Grob 12 nct cold forming, slotting machine

GROB SWITZERLAND COLD FORMING MACHINE 12-NCT ERNST GROB AG Cold forming machines slotting machines SWITZERLAND ERNST AG Cold forming machines Slotting machines

Products and Services Cold forming machines ERNST GROB AG develops, designs, and builds cold forming machines; from basic, manually loaded units to fully automated production lines. The primary fields of application for the sheet metal and solid components produced by cold forming are in the automotive industry. Our machines, however, are also operational wherever efficiency and quality are key considerations. Slotting machines sheet metal parts splined on GROB cold forming machines can be transferred to our slotting machines for secondary operations, complementing the cold forming process. Non-splined workpieces can also be slotted. The design concept of our equipment is modular and can be optimally tailored to suit the specific requirements of the application involved. TOOLS All tools used on GROB machines are developed and manufactured in GROB's in-house tool shop in accordance with the specific requirements of the materials and applications involved. In-depth expertise, plus state-of-the-art toolmaking equipment combined with continuous research and development allow ERNST GROB AG to provide optimal tooling delivered in the shortest possible delivery times. Subcontracting At our subcontract facility, we use our own cold forming and slotting machines to produce components to customer order. We can take on your production needs for individual components or small pilot runs. To overcome production bottlenecks, we also process full-scale mass volumes. Our Quality Management System is certified to ISO/TS 16949.

Engineering A cornerstone of our success is the relentless search for optimal solutions to specific engineering challenges. Our development department is key in this objective, as this is where years of in-depth experience and the latest technological expertise are merged. Close collaboration with our business partners invariably succeeds in generating innovative results that our test department rapidly converts into prototype components, which are already close to mass-production maturity. Contents Company profile 2 Industries and products 4 Production processes 6 Machine description 8 Layout, technical specifications 14 Installation, operation, service 16 12-NCT - Company profile Competencies ERNST GROB AG develops, designs, and GROB slotting machines Diversity of finished products builds precision machines dedicated to GROB slotting machines are employed to Applications for GROB-Machines are the cold forming of splined and non- finish cold formed splined or non-splined highly flexible, for example, when splined workpieces. The manufacture hollow components. producing: of slotting machines for secondary Diverse slotting and coining Clutch disc carriers and finishing operations on cold operations are undertaken at various Splined shafts formed workpieces is yet another core stations. Gearbox shafts competence of the company. Separate stations for dedicated applications can also be integrated. Steering system parts From the initial idea through to its de- tions can also be integrated. Pump shafts velopment, and right up to the industrial Extruder shafts application-the entire concept is available Splined shafts for: from a single partner: ERNST GROB AG - Printers provides customer-specific solutions, - Medical instruments from manually loaded single machines - Communal vehicles to fully automated production lines. - Helicopters

Food processing equipment

Torsion bars and progressive coil springs slotted workpieces Machines for the automotive industry GROB machines are primarily used in the automotive industry. Typical components are clutch disc carriers in auto- matic transmissions and other splined components within the power train. Gearbox shafts GROB cold forming technology GROB cold forming machines GROB cold forming machines are based on the principle of the cold roll forming in a planetary type movement process. The technology provides a solution for the cost-effective production of splined or reduction-type cylindrical workpieces. The founder of our company, Ernst Grob, further developed and refined the principle see infobox The GROB story . Components for a wide range of vehicles Thin-walled tubular components, cold rolled without support mandrels 2 ERNST GROB AG 12-NCT SWITZERLAND Dedicated partnerships Locations At ERNST GROB AG, the development ERNST GROB AG plants are located in Headquarters administration, research, department is intensely focused on the Switzerland's greater Zurich conurbation development, assembly are located refinement of existing technologies, where the company is able to benefit in Männedorf, while the subsidiary plus the development of new processes from an outstanding infrastructure production, subcontracting is to be and applications. In close cooperation with excellent transport facilities. found in Oetwil am See. with customers and other interested parties, solutions are generated that permit economic production of accurate finished parts. When required, ERNST GROB AG offers customer support throughout the entire service life of machines installed by our company. Success factor employees The key success factor of ERNST GROB AG is the professional competence and Headquarters in Männedorf subsidiary in Oetwil am see dedication of its employees. A team of highly qualified and experienced The GROB story specialists is the best guarantee for meeting the most demanding challenges. up to 1961 Dr. Ernst Grob develops cold forming machines at the machine tool works he founded in An innovative spirit coupled with an Munich in 1926. inherent flair for technical solutions 1962 1962 Dr. Ernst Grob founds a company making cold rolling machines in Männedorf and delivers the first one to Sulzer, Zuchwil, Switzerland. are the foundation on which innumer- 1963 Further machine deliveries to Germany, Italy and Japan. Subsequent set-up of global able and unique developments are sales and marketing network. based. 1979 Introduction of PLC technology and establishment of in-house electrical department. 1984 Introduction of multiple axis CNC technology. 1985 Following death of Dr. Ernst Grob: establishment of ERNST GROB AG. Business continued and expanded by his grandson and current owner, Mr. Daniel Dériaz. 1991 Acquisition and expansion of a subsidiary plant of ERNST GROB AG in Oetwil am See, Switzerland. 1999 Quality Management Certification to ISO 9001. 2001 Expansion of product portfolio with type S8 slotting machine for hollow parts and delivery

