Danobat HGWT Heavy duty cylindrical grinding

DANOBAT – Got a Challenge?

Heavy Duty Cylindrical Grinding Solutions

At Danobat, we are committed to bringing positive change to people, businesses, and the environments we work in. We achieve this by developing innovative solutions that enable us to tackle future challenges.

We generate high-value technological solutions that enhance our clients' competitiveness. Our approach is rooted in resourcefulness and engagement to provide innovative and customized solutions to various challenges. We are committed to the entire process and the results, from beginning to end, adapting to each specific need.

Our offerings are backed by qualified specialists, in-house technology, and a corporate culture that places people at the heart of our organizational system, ensuring an optimal customer experience.

We specialize in delivering high-value, innovative technological solutions that help industries enhance their competitiveness. Our mission is to offer tailored responses to the needs of our customers, leveraging our expertise in industrial manufacturing technologies with intelligence, creativity, rigor, and professionalism.

Our Solutions Include:

Holistic solutions

Grinders

Lathes

Measuring systems

Advanced engineering services

System integration

Automation

Digital Focus & Advanced Services

Digital technology has revolutionized how we shop, travel, and communicate. At Danobat, we embrace this digital transformation and offer advanced services that address the evolving needs of the industry. We anticipate changes in the sector, offering high-value services customized to meet specific customer challenges.

Danobat Digital Suite includes:

Intuitive interfaces

Process simulation

Connected machines

Production simulation

Digital factory solutions

Advanced training

Smart components

Real-time remote information

Maintenance service

Spare parts and obsolescence management

Our in-house software enhances machine control, cells, and lines while optimizing processes.

Heavy Duty Cylindrical Grinding Solutions: HG-WT

Strategic industries such as energy, transmissions, railways, capital goods, and aerospace require innovative solutions that ensure maximum profitability. Our heavy-duty horizontal grinding machine range is designed in close collaboration with end users to provide a complete, tailor-made solution, including the machine and all related processes.

Horizontal Grinding Range - HG

These cylindrical grinding machines have been developed to meet the demanding requirements of various applications, ranging from 1500 mm to 5000 mm in length. Industries like turbine shafts, large transmissions, rail unit axles, and landing gear components benefit from our tailor-made configurations.

We offer complex processes with in-process measuring, specialized dressing systems, and custom enhancements. The independent axes structure is ideal for single or double wheelhead configurations, optimizing versatility with sequential grinding operations.

Technical Characteristics:

Cross Slides Configuration: WT Series

The WT machine range is ideal for grinding even the heaviest cylindrical workpieces, with capacities for components weighing up to 15 tonnes and lengths up to 10,000 mm. The cross-slide configuration ensures stability while optimizing the machine's footprint.

These machines are perfect for high-end grinding needs in industries like extrusion screws, printing rolls, machine tool components, and electric motor shafts. The WT series allows for a single or double wheelhead setup to maximize productivity with simultaneous grinding operations. A prime example is our WT-72, designed for the mass production of axles for rolling stock and rear axles for trucks.

Danobat offers innovative, high-performance grinding solutions for the most demanding industries. We help our clients stay competitive and optimize their processes with customized solutions tailored to their specific needs.

Technology - Machine Structure

The machine structure is crafted from stress-relieved pearlitic cast iron, optimized using finite element analysis to ensure maximum stability and rigidity for superior grinding accuracy. This structure guarantees thermal stability through specifically designed coolant channels.

X and Z Axes

Axes architecture is designed through the center of gravity to eliminate vibrations.

Moving slides feature ground and hand-scraped V and flat slideways, with an antifriction coating to prevent thermal expansion and stick-slip effects.

The axes are driven by a ballscrew, directly coupled to a CNC servomotor.

High-resolution linear scales are used to control the positioning with precise accuracy.

Swivelling B-axis

The B-axis offers automatic wide-range swivelling, driven by a torque motor for zero backlash and reduced maintenance.

High-resolution rotary scales ensure perfect angular positioning.

The system supports continuous positioning, featuring mechanical locking and a pneumatic unlocking system.

Repeatability is 1 μm on a 650 mm radius.

Precision Assembly Unit

Our Specialized Precision Assemblies Unit is staffed with experienced fitters specializing in bearing and spindle components.

