MACHINE KNIFE INDUSTRY MACHINES + ROBOTIC CELLS FOR grinding sharpening polishing milling CONTENT MACHINES AND ROBOTIC CELLS MACHINE KNIVES, WORKPIECES 4–5 GRINDING MACHINES FOR SINGLE WORKPIECES 6–55 Flat and surface grinding of workpieces in 6–27 plane-side transverse or front-side deep grinding process Flat bevel grinding machines 6–15 Rotary table grinding machines 16–23 Face, bevel or serrated grinding of workpieces in face, 24–51 circumferential, longitudinal and deep grinding processes Peripheral grinding machines 24–45 Rotary table grinding machines 46–55 ROBOTIC GRINDING AND POLISHING SYSTEMS 56–77 Machining of circular knives 58–61 Sharpening of machine knives 62–65 Accessories 66–75 ROBOTIC PROCESS TECHNOLOGY / AUTOMATION 76–79 Integration of production processes; measuring technique 76–77 Bin-Picking 78–79 STEEL STRIP GRINDING MACHINES 80–105 Smooth grinding 80–85 Straight finish grinding 86–87 Squeegee grinding 88–89 Scalloped and serrated grinding 90–91 Gothic arch grinding 92–93 Serrated grinding simultanously on up to 44 strips 94–95 Plunge grinding and polishing 96–97 Accessories 98–105 METAL-CUTTING PROCESSING MACHINES 106–111 FOR METAL STRIPS Modular strip edge trimming – lines 106–109–111 Strip edge trimming for heavy-duty use 110–111 REQUEST FOR QUOTATION 112 Questionnaire for technical data Heinz Berger Maschinenfabrik Kohlfurther Brücke 69 Tel. +49 (202) 24742-0 [email protected] GmbH & Co. KG 42349 Wuppertal, Germany Fax +49 (202) 24742-42 www.bergergruppe.de 2 3 1 Flat and surface grinding on workpieces • Flat and bevel grinding p. 6–15 • Surface grinding on long knives p. 14–15 • Flat grinding p. 16 MACHINE KNIVES WORKPIECES 2 Serrated/scalloped grinding of workpieces • Serrated grinding p. 28–29 • Scalloped and serrated grinding p. 30–43 MECHANICAL PROCESSING The term "machine knives" covers a large number of workpieces of the most varied geometries and OF MACHINE KNIVES sizes. Due to the multitude of workpiece shapes and the complexity of some geometries, different grinding processes are used. 3 Bevel/arc and serrated grinding on ciruclar knives • Bevel/arc grinding p. 46–53 • Surface/bevel grinding p. 52–55 • Serrated grinding p. 44–45 4 Straight finish grinding, serrated and scalloped grinding on steel strips • Straight finish grinding p. 80–87 • Squeegee grinding p. 88–89 • Serrated and scalloped grinding p. 90–91 p. 94–95 • Gothic arch grinding p. 92–93 • Plunge grinding and polishing p. 96–97 4 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES 5 back to content 2 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING Grinding with CNC technique SHARPENING For the machining of machine knives the Berger Gruppe offers a wide range of CNC-controlled SERRATING machines. Various machining operations can be carried 1 out, such as surface grinding, radii grinding, flat 3 grinding, serrated and scalloped grinding, shar- pening, polishing and hollow grinding. The machines are primarily used in the cutlery, machine knife, tool and surgical industries. Grinding machines are employed as follows: • flat bevel grinding machines • rotary table grinding machines • peripheral grinding machines • rotary index table grinding machines • hollow grinding machines Examples of use (pictures) • contour grinding machines 1. Flat bevel grinding machine of the series BG1/ZA/NT2-CNC for surface grinding of • sharpening machines gardening shears (picture 1) 2. Exemplary structure of a machining cell with flat bevel grinding machine BG/NT2- CNC, robot loading and unloading and rot- ating bar magazine (picture 2) 3. Grinding of circular knives with peripheral grinding machine of the series RFS4-CNC (picture 3) 6 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES 7 back to content FLAT BEVEL GRINDING MACHINES FRONT SIDE GRINDING MACHINES Plane-side transverse or front-side The workpiece is machined with the side faces deep grinding process of a cup grinding wheel. Depending on the dia- meter of the cup grinding wheel, workpieces Surface grinding is a widely used grinding pro- with a grinding length of up to 1 200 mm can cess for the machining of machine knives. It is be processed. mainly used for processing flat and plane work- pieces. Surface grinding can be achieved both If the workpiece is processed in a deep grin- in deep grinding and pendulum grinding. ding process, a large amount of material can be removed and a good surface quality can be The flat bevel grinding machines – also known achieved. as front side grinding machines – process workpieces in plane-side transverse or front- side deep grinding. With a cutting speed of up to 50 m/s, a multi-sided smooth grinding of machine knives is achieved. When grinding with the plane side grinding method, the material removal results in a bevel on the wall (drawing p. 9). Depending on the task and the