First slotting machine General Motors Strasbourg. Start-up production newly constructed workshop Oetwil am See. Certification subcontracting facility Oetwil am see 1S0/TS 16949. Introduction torque drive technology NCT. Modern centralised office building Maennedorf occupied. Market roll-out newly developed stroke-stamping process. Opening Beijing representative office. Quality inspection state-of-the-art methodology 50 years jubilee ERNST GROB AG. ERNST GROB AG Rohrgasse 9 CH-8708 Männedorf Phone 44 922 77 00 Fax 44 922 77 88 info 3 12-NCT Industries products Industries Machinery ERNST GROB AG smaller volumes different: specificatíons extremely installed primarily automotive components wide range applica- long highly accurate splines 10 metres length met. OEM s suppliers use GROB direct produced ERNST GROB AG. Materials geometríes Finished products majority applications, steel specífied workpiece material. Also Splined components produced mainly requíred half-shafts, steels case-hardening, steels heat treatment stainless steels suitable. However, alternatives tíons, high precisíon surface finish essential. Large-scale small volume aгe productíon GROB cold forming process alsoGROB cold forming technology. Both cylindrical thick-walled hollow shafts solid ones suitable cold forming. The profíle geometry splíne gap virtually identical profíle rollíng tool. Hence, a11 common standard profiles almost desired tooth geometry, parallel flanks, involutes including undercuts linear ba11 bearing buttress tooth profiles feasible. Double clutch disc carrier Disc carrier processed stroke-stamping 4 ERNST GROB AG 12-NCT GROB

