re-engineering of machine tools · and the company has produced some of the most advanced grinding...

Re-Engineering ofMachine Tools

Newall UK Ltd. is part of the Danobat Group, who are a leading European Machine Tool manufacturer. For a century the name ‘Newall’ has been associated with innovative engineering and the company has produced some of the most advanced grinding machine tools ever built.

The Danobat Group currently employs a staff of 1300 and their annual turnover exceeds 225

machine tools. Our major business is grinding and turning machines in which we have the skills to provide support to our customers in the automotive, aerospace, steel mills and general engineering facilities. The company re-engineers and rebuilds machines for a varied customer base for many marques of OEM manufactured machines. Newall have their own design office and customer support department.

million Euro. The Danobat Group is part of the industrial sector of Mondragon Corporation, based in the North of Spain. With assets totalling 32,840 million Euro and over 103,000 employees, Mondragon is one of the largest private business organisations in Europe.

Newall UK Ltd. employees have manufacturing and service experience on high technology

Danobat Group facilities

Company Profile

NEWALL

Re-Engineering of Machine Tools2

PeterboroughTypical applications for the Newall range of precision CNC controlled machines can be found in leading high volume automotive manufacturers, specialist aerospace manufacturers and service providers throughout the World.

Our expertise is in utilising the latest technology components and incorporating them into existing machine tools. The machine performance is therefore increased and overall output improved.

The company is forward thinking, incorporating both the customer’s process and machine design for the manufacture of re-engineered machines.The company is export led with 65% of our turnover being generated outside the UK.

The company will develop new products by continuous research and development. Our aim is to be ahead of our competition and be Number 1 in the market place.

Newall have been accredited the quality standard ISO 9001 to ensure highest levels of quality control.

ALBION AUTOMOTIVEAMERICAN AIRLINESANDORIA MOTBRITISH TIMKENCASE NEW-HOLLANDCOOPER ROLLING BEARINGSFINNAIRFORD EUROPEFORD SOUTH AFRICA GENERAL ELECTRIC GETRAG FORD TRANSMISSIONS GKNJOHN DEEREKAWASAKIMESSIER DOWTYPERKINS ENGINESPSAROLLS-ROYCEROTARY POWERRVISKFTRWTRIPLEX MACHINING

Newall facilities

Some of our valued clients are:

Re-Engineering of Machine Tools 3

Before

After

The above machines were modified and re-engineered,with the fitting of the following new items:

CNC // CNC DRESSING // GAUGING SYSTEM // HYDRODYNAMIC WORK SPINDLES // TAPER CORRECTION // LINEAR RAIL SLIDEWAYS // DIGITAL DRIVES

Camshaft Grinders.Angle Approach Grinders. Single and Twin Wheel Crankpin Grinders. Single and Multi-Wheel Journal Grinders.Transmission Shaft Grinders.Universal Grinders.Centreless Grinders.Cam and Crank Lathes.Valve seat grinding.

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Automotive Products

Characteristic Lower tol. Upper tol. Average No. Comps Cam

Taper pin 1 0 0.005 0.0013 30 2.793

Taper pin 4 0 0.005 0.0017 30 2.008

Circularity pin 1 0 0.005 0.0018 30 1.97

Circularity pin 4 0 0.005 0.0022 30 1.85

Bellow are capability results of the machine shown. The capability must be better than CAM 1.3

Characteristic Lower tol. Upper tol. Average No. Comps Cam

Taper pin 1 0 0.005 0.0040 30 0.64

Taper pin 4 0 0.005 0.0041 30 0.67

Circularity pin 1 0 0.005 0.0039 30 0.709

Circularity pin 4 0 0.005 0.0035 30 0.74

Re-Engineering

Newall re-engineers machines to the highest standards and specifications, without compromise on quality, efficiency and productivity.

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Gauging.System control updates.Sound proof enclosures.Air conditioning and temperature control.New component tooling and software.

Retrofits:

Slideway collimation.Slideway re-scraping.Work Spindles.Service and maintenance contracts.New electrical control for replacement of obsolete equipment.

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Overhauls:

Aerospace Products

Low & High Speed Blade Tip Grinders.Creep Feed Grinders.Stator Case Grinders.Gap Bed / Landing Gear Grinders.

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Applications of on-site Retrofitting

CNC DRESSING

The corner radii generated on the grinding wheel are much more accurate and the percentage of radius created is greater. The speed of dressing can be controlled for both the periphery and radii of the grinding wheel. This is important for radii quality and surface finish. All feeds and speeds are programmable to enable the dressing cycle to be optimised. Both taper and barrel forms can be programmed. New forms are easily programmed not requiring former plates or stylus.

TAPER CORRECTION UNITS

The taper correction facility can be retrofitted to existing machines. This consists of: pneumatic taper compensators, which will be controlled through Herion control valves via the CNC.

By using these compensators the machining time cycle will be improved as compensation takes place while grinding. The taper units have no mechanical moving parts and require no maintenance.

PNEUMATIC STEADY

The steady is pneumatically operated and fitted with Poly Crystalline Diamond tips.

The steady has a -0.250 mm diameter offset. The diameter can be remotely adjusted or automatically adjusted by the CNC, adjustment range is ±0.007 mm.

SYNCHRONISED WORK DRIVES

The system of the synchronized drives is controlled from a CNC.

Advantages: no setting of mechanical lay shafts and no mechanical gears with backlash along with the fitting of CNC control are needed. This improves accuracy of angular position of pins in the same plane and allows multi cylinder crankshafts on the same machine without retooling the machine.

