Leistritz Profile and Keyseating Machines

Leistritz Profile and Keyseating Machines 

As mechanical engineers with years of experience, we are a competent partner for many different industries: from drive engineering to woodworking - the Leistritz Polymat and Polyjet series of machines are employed in just about every branch. Our design and manufacture specialists work constantly to advance our technologies. We have continuously improved our profile and keyseating technology over many decades to deliver the highest quality from one source. The customer's benefit is always our top priority. As a reliable partner with a global service and sales organization, we offer a 24-hour tool grinding service and accompany our customers on their path to success.

The keyseating process cuts a keyway in a stepwise manner. A cutter is pulled vertically with a continual stroke movement along the borehole, combined with a horizontal thrust motion. The thrust is delivered after each stroke by a feed bar that thrusts the cutter in steps between the cutter guide bar and cutter bar. To ensure gentle machining for the tool and workpiece, the cutter is automatically lifted off before the upward movement. The keyseating machines are equipped with a twin-column hydraulic guidance system. The in-line arrangement of the tool and tool slide creates a fully linear alignment of forces within the tool and machine system. This avoids lateral forces and leverage, so the machine is extremely long-lasting and virtually free of wear.

Advantages over slotting:
- Significantly greater precision, since the tool is guided over the entire keyway length (offset, depth, axis parallelism)
- Higher surface quality, since the tool and workpiece make one unit due to the centering elements
- Higher cutting values, since the cutter cannot deviate from its path while cutting (cutting speed, feed)
- Workpiece and tool are clamped into a single unit, resulting in longer tool lives and optimized process parameters
- Significantly wider and longer keyways can be cut (length up to 1500 mm and width up to 125 mm)

Advantages over broaching:
- CNC-controlled machining of keyways into blind holes, helical keyways, and oil grooves at superior quality
- Low space requirements, even for large keyway lengths or widths
- Gentle cutting for the workpiece (no warp)
- Low tool costs, since the customer can resharpen the cutters
- Short delivery times for tools and reasonable prices for special sizes
- Economic elements for workpiece centering and clamping
- Easiest automation with integration of quick-clamping units (hydraulic/pneumatic)
- Flexibility in adapting tool widths

Polymat 25/32 NC
Machines in the NC series are an economic solution for the task of cutting through-keyways/profiles into through-holes, either as single keyways or multiple keyways. Typically, manual indexers are built onto the machine for multiple keyways. NC machines generally come as 2-axis machines (controlled axes).

Polymat 70/100/125 CNC
CNC machines have controlled axes, which allows interpolation of the axes. Accordingly, in addition to the standard feather keyways according to DIN 6885 or custom profiles in through-holes, these machines also cut oblique keyways, oil grooves, keyways into blind holes, helical keyways, and regular and irregular multiple-keyways/profiles (serrated/spline/involute profiles/...). In addition to manual indexers, automated indexers (3rd CNC axis) can also be used on these machines. Single copies and small batches are therefore just as economical to produce as large-scale production if, for example, the machine is integrated into a full manufacturing process, is automatically loaded, and works over several hours unmanned.

Polyjet
The "hard" keyseating machine POLYJET 50 offers users a new dimension in profile and keyway cutting. This new machine generation combines the performance of much more complex broaching machines with the flexibility and efficiency of keyseating machines. The extremely high cutting speed of up to 120 m/min allows hard machining. The Polyjet can be used for soft machining when short machining times are demanded.

With precision-made, superfinished piston rods, the twin-column hydraulic guidance system ensures utmost precision in the tool slide. The piston rods and hydraulic oil provide guidance and drive in one unit. The hydraulic oil also ensures permanent lubrication of the system. Accordingly, the machine has no lubrication/maintenance points.

S7-314 PLC controller, 5.7" display with membrane keypad
Control of 2-4 CNC axes
Tool feed (X), one rotation axis (B) for multiple keyways and expandable for automatic loading
User guidance in local language
Storage capacity for approximately 250 programs for all important parameters:
- Diameter
- Keyway width
- Keyway depth
- Keyway length
- Feed rate
- Tool type
- Cutting speed
- Idle stroke programming
Precise assumption of Z-axis position using CNC technology
High-precision rotary encoder systems in all axes
Error diagnostics system with onscreen fault display
Interface optional for PDA and program transfer