses are tailored to the respective requirements of the maintenance departments. On request, they can also take place on the customer s premises. Studer specialists collaborate in grinding problems, in order to achieve the optimal solution The after sales service is able to speak the user s language and operates on a worldwide basis. This ensures that the service technicians do not have to travel far to make customer visits. The well thought-out service offer enables them to support the user to operate the machine in an optimal manner. And spare parts availability is guaranteed for a minimum of 10 years after installation. - Commissioning - Training - Production support - Warranty extension - Maintenance - HelpLine - Repair - Spare parts - Teleservice - Inspection - Overhaul 15
Main dimensions Distance between centres 1000/1600 mm (39.4 /63 ) Centre height 175/225 mm (6.9 /8.9 ) Max. workpiece weight between centres Cross slide: X axis 130/150 kg (286/330 lbs) Max. travel 275 mm (10.8 ) Speed 0.001 5000 mm/min (0.000,04 197 ipm) Resolution 0.0001 mm (0.000,004 ) Longitudinal slide: Z axis Max. travel 1050/1650 mm (41.4 /65 ) Speed 0.001 10 000 mm/min (0.000,04 394 ipm) Resolution 0.0001 mm (0.000,004 ) Swivelling workpiece table (175 mm centre height only) Wheelhead 8.5 deg/6 deg Fitting taper dia. 63 mm (2.5 ) Drive power Grinding wheel left, dia. x width x bore Circumferential speed Swivel range Hirth gear resolution Swivel time for 180 deg Internal grinding device for high-frequency spindles 7,5 kw (10 hp) 400 x 63 (80F5) x 127 mm [16 x 2.5 (3.15 F5) x 5 ] 35 m/s (6890 sfpm) 15 to + 225 deg 1 deg Spindle dia. dia. 120 mm (4.72 ) Speed range Internal grinding unit for belt-driven spindles 6 s 24 000 120 000 rpm Spindle dia. dia. 100 mm (3.9 ) Speed range 20 000 60 000 rpm Options: Driving power 9 kw (12.3 hp) Grinding wheel right, dia. x width x bore 400 x 40 x 127 mm (16 x 1.57 x 5 ) Grinding wheel left, dia. x width x bore 500 x 63 (80F5) x 203 mm [20 x 2.5 (3.15 F5) x 8 ] Grinding wheel right, dia. x width x bore 500 x 63 (80F5) x 203 mm [20 x 2.5 (3.15 F5) x 8 ] Circumferential speed Constant cutting speed B axis, infinitely variable fine adjustment Positional stray (repetition) +/ 1 Positional deviation (angular deviation) within 5 Active length positioning on grinding head Integrated, automatic grinding wheel balancing system 50 m/s (9840 sfpm) 0.0001 deg 16
Universal workhead for live spindle grinding or external grinding between centres Hydrodynamic bearing non-swivel Speed range 30 1000 rpm 30 1000 rpm swivel Fitting taper Morse 5 Morse 5 Spindle feedthrough dia. 30 mm (1.18 ) dia. 30 mm (1.18 ) Drive power 1 kw (1.4 hp) 2.8 kw (3.8 hp) Load during live grinding 100 Nm (74 ft lbs) 100 Nm (74 ft lbs) Max. workpiece weight between centres 130 kg (286 lbs) 130 kg (286 lbs) Roundness accuracy during live grinding 0.0003 mm (0.000,012 ) (Option: 0.0002/0.0001 mm) Roller bearing Universal workhead ISO50 For live or external grinding between centres Speed range 1 1000 rpm 1 1000 rpm 0.0003 mm (0.000,012 ) (Option: 0.0002/0.0001 mm) Chuck workhead ISO50 For live or external grinding with rotor centres Fitting taper/cylindrical external holding device ISO50/dia. 110 mm (4.32 ) ISO50/dia. 110 mm (4.32 ) Spindle feedthrough dia. 50 mm (1.97 ) dia. 50 mm (1.97 ) Drive power 3.8 kw (5.2 hp) 3.8 kw (5.2 hp) Load during live grinding 180 Nm (134 ft lbs) 250 Nm (186 ft lbs) Max. workpiece weight between centres 150 kg (330 lbs) Roundness accuracy during live grinding 0.0004 mm (0.000,016 ) [Option: 0.0002 mm (0.000,008)] C axis for form grinding standard, indirect measuring system 0.0001 deg 0.0001 deg 0.0004 mm (0.000,016 ) [Option: 0.0002 mm (0.000,008)] high-precision, direct measuring system Tailstock Fitting taper Morse 3/Morse 4 Travel of barrel 35 mm/60 mm (1.37 /2.36 ) Diameter of barrel 50 mm/60 mm (1.97 /2.36 ) Fine adjustment for taper corrections ± 40 µm/± 80 µm (0.0016 /0.0032 ) 0.0001 deg Options: Hydraulic barrel retraction with foot control NC tailstock with 148 mm stroke 17
Control Fanuc 16i -TA Guaranteed working precision Straightness of surface line Measured length 950 mm (37.4 ) 0.0035 mm (0.000,14 ) Measured length 1550 mm (61 ) 0.005 mm (0.000,20 ) Connection values Total connected load Air pressure 30kVA 5.5 bar (80 psi) Extraction capacity for cooling lubricant mist 1100 m 3 /h Total weight Distance between centres 1000 mm Distance between centres 1600 mm 6500 kg (14 300 lbs) 7200 kg (15 840 lbs) The information given is based on the technical levels of our machine at the time of this brochure going to print. We reserve the right to further develop our machines technically and make design modifications. This means that the dimensions, weights, colours, etc. of the machines supplied can differ. The diverse application possibilities of our machines depend on the technical equipment specifically requested by our customers. The equipment specifically agreed with the customer is therefore exclusively definitive for the equipping of the machines, and not any general data, information or illustrations. 18
2250/88.58 1) 2) 1995/78.5 4713/185.6 M.: 1:50 3687/145 4717/185.7 Distance between centres 1000 mm (39.4 ) 1) 2) 4713/185.6 2017/79.4 3) M.: 1:50 5187/204.2 6017/236.9 Distance between centres 1600 mm (63 ) 19
Fritz Studer AG CH-3602 Thun Telephone +41-33-439 11 11 Telefax +41-33-439 11 12 www.studer.com ISO 9001 VDA6.4 certified 08.2007 / Printed in Switzerland