Example clutch disc carríer Clutch disc carriers typical finished products. They installed automa- tic transmissions direct shift gear- boxěs íDSG . T clutch disc carríer p. 4, processed GROB coid forming machine sub- sequently finished GROB slotting machine. Example uníversal joínt shaft Clutch dísc carrier Clutch disc carrier reduced tooth típ The splines tubular drive shafts produced GROB cold forming process. The weight savings achieved also translate reduced fuel consumption. Moreover, safety enhanced hollow elements telescope crash. Example solíd materíal stock coid formed ge- nerate modules 5 above. Chrome steel workpiece Brorize workpiece universal joint made aluminium steel splíned shaft module 5 ERNS7 GROB AG Rohrgasse 9 CH-8708 Mannedorf Phone 12-NCT Production processes The GROB cold formíng process ín bríef 1n GROB cold forming process, entire forming workpíece whìch turníng about own axis. At tíme, workpiece moves axial direction, thereby This procedure allows high degrees accuracy surface generating spline geometry along length. This process produces extremely precise components famílíar benefits chipless forming; cold work hardeníng, enhanced materíal microstructure, material savings. Forming clutch dísc carríers Cold forming sheet metal components cup-shaped preforms. The clutch disc carriers formed rollíng tools profile mandrel, thereby generating internal external splines. Reduction The preformed sheet metal cup reduced concave pro- filed rolling tools splines generated man- drel. Internal splines formed. Dírect reduction Relatively short splines formed sheet metal disc direct reductìon. The mandrel creates internal splínes. The concave profile rolling tools defines outer diameter. 6 ERNST GROB AG 12-NCT GROB ZWITZERLAND spin-grobing By spin-grobing, sheet metal disc spun cup- shaped preform. In clamping, splines formed rolling toois mandrei. Stroke-stamping Wíth stroke-stamping process it is possible form splines close shoulder. splines clutch disc carríers longer need continuous; solíd ríng can remaín open end component províde reínforcement. Forming solid materíal lndividual profiles generated solid material used make, example, hubs, flanges oг fork shafts: ínvo- lutes, buttress tooth, ball bearing parallel flank profiles aгe feasible. Tooth tips calibrated chamfered by rollίng. Reductíon bar materíal By reduction, example torsíon bars chairlifts, diameter stock material reduced wíthout need machining. Thanks chipless forming process, orientation grain flow remains unbroken; the microstructure homogenous substantíal savings weight material. ERNS7 GROB AG Rohrgasse 9 CH-8708 Männedarf Phone info 12-NCT Machine description Performance leap wíth new dríve concept ERNST GROB AG extended technological 12-NCT series. At heart offering numerous benefits higher processing speeds, more accurate profiles reduced changeover times. Cold Forming Machine 12-NCT 12-NCT assembly: welded frame, cast iron bed roller head carrier Forming zone 8 ERNST GROB AG 12-NCT GROB SWITZERLAND - Salient features 12-NCT Primary elements glance Reduced changeover times elimination mechanical ínterchange elements Number splínes freely selectable contínuous indexed pitch mode Dynamíc dríves provide hígher speeds feed tates Option using 2 rolling tools per head reduces processíng tímes Greater accuracy prismatíc guideways rigid main spindie Smaller numbers splines also be formed hígher speeds Spline alignment corrections possible Wider range applícations, reduction, spin-grobing stroke-stamping Legend Minímal maíntenance costssion product portfolio type S8 slotting machine hollow parts delivery

Forming zone Lower tooling costs 2 spinning heads 3 Radial depth positioning motors 4 Countercenter 5 Carriage guides Control panel 6 Carriage with torque motor 7 Feed drive All functions can be input and accessed via the logically arranged control panel. Electrical cabinet and controls of a custom-built 12-NCT controls at rear, layout of electrical cabinet ERNST GROB AG Rohrgasse 9 CH-8708 Mannedorf Phone 12-NCT Electrical controls and drives, axis functions In place of a conventional main spindle has allowed the further development of the prismatic guideways drive for workpiece rotation, the 12-NCT of the entire drive and control concept has also enhanced accuracy. Two lead features a torque motor. This direct Elimination of the indexing plate screws are arranged in the same plane drive system is free of backlash and and other mechanical elements has as the main spindle, thereby ensuring operates at high peak, nominal and permitted the bedding of the main ideal force application conditions. standstill torque ratings. The transition spindle to be optimized. The self-centering Hydraulic system The separate hydraulic power unit with integrated cooling supplies the torque motor, the counterplate, the roller head retraction cylinder and the elevator cylinder, as well as those for the splash guard movement with its corresponding coolant. Carriage with torque motor Legend C C axis: Workpiece rotation drive Z Z axis: Workpiece feed X X axis: Roller head depth movement B B axis: Roller head rotation drive A A axis: Swiveling angle J Roller head and carriage zone Oil filtering system 10 ERNST GROB AG 12-NCT SWITZERLAND Automation solutions Gantry loader Double gripper flexible gantry loader and transport conveyor, for example, are used for handling workpieces within the production system. In the majority of cases, the entire workpiece spectrum can be catered for via the program selection, without a need for manual changeovers or adjustments. The gantry loader features a horizontal and a vertical NC axis, plus a pneu- matically actuated double gripper unit incorporating a swiveling module for blanks and another for finished com- ponents. Conveyor belts Arrangement of conveyor systems is customer specific and depends on the integration potentials of the production Gantry loader with blank and finished component line, Conveyor belts and tracks, robots or other handling equipment can be installed. Infeed and outfeed conveyor belt ERNSΤ GROR AG Rohrgasse 9 CH-8708 Mäппedorf Phone 12-NCT Special purpose stations To complement the forming process, other production processes can be carried out before or after the spline operation. Typically, these are creating preforms or various slotting operations, undertaken on integrated special purpose stations. Example of an integrated slotting station Thanks to the compact design concept, it is possible to integrate a slotting station inside the noise reduction cabin of a GROB cold forming machine. Hence, a slotting operation can follow spline forming in one and the same produc- tion cycle. As handling is done by the same auto- mation system, the processing times are held to a minimum. Integrated slotting station Potential operations: trimming to length, punching holes or slots, coining in snap ring grooves, plus a wide range of other features, Clamped and slotted workpiece Tooling with finished workpiece ERNST GROB AG 12-NCT SWITZERLAND Characteristics of the 12-NCT The 12-NCT machine generation incorporates the following technical and design improvements: Prismatic guideways The self-centering effect of the prismatic guideways helps to achieve greater accuracy. Lead screws Twin lead screws are arranged in the same plane of forces as the main spindle. Torque motor The main spindle drive has been laid out as a torque motor. 2 Drives Roller head approach X axis is achieved through two electronically coupled drives. Improved space conditions The use of the torque motor has improved the space conditions within the carriage, thus allowing optimized bedding of the main spindle. Advantages of this drive A substantial number of expensive changeover elements is eliminated. concept For many applications, it is now possible to operate with two rolling tools per roller head, significantly reducing processing times. The number of splines or teeth is freely selectable. Changeover from continuous to indexed pitch mode is electronic. Smaller numbers of splines or teeth can also be formed at higher speeds. Non-productive times between combined processes from spin-grooving and spline forming have been reduced by more than half. Speeds The new dynamic drives permit greater rapid traverse speeds, plus higher rotary speeds and feed rates. Cycle times Depending on the application, cycle times can be reduced by 20 to 50. The design and constructional measures described above have led to the further enhancement of an already elevated level of quality: Accuracy Both runout and pitch error have been further reduced. Spline alignment correction Spline alignment correction is possible. Wall thickness variations Variations in wall thickness within splines resulting from material deviations are significantly reduced thanks to the short clamping mandrel, the new spindle bedding concept and the prismatic guideways. ` Compared to earlier machine generations ERNSΤ GROB AG Rohrgasse 9 CH-8708 Männedorf Phone 12-NCT Layout, technical specifications 

