Walter Vision 5-Axis CNC Tool Grinder with Wheel Changer

TECHNICAL SPECIFICATIONS:

Maximum diameter (complete grinding): 12.6”
Maximum tool length for peripheral grinding : 14.6”
Maximum tool length for end teeth grinding: 11.8”
Maximum tool length for complete grinding: 11.8”
(Lengths measured from the ISO 50 workhead taper gage point)
Linear axes rapid traverse rate: up to 2000 ipm
Rotary C-axis: 120° ipm
Workhead A-axis: 750 rpm
Note: The Workhead cannot be used as a Cylindrical Grinder.

59.0 HP High Frequency Grinding Spindle
Grinding head with liquid cooled and asynchronous controlled motor spindle with one spindle end and HSK 50 interface.
Peak output: 59.0 HP
RPM, variable speed 0 to 10,000 rpm
Diameter of Motor Spindle 5”
Max. grinding wheel diameter (automatic wheel change): 6”
Max. grinding wheel diameter (manual wheel change): 8”


Grinding Wheel Changer:
Automatic grinding wheel changer with 12 changing stations. The grinding wheel sets are changed along with the corresponding coolant manifold in under 10 seconds.

Dimensions for Automatic Wheel Changing:
Maximum grinding wheel diameter 12 stations: 6”
Maximum grinding wheel diameter 6 stations: 8”
Maximum length L1 of grinding wheel holders: 3.3”
Maximum number of grinding wheels: 3
Maximum weight of the grinding wheel set: 8.8 lbs

CONTROL:
- GE Fanuc Series 31i Model B5
- Digital drives
- Dual Check Safety for safe axis and spindle operation
- HMI computer: PC Intel Core 2 Duo, 2.25 GHZ, 1 GB Cache, 4 GB RAM, PCI Bus
- Windows XP Professional Embedded
- 15" TFT touch screen monitor
- Fanuc ASCII keyboard
- Hard Drive SSD, 16 GB
- Four (4) USB 2.0 Interfaces, 2 accessible from outside
- Ethernet interface
- Control resolution: linear.000,1°-axes.000,004", rotary axes
2 NC channels, 12 NC axes, 4 spindles
Operator language: English, Spanish, French, Italian, German, Portuguese


MACHINE FEATURES & TOOLING:
Integral coolant enclosure with fluorescent work light, semicircular polycarbonate operator access door with automatic door lock, and semicircular polycarbonate service access door.
Air conditioner, 8,500 BTU
*Maximum ambient temperature: 113°F
*Maximum relative humidity: 90%

Auto-probing:
Automatic positioning and measuring device to greatly reduce the setup time for regrinding and minimize operator error for:
- Radial and axial positioning
- Spiral lead
- Measuring of the cutting edge position depending on the grinding program.

TOOLING
Calibration ball (for use with Automatic Machine Calibration (AMC) & the optional Internal Measuring System
Grinding Wheel Adapter, L1=1¼" (45 mm) (2 wheels)
Test bar for measuring reference points, ISO 50, length
Setting disk with short taper for machine measurement Maintenance, Operator and Software Manuals on
Three (3) anti-vibration/leveling pads
Machine drip pan
Control pendant tool shelf

Compressed Air:
Minimum supply: Clean & Dry at 80 PSI
Standard: 7.1 SCFM
Production Package: 8.5 SCFM

Electrics:
Standard voltage: 400V/3ph/60hz
Voltage: 208, 240, 480 or 575/3ph/60hz available via included
Power supply requires Star Y connection with center point grounded to earth.
Proper grounding of machine is required. Refer to machine floor plan.
Maximum permissible voltage fluctuation +/-5%
Maximum permissible frequency fluctuation +/-1%
Power requirement for the standard machine: 45 KVA
Control Voltage: 24 VDC

Safety:
Interlocked operating door. Operate protection foot pedal safety switch during manual operation stops all axis motion. Reduced axis speed in setup mode. Wheel sticking function allows spindle to run up to 1,000 RPM with door open in manual mode.

Dimensions and Weight:
Length 146”
Width 111”
Height 120”
Weight 16,000 LB

Coolant System:
Ebbco Evolution Coolant System 150 Gallons, Ebbco Evolution cartridge coolant system with 24,000 BTU coolant chiller for up to 1 machine. Quiet new chiller fan design. Includes upgrade to 100/300 PSI coolant supply pump and additional filtration vessels for capturing HSS swarf

Mist Collector:
Smog Hog mist extractor, 1000 CFM, 95% efficiency rating on the removal of airborne oil mist particulates.

