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Mayes and Warwick has utilised the S33 high-precision CNC grinder from Studer to keep pace with the growing demand for its output.

Mayes and Warwick thread and form rolling dies are manufactured using top-quality branded tool steels and high-speed steels.

All are heat treated using vacuum heat treatment facilities to ensure respectable hardness, wear resistance and longevity.

Mayes and Warwick produces a full range of flat thread rolling dies in an infinite variety of thread profiles for rolling all types of screws, bolts and fasteners.

Also manufactured are rolling dies for many kinds of lock bolts and rivets.

Dies can be manufactured for screws and fasteners featuring all standard thread forms, from 1.1mm to 32mm diameter (0.043in to 1.1/4in) with pitches from 0.32mm (>80TPI).

The company utilises CADCAM technology and manufactures its products on advanced CNC milling machines, lathes, turning centres and grinding machines.

To help keep pace with the growing demand for the company’s output, Peter Lawrence, managing director at Mayes and Warwick, undertook a search for a high-precision CNC grinding machine to replace an older Matrix machine.

In addition to other in-house grinding applications, the main work of the machine would be grinding very precise annular grooves onto in-house manufactured crushing rolls.

These accurate rolls are used within a process critical to the accuracy of the company’s products.

The crushing rolls are used to ‘crush’ extremely precise thread forms onto the company’s grinding wheels; the treated wheels are subsequently used to grind thread forms onto the company’s high-quality thread and form rolling dies.

Mayes and Warwick contacted Micronz, the UK agent for Studer; Micronz and Studer understood its requirements and recommended its S33 as the solution.

An in-depth demonstration replicating some of the company’s most challenging grinding tasks convinced Mayes and Warwick to make the purchase.

Now in full production, the S33 is providing the promised levels of high-quality output, Lawrence said.

Manufactured with distances between centres of 650mm (25.6in) and 1,000mm (39.4in), the Studer S33 CNC universal cylindrical grinding machine was designed for grinding medium-sized workpieces in individual and series production.

The machine’s solid Granitan S103 machine base forms the basis for this robust cylindrical grinding machine.

The dampening properties of the machine’s base helps ensure good surface quality of the ground workpieces, extended service life of the grinding wheel and therefore reduced downtime.

Temporary temperature fluctuations are efficiently compensated for by the favourable thermal behaviour of Granitan, resulting in high dimensional accuracy at all times.

The machine’s longitudinal and cross slide, V and flat guideways are moulded directly onto the machine base and are treated with a non-abrasive 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 setups.

The guideways offer high accuracy through the machine’s entire speed range with high load capacity and dampening levels.

Changing over from grinding between centres to live spindle grinding is said to be particularly easy on the S33; only a few movements are needed to withdraw the tailstock to its park position and free up the space required for internal grinding.

Reference points from grinding wheels to dressing tool and workpiece can be registered quickly with the help of Quick-Set, Studer’s software-controlled set-up device.

An external wheelhead with a belt-driven spindle, which can be manually adjusted to 0deg or 30deg, is available for production applications.

Studer’s turret wheelhead, with two motor spindles and an internal grinding attachment, enables the grinding of more complex workpiece geometries in a single clamping.

Thanks to the machine’s geometry, the entire distance between centres can be traversed with all grinding wheels.

The motor spindles that contribute to grinding accuracy are manufactured entirely in-house.

The S33 universal workhead enables both live spindle grinding and grinding between centres.

The machine can also be fitted with a specially designed chuck workhead for chuck applications.

All low-maintenance workheads are equipped with roller bearings; they also feature good roundness accuracy figures of less than 0.0004mm (0.000,016in), which can be optionally improved to less than 0.0002mm (0.000,008in) during live spindle operations.

Fine adjustment allows for taper corrections within the 1um range throughout live spindle operations.

As with the S33 tailstock, the machine’s workhead is also equipped with a pneumatic lifting device to facilitate movement during set-up and resetting.

An optional C-axis enables thread and form grinding, increasing the machine’s potential applications.

A controlled power chucking cylinder – which actuates a power chuck and spring collets – is also available for automatic workpiece clamping.

The generously dimensioned barrel, designed for the use of Morse 3 (4) taper centres, glides in the tailstock housing.

Centre pressure can be adjusted with the absolute precision required for grinding high-precision workpieces, while fine adjustment enables taper corrections in the range below 1um when grinding between centres.

If required, the S33 tailstock can be equipped with a hydraulically actuated barrel retraction for workpiece changeover, and a pneumatic lifting process facilitates movement during set-up and resetting.

In order to guarantee optimum thermal stability, the S33’s tailstock is flooded with cooling lubricant, as are the barrel and the diamond holder.

The Studer S33 uses a Fanuc 0i-TD CNC control with integrated PC and 15in touch screen.

All controls are clearly and ergonomically arranged, while an important role is played by the manual control unit, which facilitates set-up close to the grinding process.

The mechanical engineering concept of the S33 is complemented by a grinding software program developed in-house by Studer in collaboration with customers.

The user interface, Studerwin, plus the software modules of Studergrind, create a stable programming environment and contribute to the overall efficiency of the machine.

The S33 has the option of fully integrating in-process gauging and sensor technology for process monitoring, in addition to contact detection and automatic balancing systems.

Windows control enables standardised programming of all of the S33’s different systems.

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