HYDRODYNAMIC WORKSPINDLECONVERSIONS

The existing spindle assemblies, which are unpressurised, can be modified in both the spindle and bearing housing details. The modification covers both flow and pressure monitoring to ensure protection of the spindle assemblies. The advantage of this modification ensures that spindles are protected against seizure and quality of circularity is vastly improved.


SLIDEWAY RECTIFICATION

Slideways are reground and scraped and collimated to bring back to the OEM tolerances.

On standard ‘V’ and flat slideways these slides are regrooved for the lubrication of the slide assembly.

New lubrication systems are incorporated during the rebuild of slideways with monitoring of lubrication. The slideway protection covers are replaced in order to prevent the ingress of grinding debris.

In certain cases the slideways can be converted to rolling element or hydrostatic slides. Dependant upon the slideway configuration, linear motors or servomotor driven ballscrews are fitted and aligned during the slideway rectification process.

If the machine is returned to our facility then the machine castings are totally painted as per new machine finishes, however if the work is complete at the customers facility, then they are cleaned.

GRINDER CONVERSIONS TO CNC

With the retrofitting of new CNC controls along with linear motors and digital servomotors, old hydraulic and master cam bank machines are re-controlled to allow profiles to be generated electronically. The machines control system has the facility to have program profiles previewed prior to grinding of components. New profiles can be loaded on or offline by file transfer or by disc.

The system has the possibility of loading correction data of unsmoothed software.

CNC RETROFITS

The picture shows a CNC retrofit of an angle approach machine where graphics are developed for each type of application.

The manufacturer of the CNC is at the customers choice and not by Newall UK Ltd. We have retrofitted the following CNC controls:

Fanuc, Siemens, Indramat, NUM, H&K, B&R, etc.


PCC Feed System

SYSTEM

The Feed system is capable of being retro fitted to all types of grinding machines with a single & multi axis feed or as an upgrade to existing systems to improve performance on older machines.

The system is compatible with :

Stepper motor.Analogue servo motor.Digital servo motor.

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FEATURES

The system can operate in full auto cycle manual mode with a speed control pot for fine control by the operator. The System has four feed rates in Automatic mode, which are easily programmable by the operator as are the feed change points. The System will operate with or without gauging. Without gauging a programmable size adjustment is available at the push of a button. With gauging the feed position zero is reset on the gauge size signal. Although the basic system is a single axis control, it can be programmed to act as a dresser control unit as well as with a further 2 axes available.Programmable dwell points between feed rates.Programmable back off at change point coincidence.Programmable positions for gauge and steady insertion.4 auxiliary outputs for other ancillary equipment operation.Built in diagnostic messages are displayed on the screen.Software available for monitoring of the plc with in house Laptop computers.

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ADVANTAGES

These are some other advantages:

Cost effective.Typical time required for fitting 4 days.Reduces machine downtime where feed systems and components are now obsolete.Operator friendly interface.12 month guarantee.Full documentation.


Facilities & Shop floor

DESIGN FACILITY

We have our own mechanical electrical and software design facility. We have AutoCAD design using a multi seat facility which can be accessed remotely by our engineers.

From the design facility we supply customer support directly linked to the customers machine.

SHOP FLOOR

The shop floor is divided into several sections were specific actions are carried out. The sub areas are:

Inspection.Machine strip.Paint shop.Sub assembly build.Spindle overhaul section.Electrical build.Machine build.Demonstration area for group products.


Sales

Newall UK Ltd.- member of the Manufacturing Technologies Association- supplies the sales, spares and service support for the Danobat Group manufactured machines in the UK.

Horizontal & Vertical Lathes.External, Internal & Universal Cylindrical Grinders.Plane and Creep-Feed Grinders.Jet Engine Rotor & Stator Grinders.Landing Gear Component Grinders.Centreless Grinders.

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HORIZONTAL LATHES

VERTICAL LATHES

VERTICAL TURNING CENTRES

Maximum turning diameter 900mm.




SERVICE

SPARES

Our belief at Newall is that quality built machine tools must be supported by continued quality service care. Our service department is focused on reducing downtime to a minimum and assuring our customers machine tool performance.

Our service department has 8 factory trained service engineers who are able to focus on all the technical aspects of the machine.

Service and repair to existing machines on the customer’s site:

Maintenance Contracts.

On site machine tool refurbishment.

On site retooling and component update.

On line breakdown service and support.

Service contracts for preventative maintenance.

Newall UK Ltd. owns the intellectual property of the marks listed below and operates a spares service to all the customer base.

To Contact spares or service:

Phone: +44 (0)1733 265566Fax: +44 (0)1733 843819Email: [email protected] [email protected]

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CENTRELESS GRINDING MACHINES

INTERNAL GRINDING MACHINES

CYLINDRICAL GRINDING MACHINES

Sales, Service & Spares

Maximum component size diameter 0,5-50 x 200 mm (infeed).

Maximum swivelling diameter 600mm.

Maximum distance between centres 6000mm.


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NEWALL UK Ltd1 Sturrock WayBretton - PeterboroughPE3 8YJ CambridgeshireUNITED KINGDOMTel.: +44 (0) 1733 265566Fax: +44 (0) 1733 843819E-mail: [email protected]://www.newall-uk.com

Centerless grinding machines

Other DANOBAT solutions

Vertical grinding machines Internal grinding machines Heavy duty universal grinding machines

Horizontal lathes Vertical lathes

re-engineering of machine tools · and the company has produced some of the most advanced grinding...

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