Quality control checks are performed at every stage of the assembly process.

All assemblies take place in a clean-room environment with controlled temperature, ensuring traceability and interchangeability for any future replacements.

Workheads and Tailstock

Modular designs allow for maximum application adaptability.

Selected materials ensure stable temperature performance.

Compressed air lifting systems make set-up procedures more comfortable and efficient.

Grinding Spindles

First-class quality spindles are customized for each application, featuring high-precision bearings with lifetime constant grease lubrication.

The materials used ensure stable temperature performance, and the spindles are powered by built-in motors.

Cutting speeds are automatically controlled via frequency drives.

Independent temperature control and an efficient liquid-cooling system are in place.

Modular Wheelhead

We offer a diverse range of wheelhead options, enabling multiple operations in a single setup. This includes straight or angular infeed types, swivelling B-axis for OD and taper grinding, and full B-axis rotation bodies. These can accommodate multiple external spindles, internal spindles, and measuring systems, offering the most flexible grinding solution.

Wheelhead Configurations:

Straight and Angular (S1, S5, A1, A5)

Swivelling B-axis configurations (BL5, BL7)

Accessories

Tooling:

Clamping and driving automatic systems for railway axle applications.

Internal grinding steady rests.

External grinding steady rests.

V-supports with handwheel height adjustment.

Dressing Systems:

Resin-bonded diamond wheel truing system.

Dressing disc spindle.

Internal grinding wheel dressing system.

Standard chisel diamond holder.

Measuring Systems:

Non-contact measuring systems.

Touch probe.

Danobat MDM – Absolute multi-diameter measuring system for in-process measurement of continuous and discontinuous surfaces. It can also perform post-process measuring for diameters, roundness, and cylindricity.

Measuring System Specifications:

Precision: 1 μm

Repeatability: 2 μm

Resolution: 1 μm

Coolant Systems

Coolant filtering system.

3D printed nozzles with automatic CNC compensation.

High-pressure wheel cleaning.

Fine filtering system.

Special Spindles

Hydrostatic spindles.

Internal mandrel spindles.

Machine Enhancements

Hydrostatic guides for wheelhead X-axis.

C-axis rotary encoder for workhead.

Automatic tailstock displacement.

Automatic taper correction.

Innovative Solutions

All of these technological solutions add significant value to your manufacturing applications, helping to improve your factory's competitiveness. We provide customized solutions designed with intelligence, commitment, creativity, and rigor.

Our expert team, highly specialized in the field, is available to study your needs and provide tailored machinery and processes. In partnership with your organization, we aim to anticipate future industry trends and ensure that you stay ahead of the competition.

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Innovative Applications

Extrusion Screws

Automatic grinding solution for extrusion screws.

Combined system with measuring systems and CNC-controlled auto-centring steady rests to maximize production capacity.

Ideal for geometrically complex workpieces.

Capable of grinding a wide variety of materials including molybdenum, Inconel, HVOF coatings, chromium, tungsten carbide, steel, and ceramic alloys.

Printing Rolls

High accuracy and surface finish achieved thanks to hydrostatic guides on the wheelhead axis.

Custom software for grinding concave and convex contours.

Grinding capability for straight wheels up to Ø 1250 mm.

Danobat’s absolute multi-diameter measuring system is fully integrated into the main control panel.

Rotor Shafts

Internal and external grinding solutions for rotor shafts.

Focused on grinding base materials, chrome plating, and tungsten carbide.

Special dressing and truing devices for diamond grinding wheels.

Custom driving solutions with additional high filtering systems for tight surface finish requirements.

Capability for fitting superfinishing attachments.

Transmission Shafts

High-accuracy grinding for heavy-duty parts.

B-axis solution for machining versatility on both ends of the gear shaft.

Reduced setup times due to optional automatic tailstock movement over the table.

Burnishing attachment and taper measuring capabilities.

Assembled Gas Turbine Rotors

Integration of all operations in one single setup.

Optimized rotor manufacturing cycle time.

Capability for wet or dry grinding, depending on the customer’s engine manual.

Custom clamping and driving fixtures for various rotor types.

Electric Motors

Automatic face-driving systems for grinding complete parts in a single setup.

