Ger cu cnc cylindrical grinders

Ger cu cnc cylindrical grinders

CNC cylindrical grinders of the C and CU series are designed for universal external and internal grinding and facing operations and incorporate the latest technology, as well as a complete range of different technical configurations in accordance with the specific applications and requirements of the parts to be ground.

CNC cylindrical grinders from the CM, CP, and CPA series are ideal for grinding medium and large rolls for metal sheet lamination, engine shafts, printing, shipbuilding, and wind turbine industries, which require high precision and great flexibility. Easy machine adjustment and short part set-up are provided either for single parts or for small, medium, or large series.

FRAME
Made from stabilized and strongly ribbed pearlitic cast iron, the frame provides the whole machine with a high level of rigidity. Thermal stability was an important factor taken into consideration during the design of the frame, in order to ensure maximum precision and repeatability during operation.
The machine structure is based on a monoblock (up to 4,000 mm between centers) T-shaped bed. The longitudinal part of the bed supports the table during its longitudinal "Z axis" travel, and the transversal part supports the movement of the "X axis" wheel slide.

WHEEL HEAD
The single spindle wheel head is fixed in standard, and optional additional configurations of multi-spindle wheel heads with manual or automatic "B axis" rotation and continuous or Hirth tooth positioning are also available upon request. Thanks to these options, GER enables you to select the most appropriate machine configuration for your specific needs, incorporating different wheel assemblies to ensure the best performing combined external-internal grinding process.

WORK HEAD
The work head has a particularly rigid structure which enables the uniform rotation of the part during machining. The spindle is mounted on high precision angular contact bearings, axially preloaded, and equipped with variable rotation speed. Integrated water-cooled Siemens motor directly drives the work-head for the highest positioning and interpolating accuracy for C-axis grinding.

TAILSTOCK
The tailstock has a monoblock design with manual quill movement. It integrates a flexible, adjustable pressure device to prevent part deformation due to thermal dilatation. It has a multiple diamond dressing station and manual taper correction device (except in the CP and CPA series). Options include hydraulic operation of the tailstock and CNC-driven motorized tailstocks.

C AXIS
The interpolation of the part rotation axis (C axis) with the transverse X axis allows precise grinding of non-round shapes such as cams, polygons, squares, or free section parts, which is especially interesting for punch and die manufacturers.

WHEEL BALANCE SYSTEM
Traditional grinding wheels develop dynamic imbalances over time due to their heterogeneity. A balancing head with sensors for detecting vibration and an electronic unit processing and moving masses to compensate unbalancing can ensure a perfectly balanced spindle during the entire life of the wheel. Balancing can be carried out using wheel balancers integrated either internally or externally to the wheel spindle.

POSITIVE PART STOP
It allows starting/stopping the work head spindle at the desired angular position, with a high level of precision and repeatability. This option is available for the standard wheel head and is essential for gantry loaded and fully automated machines.

HYDROSTATIC GUIDE WAYS
Ideal for operations involving C axis where fast movements of the wheel head with precise positioning are required. Hydrostatic guide ways prevent undesired stick-slip effects.

GAP
In CNC grinders, transitioning from fast approach speed to working parameters must occur outside the part. Significant time savings can be achieved in cycle times if these speeds are automatically switched by a GAP device managing wheel spindle power consumption when the wheel makes contact with the part.

CRASH
During the grinding cycle, the wheel may collide with unexpected obstacles (due to incorrect machine use), resulting in damage to both the part and the machine itself. The power consumption-managed anti-collision system, CØSH, properly configured, can prevent an imminent collision by aborting the cycle and retracting the wheel head.

DRESSERS
Working with properly dressed wheels is essential for high-quality grinding. GER offers many different dressing station options depending on the process and quality requirements of each part.

INTERNAL GRINDING SPINDLES
GER can integrate different types of internal grinding spindles into the machine, depending on the specific requirements of the operations to be performed:
- Belt and pulley-driven internal spindles
- Built-in electro spindles
- Motorized spindles

CLAMPING DEVICES. TOOLING
- Mechanical chucks
- Hydraulic chucks
- Pneumatic chucks
- Magnetic chucks
- Pneumatic collet chucks
- Custom clamping devices, depending on specific needs

STEADY RESTS
- High precision manually operated two-point steady rests for holding parts requiring external grinding.
- High precision manually operated three-point steady rests for holding parts requiring internal grinding.
- Hydraulic self-centering steadies and motorized steadies for applications in need of the highest geometrical accuracies.

MULTIFUNCTIONAL PORTABLE HANDWHEEL:
An ergonomic portable control panel with a handwheel for manual operation of the machine. It is equipped with an emergency pushbutton.

