As partner for precision Junker simplified processes and developed a flexible and efficient grinding machine concept that provides high quality with in process measuring of all critical dimensions including form scanning and automatic shape correction.
Sullair, located in Michigan City, Indiana, a Junker customer since 2011 has changed their finishing process to eliminate the demand to pair shafts and achieve highest compressor efficiency. In the past, the process required multiple grinding machine setups to finish a shaft.
Diameters and faces of the shaft were ground on the Junker QUICKPOINT prior to grinding the compressor flutes on form grinding machines.
Today with the JUMAT 6L all of this is done in one setup and one machine. In addition, for faster changeovers and to control process quality the machine in process measuring systems measures key features and automatically adjust the process to produce highest quality without operator intervention.
Junker developed the capability to measure the complex compressor flute profile and correct the dressing path to dress the CBN wheels complete automatically.
The correction is essential as tool pressure varies depending on the contact zone of the shape. It is necessary to apply a wheel with an incorrect shape to make a perfect part. The Junker grinding machine masters this with ease and for an optimum accuracy, the machine produces parts with a total lead variation of +/- 3 microns and a profile accuracy of less than six microns.
For the different flute shapes and for rough and finish grinding – the machine is equipped with a wheel changer. The machine programs call up the correct wheels and manage their life
span. If a wheel has reached the end of its life, the controller requests a new wheel and alerts the production manager to purchase a new one.
The parts are presented to the machine on a conveyor with an autonomy of a full shift. Parts are loaded into the machine by an internal gantry system. With that, the safety of the entire system is safeguard and grinding with straight oil possible.
Junker rotor shaft technology provides the capability to grind highest efficiency compressor shafts in one setup with controlled part quality by the grinding machine. It says the JUMAT is a “game-changer for the grinding market.