Auto Clamping System:
Automatic tool clamping system with quick connection, foot switch

Work Table:
C-axis work table, T-slotted for mounting work supporting fixtures.


Machine Options:

Automatic High Frequency G II Wheel Dresser
Includes: Frequency converter and Diamond dressing disc.
Does not include dressing software.
Dresser can be used for in-process dressing of
Vitrified CBN and conventional aluminum oxide wheels.
Auxiliary High Frequency Spindle
Up to 50,000 RPM
ER 16 collet nose
Glass Scales, Linear Axes
Automatic Fire Extinguisher, CO2
EBBCO Evolution 40-60-3-M Coolant
400 gallon capacity
35 GPM
Evomatic cartridge coolant system
120,000 BTU coolant chiller
Microfilter
Flow Monitor
Pressure relief system
100/300 PSI coolant supply pump

Grinding Software

Tool Studio Basic
Tool Studio is a programming platform with wizard technology that allows the user to program highly complex and standard tools with an easy-to-use graphical interface. The programmed tool is displayed in 3 dimensions on the screen and is an exact reproduction of the tool produced by the grinding machine. The Tool Studio Basic software can be used to manufacture and regrind endmills, drills, reamers and spherical cutters.


End Mills
For cylindrical and tapered shank type tools with included conical angle of up to 90° and the following end forms;
Square End,
Corner Chamfer,
Corner Radius,
Ball Nose,
Double Radius and Beveled Corner
Ball Nose with up to 4 MGM clearances.
Corner Radius with 2 MGM clearances.
Ball Nose Left/Left and Right/Right.
Corner Radius Left/Left, Right/Right, Left/Right, & Right/Left.
Wizards from 1 tooth up to 16 teeth (12 teeth for Ball Nose).
Single Pass or Multi Pass fluting.
Radius washout at flute end.
• Automatic collision detection and Automatic Machine Move Optimization (AMMO)
• Regrinding constant helix, constant lead, digitizing changing helix.
• Equally and unequally indexed flutes.
Ball Nose End Mills with S-Gash
Wizard for cutting edge combinations 2/2, 3/3, 4/2 (End Teeth / Long Teeth)
Grinding with outside diameter or side of the grinding wheel
Start angle for generating definable chisel point.
Rake angle up to 30° negative, definable at up to 10 points through the radius section.
Drills
2 & 3 flute drills with cam relief, facet and Form E style points and the following gashing options; Conventional, split point, double split point, & radius and core style gashes.
Coolant hole probing.
Main cutting edge correction.
Flute wash out feature.
Reamers
Reamers with short lead-in chamfer, long lead-in chamfer, or double lead-in chamfer. Straight, Left/Right, Right/Left, Right/Right & Left/Left

Tool Studio Advanced
Prerequisite: Tool Studio Basic The Tool Studio Advanced is an extension of the Basic Tool Studio software and gives more capability to create non-standard, custom or proprietary type tools. With this enhancement, the user can;
• Add grinding operations.
• Add Flexprog (NC-Code) operations.
• Edit Java scripts.
• Create User-Defined Tools.
20 gram probe upgrade-For IMS or applications where chipping is a concern (eg PCD Tooling)

Automatic Machine Calibration (AMC) for Tool Studio
Automatically maintains the correct wheel shape during production.
Includes all common wheel forms. Full 3D simulation

Walter Window Mode (WWM) Package 1 Cyclindrical Endmills
Walter Window Mode (WWM) Package 2 Tapered Helical Endmills
Walter Window Mode (WWM) Package 3. Drills & Step Drills
Walter Window Mode (WWM) Package 15 PCD Pockets

Internal Measuring System (IMS) for WWM Packages 1&2

Automatic Machine Calibration (AMC) for WWM
Includes 3D simulation of the grinding process

Optional Loaders & Related Tooling

Stacked Pallet Loader for Cylindrical Tools
Automatic load/unload up to 504 tools with shank diameters from
.125 to 1”.

Complete Hydraulic Package
Consists of hydraulic supply unit (503877-570) and the hydraulic preparation gear (503895-570).

Automated worktable with one (1) automatic sliding carriage
- Supports long tools with a variety of manual and automatic steadyrests and tailstocks (additional options)
- 290 mm (11.4") traverse
- Programmable movement before, during, & after grind
- Includes 750 RPM hollow-shaft direct drive motor for A-axis workhead
- Center height of the ISO 50 workhead changes from 200 mm (7.9") to 145 mm (5.7")