CT Machine Tools delivers micron accuracy for The Barden Corporation

Over many years in near constant production, one original machine in particular had developed significant signs of wear. Backlash in the infeed slide not only made setting more time consuming, but accurate compensation was also a slow process. Obtaining the required component precision from the machine became increasingly problematic. At a time where production volumes are increasing and demand for higher precision is greater than ever, Barden elected to future-proof the process while also seeking immediate production benefit. All machine movements were reconditioned as part of the project, with many being converted from hydraulic or manual operations to run through the new control system. In all, seven movements can be set and fine-tuned electronically through the touchscreen, with the added benefit of being able to store this data as a part program. By being able to recall this information each time the part is ground, consistency of setting and, therefore, finished product is heightened, both between operators and across shifts. The interface generated was bespoke to Barden's production requirements, further targeting ease of use by tailoring the machine to suit existing processes. The new control system and servo driven ballscrew conversion, as well as reconditioning work undertaken on the slide, gives repeatable and accurate single micron movement at a touch of the screen, without the need for a standalone DRO or continual operator refinement. The result? Single micron tolerances on diameter and roundness are achieved with comparable ease. According to CT's manufacturing manager, Phil Baker, the machine is one of the finest the company has ever produced. "The precision Barden required was always going to make this build a challenge, but this in turn makes the sense of achievement throughout our team even greater," he highlighted. "Many other users favour centreless grinders, primarily for throughput, and are working to tolerances more open than those Barden require. Although the machines we build carry a general precision as a matter of course, it's not often pushed to such fine limits as it has been with this project. To deliver this performance consistently, the machine has to embody mechanical rigidity, as well as a powerful control, yet interface with the operator in a natural way to make it easy to use to its full potential."