Bourn & Koch Vertical Cylindrical Grinder Also Mills, Turns
IMTS Spark: Bourn & Koch’s MT³ is a multifunctional machine tool platform capable of performing grinding, milling, turning and drilling/tapping operations in one setup.
The newest addition to Bourn & Koch’s lineup of American-made machine tools is the MT³, a multifunctional machine tool platform capable of performing grinding, milling, turning and drilling/tapping operations in one setup. The machine is primarily designed as a vertical cylindrical grinder, supplementing the company’s current VBG offering. The MT³ comes standard with a 42" diameter T-slot worktable and precision grinding spindle with an HSK-50A connection. The machine’s spindles are interchangeable via an HBK-200 clamping system, allowing the right spindle to be used for each application. The machine is equipped with custom workholding from Advanced Machine & Engineering to manufacture a hob spindle cartridge from one of Bourn & Koch’s 400H hobbers in one setup.
The machine is expandable from a vertical grinder to a “one and done” machine tool system, incorporating various spindles and tools into an added optional cell. These components can be quickly changed via a FANUC R2000 robot and Bourn & Koch’s Alien Claw end-of-arm tooling.
A spindle rack and disc-style toolchanger are incorporated to the cell. Users can program the machine via combination of Bourn & Koch’s grinding HMI and FANUC Manual Guide-i, employing a FANUC 0i CNC control for all machine functions. A virtual y-axis allows for the machine to perform standard milling functions. The MT³ spindle features a powerful FANUC Beta-il 160M motor capable of producing 30kW from 2,000-10,000 rpm, providing ample power and range for a variety of grinding, milling, and drilling/tapping applications. This machine platform is modular, with future plans for a vertical gear hobbing machine and a five-axis machining center in the works.
Roughing and finishing on a single machine, using a single setup, has appeal for most shops. The advantages in time savings and accuracy are obvious. Eliminating the transport of workpieces between machines, as well as the setup for those secondary operations, is a boon for throughput. Critical features that need to maintain dimensional relationships can be much more reliably produced if machined complete in one clamping.
Optimizing a camshaft lobe grinding cycle has traditionally been based less on science and more on educated guesswork and numerous test grinds. Now, computer thermal modeling software can predict areas where lobe burning is likely to occur, in order to determine the fastest possible work speed that won't thermally damage lobes and greatly reduce the number of requisite test grinds.
It sounds like a contradiction in terms-between centers and centerless grinding on one machine. But for some categories of workpieces, it's a viable production process that can yield machining time reductions of 45 percent over separate grinding operations.