ERNST GROB AG 12-NCT SWITZERLAND Technical Specifications 1 Machine specific data: sheet metal workpieces Controls Fanuc or Siemens Workpiece diameter Roller head speed m/min-1 0-1600 Lower range mm 50-250 Carriage rapid traverse mm/min 30000 Intermediate range mm 100-300 Roller head fast approach mm/min 1600 Upper range mm 150-350 Electrical power supply V AC 3x400 stroke-stamping range mm up to 2502 Power consumption kW up to max. 50 Compressed air bar Total weight kg 22500 Machine specific data: solid material Spline forming with countercenters Workpiece diameter Lower range mm 50-250 Intermediate range mm 100-300 Upper range mm 150-350 LW Space between spindle nose and roller head car LZ Max Spline length mm max. 2502 Spline forming with guide bushes on roller head side Workpiece diameter mm 50-150 LW mm 1000 LZ mm max. 6002 Spline forming with guide bushes on roller head side and follow-up reclamp3J Workpiece diameter mm 50-100 LW mm 1000 LZ mm from 600 As GROB machine concepts undergo continuous development refinement, all technical specifications are subject to change without notice. Z Workpiece and its related accessories can influence this dimension. 3 Greater lengths possible with extended machine bed or follow-up reclamps. ERNSΤ GROB AG Rohrgasse 9 CH-8708 Männedorf Phone Fax 12-NCT Installation, Operation, Service Up to transfer to end-user Customized installations are built and set up at the GROB facility by a team of specialists. Our experienced service engineers participate in every prelimi- nary acceptance procedure together with the customer. Following delivery to the customer's plant, they ensure seamless installation and handover of the equipment. Assembly shop Machine assembly Operation and service The cold forming machine stands on anti-vibration pads and can be installed GROB machines are renowned for their without the need for foundations. durability under full production condi- tions. Virtually all machines produced since 1962 are still fully operational across the globe. ERNSΤ GROB AG offers its customers competent, prompt and comprehen- sive repair and spare parts services during the entire lifetime of the machine. No foundation required spare parts available to order 16 ERNST GROB AG 12-NCT GROB SWITZERLAND ERNSΤ GROB AG Cold forming machines slotting machines Rohrgasse 9, Box CH-8708 Männedorf Switzerland Phone Fax 

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