workpiece, different geometries can be processed. The solution presented on page 8 involves five workpiece axes and one tool axis. • Expoxy resin bonded grinding wheels with 450–710 mm Ø • Feed speed 30–50 m/s Feed 700–2 000 mm/min • Ø Q'w = 8–12 [mm³/ (mm s)] e. g. 4.0 mm • max. Q'w = 25 [mm³/ (mm s)] • max. cutting weight 3–10 g/s e. g. 2.0 mm 8 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES 9 back to content FLAT BEVEL GRINDING MACHINES DG/NT-CNC Space-saving surface grinding • two to four axes: one tool axis and up to three workpiece axes CNC grinding machine with three or four • smooth grinding on several sides axes and vertical grinding spindle for the • tactile or AE measuring system for grin- surface grinding of machine knives, hand ding wheel wear compensation tools, scissors, and related parts • grinding length: up to 450 mm • cup wheel Ø: 500 mm • spindle drive: 30 kW • cutting speed: up to 50 m/s • 30% less required space in comparison to the horizontal arrangement of the grinding 3 spindle • good stability thanks to a solid welded cons- truction of the machine housing • prevention of vibrations during processing due to a machine housing filled up with mi- neral cast • user-friendly, Windows-based controls with interfaces for robotics, PLC, measuring tech- nology and other applications • “Esprit” CAM interfaces • wear-free main axis drive with linear motor, achieving rapid traverse speeds of 80 m/min (262 ft./min) • precision, backlash-free positioning, using direct measuring system • compact, precision gearbox with high rigidity to control cutting edge angle • as a single or a double machine available due to two separate machine housings 10 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES 11 back to content 1 2 FLAT BEVEL GRINDING MACHINES BG-CNC Surface grinding Here we differentiate between workpiece and tool axes. Depending on the task at hand, different ver- sions with different grinding lengths, grinding The workpieces are held by means of specific wheel diameters or grinding segments and clamping devices. 3 4 axis geometries are offered. • grinding length: 1 000 mm • grinding wheel Ø: 80–710 mm • spindle drive 6.5–45 kW • cutting speed: up to 50 m/s • mounting flange for grinding wheel or grin- ding segments • spindle with backlash-free preloaded preci- BG/NT2-CNC: Arrangement of the axes sion bearing, designed for peripheral speed of up to 50 m/s • workpiece and tool feed with four or five axes and one tool axis (design according to task) • digital axis drives on preloaded ball screw Y or precision reduction gear Examples of use (pictures) BG/ZA/VSS/NT2-CNC: Arrangement of the axes 1. Workpiece holder in combination with elec- tromagent (picture 1) 2. Grinding of screwdriver blades arranged in magazine (picture 2) 3. Grinding with rotation axis and serrating (picture 3) 4.. Grinding of chipper knives with BG/ZA/ VSS/NT2-CNC using segments (picture 4) 12 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES 13 back to content 2 3 FLAT GRINDING MACHINES FS-CNC Flat grinding of machine knives • four-axle CNC control (1 tool and 3 work- piece axes) CNC controlled vertical precision flat grinding • programmable angle adjustment with elec- machine with up to four axes for flat grinding tronic locking of long knives with a maximum length of • tactile measuring system for grinding wheel 4 5 4 000 mm wear compensation (optional) • grinding length: up to 4 000 mm • magnetic table with 4 magnets of 1,000 × • grinding height: 200 mm (or on request) 250 mm, single magnet with demagnetiza- tion unit • cup/segment grinding wheel Ø: 450 mm • carriage speed 0–60 m/min programmable • segment head Ø: 450 mm • good access to the grinding chamber of the • grinding motor: 30 kW, 1 000 rpm carriage through lateral opening • cutting speed: up to 50 m/s • four-axle digital CNC control • vertical guide with precision roller linear 1 guidance • X-axis (carriage) with gear rack in con- nection with servomotor and gear unit • continuous, programmable adjustment • Z-axis (moving of the vertical feed / • automatic interval-controlled central grease plunge grinding) on preloaded ball gea- lubrication with control and fault indication ring spindle by a brushless AC servo- • designed for wet grinding motor, stroke app. 200 mm (7.87") • A'- + A-axis (tool carrier block), swiveling Examples of use (pictures) at grinding angle (option) 1. Access to change segments from the front • coolant supply through hollow shaft in the (picture 1) grinding spindle for internal cooling of the 2. Precision vertical surface grinding machine grinding segments of the series FS-CNC (picture 2) • A-axis/A'-axis: two servomotor gearbox 3. Mounting of grinding segments / segment units, each at the end of the shaft for pre- head (picture 3) cise angle adjustment or with servomotor 4.