Dual-side wheelhead angular approach.

Combined solution with measuring systems and auto-centring / follow-up steady rests to maximize production capacity.

Ideal for geometrically complex workpieces: conical, cylindrical, screws with variable pitch, and hardened screws.

Digital Focus

To advance towards the creation of smart factories, where all equipment is interconnected and can operate autonomously, Danobat offers an innovative digital solution, combining the latest digital technology and over 65 years of expertise in machine tools and production systems. The digital offering focuses on two key benefits: solution efficiency and user-friendliness.

Data System

A platform for data capture, storage, and processing, delivering real-time and historical information on machine conditions to help you optimize machine utilization.

Key Features:

Real-time and historical data on a wide range of key machine parameters.

Automatic reports to support decision-making.

Improved machine utilization by anticipating potential failures.

Danobat Digital Suite

The Danobat Digital Suite offers a user-friendly interface for intuitive operation that assists operators in optimizing machining processes.

Key Features:

Centralized Information for easy access and fast decision-making.

Intuitive operation aids with multitouch capabilities, including easy documentation and troubleshooting guides.

Energy-efficient technology for dynamic grinding and preventive maintenance schedules.

Integrated Modules:

Profile Editor

Contour Module

Threads Module

Forms Module

CAD file import for enhanced versatility.

Services

Danobat offers specialized services throughout your equipment’s lifecycle—from engineering and machine setup to technical support and spare parts. With a network of professionals across 40+ countries, we ensure fast, effective, and localized service.

Danobat Centres of Excellence

These international centers focus on machining high-precision components to help customers maximize efficiency and productivity. Equipped with state-of-the-art Danobat technology in machining, measuring, and control, these centers enable cooperation and knowledge-sharing between customers, suppliers, and partners.

Original Spare Parts

Danobat understands the critical importance of machine availability to maintain production. We stock over 100,000 references of original spare parts, ready for immediate dispatch from warehouses around the world.

Maintenance Services

Corrective, preventive, and predictive maintenance to ensure the long-term performance of your machines.

Digital solutions for continuous monitoring and identification of potential future issues.

Our service team is available worldwide for rapid machine recovery.

Competitiveness Solutions

As industries evolve, the sophistication of needs increases. Danobat helps customers meet these demands with deep knowledge of machining processes and industry-specific challenges.

Inspections

We leverage our expertise to provide a real picture of your machine’s status, ensuring efficient operations.

Process Optimization

We conduct detailed studies of machining processes to deliver optimized solutions, improving technical, production, quality, and financial aspects.

Production Optimization

With years of experience across industries, we identify opportunities for improvement, maximizing output and efficiency through simulation models and workflow analysis.

Retooling and Retrofitting

Danobat helps you prepare for future challenges with retooling and retrofitting, extending the machine life by incorporating new components and functionalities.

Obsolescence Management

Avoid production halts due to unavailable components by future-proofing your machine, replacing obsolete parts before they become a problem.

Software and Hardware Updates

We offer upgrades to both hardware and software to extend the machine's lifecycle and improve performance.

Advanced Training

Customized training to help your team get the most out of your Danobat machine, including programming, cycle optimization, preventive maintenance, and more.

The Danobat Way

If you want different results, you must do things differently. At Danobat, we combine qualified specialists, in-house technology, and a commitment to innovation to provide customized, useful, and profitable solutions. Our culture values people, putting the customer at the heart of everything we do, fostering co-creation and lasting partnerships.

Key Values:

Expertise Close to You: Our skilled team works directly with you to deliver solutions tailored to your needs.

In-House Technology: We specialize in developing intuitive, easy-to-use solutions.

Innovation for the Future: For over 60 years, innovation has been at the core of our operations, ensuring we remain ahead of industry trends.

The Value of People

At Danobat, our team’s commitment, enthusiasm, and creativity define who we are. We pride ourselves on our ability to adapt to changing environments and continuously seek new solutions to help our customers succeed.

Bringing the Future Closer Through Innovation

Our history is deeply rooted in innovation, and we continue to push the boundaries of what's possible in the world of machining technology. Since our founding over 60 years ago, innovation has been our defining trait, helping our customers stay at the forefront of their industries.