COOLING EQUIPMENT:
Efficient filtering of the cooling liquid is essential to achieve a controlled, continuous surface quality level on the ground parts. Various options can be integrated into the machine, including:
- Coolant systems with magnetic particle separator (Magnadrum)
- Coolant systems with paper filter
- Combined paper filter + Magnadrum equipped cooling systems
- Other options tailored to customer requirements

Constant production quality coupled with improved
cycle times can be achieved by implementing the most
suitable type of automatic gauging solutions, such as:

IN-PROCESS DIAMETER MEASURING SYSTEM:
Measuring the part in real-time during the grinding process enables you to improve cycle time and provides excellent geometric and dimensional process stability within very narrow tolerance ranges.

LONGITUDINAL PART POSITION DETECTION:
The machine can be equipped with a tilting touch probe integrated on the wheel head for detecting the real longitudinal position of each part within the series. The signal given by the touch probe is processed by the CNC, and the grinding program is consequently corrected by changing the Z reference of the part each time.

NON-CONTACT GAUGING:
The various non-contact gauging solutions enable automatic, precise measurement, and correction of the wheel diameter. This accessory is very useful if the customer needs to work with wheels that cannot be dressed.

AUTO SETUP:
This software module, along with the wheel measuring gauging, enables a significant reduction in part setup time, allowing the operator to program directly from the drawing.

GER machines are always controlled by the latest generation Fanuc CNC. Simultaneously, a complete Fanuc package is assembled, including motors, drivers, regulators, and more. The system features easy-to-use on-screen graphics, providing user-friendly machine operation even for less experienced personnel. The software can be modified to meet specific customer requirements.

- Easy machine-job setup
- Easy geometrical job correction, such as taper camber
- Easy dimensional correction
- Teach-in parameter input
- Customized working cycles
- Direct-from-drawing programming
- All wheel data storage
- Air gap elimination and anti-collision management
- Fast service through internet connection
- Any automatic wheel dressing possibility
- Job rotation axis interpolation for non-round shape grinding (C axis)
- Different interface languages
- Customized cycles, depending on customer requirements

- Ger type: c-cnc - cu-cnc - cm-cnc - cp-cnc - cpa-cnc
- Distance between centres: 600/1000 mm - 600/1000/1500/2000 mm - 1500/2000/2500/3000/4000 mm - 1500/2000/2500/3000/4000/5000/6000 mm - 3000/4000/5000/6000
- Centre height: 140 mm - 180/230 mm - 300 mm - 400 mm - 400/500 mm
- Maximum grinding diameter: 275 mm - 355/455 mm - 595 mm - 795 mm - 795/995 mm
- Maximum weight per part between centres: 100 kg - 300/500 kg - 2000 kg - 4000 kg - 6000 kg
- Maximum grinding weight in live grinding: 80 Nm - 125 Nm - 350 Nm - 442 Nm - 500 Nm

TRANSVERSAL X AXIS
- Maximum travel: 250 mm - 350 mm - 350 mm - 500 mm - 650 mm
- Speed: mm/min: 0,01/1500 - 0,01/6000
- Resolution: 0,0001 mm
- Measuring System: Encoder

TRANSVERSAL Z AXIS
- Maximum travel: 750/1150 mm - 850/1300/1680/2180 mm - 1750/2250/2750/3250/4250 mm - 1850/2350/2850/3250/4250/5250/6250 mm - 3350/4350/5350/6350 mm
- Speed: mm/min: 0,01/1500 - 0,01/6000
- Resolution: 0,0001 mm
- Measuring System: Encoder / Linear Scale-Règle Digitale

- Wheel dimensions: 400/50-80/127 mm - 500/80/203 mm - 600/80/304 mm - 750/80-100/304 mm - 750/80-100/304 mm 
- Peripheral speed: 45 m/seg
- Wheel motor power: 5,5 kW - 7,5/11 kW - 11/15 kW - 20/23 kW - 23
- Rotation angle: 0° Fixed-Fix /-30°, +210° Automatic Swivelling
- Rotation system: manual - automatic
- Wheel head positioning: 0,001° Continuous automatic
- Clamping system: Mechanic / Hydraulic

Workhead:
- Rotation speed: 10-800 rpm - 10-400 rpm - 10-250 rpm - 10-250 rpm
- Centre taper: MT 4 - MT 5 - MT 6 - Metric 80
- External head tape: DIN 55021 Size 5 - DIN 55021 Size 6 - DIN 55021 Size 8 - DIN 55021 Size 11

Tailstock
- Center taper: MT4 - MT5 - MT6 - Metric 80
- Quill diameter: 50 - 60 - 85 - 100 - 180
- Quill travel: 40 - 60
- Tailstock drive: manual/hydraulic - manual/cnc