PRODUCT SHOWCASE: Junker Grinding Machine Offers Alternative To Turning

When manufacturing small components with a diameter between 2 mm and 20 mm, the Grindstar grinding machine from Junker offers an economical alternative to turning. From batch sizes of 200,000, short cycle times and a long workpiece service life can drive down costs per workpiece by up to 25 percent. Its high productivity makes the Grindstar a particularly interesting alternative for large-scale series manufacturing in the automotive industry.

The innovative grinding method enables the entire workpiece contour to be ground in a single processing operation. In addition, grinding involves much lower cutting forces than those occurring during turning, allowing for faster grinding of workpieces. Another advantage of the Grindstar is the perfect coordination it allows between workpiece, abrasive, and machine. All three factors act together to enable a significant increase in productivity, up to three times faster than a lathe.

The automotive and supply industry demands high piece volume with the fastest possible turnaround. This is precisely where the strengths of the Grindstar help. From material cut-off, through profiling to ejection, every work step is covered in a single machine. This enhances process reliability and minimizes machine downtime. As a result, Grindstar achieves an impressive availability level of more than 96 percent, and an extended tool service life. Due to its innovative cooling system, the grinding wheels work precisely and to a consistent standard of quality — for up to six months or a production volume of 300,000 pieces and more.

Grinding instead of turning also impacts positively on the quality of workpieces, with significantly improved dimensional accuracy and excellent surface quality. The manufacture of burr-free parts during grinding is 100 percent guaranteed. Unlike turning, no chip impressions are created. The two profile grinding wheels in the Grindstar require no dressing and use an innovative lubrication method. The flushing system prevents particles from being deposited on the grinding wheels, eliminating the need for the reworking process frequently required when turning. This reduces the production time required and saves the need to invest in additional machinery for surface grinding or polishing.

When it comes to the choice of material, the Grindstar offers maximum flexibility. Of particular interest for the automotive industry, with its increasing demand for lightweight technology, curable plastics and glass fiber-reinforced plastics can also be quickly and reliably ground. Materials that can be ground include high-alloy tough steels, hardened materials, and even ceramics.

CBN or diamond can be used as abrasives. Junker knows which grinding wheel specification is the most suitable for which material. With the Grindstar, the company offers far more than just a grinding machine. Behind it is a concept permitting adaptation by experts based on their many years of experience. This expertise assures that every Grindstar is precisely adapted to the specific needs of each customer. The Grindstar is quick and simple to set up, entirely in keeping with the plug-and-play principle.

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