When manufacturing small components with a diameter of between 2 and 20 mm, the GRINDSTAR grinding wheel or other abrasive tool for the purpose of removing metal and finishing workpieces to close tolerances. Provides smooth, square, parallel and accurate workpi…" title="Powers a grinding wheel or other abrasive tool for the purpose of removing metal and finishing workpieces to close tolerances. Provides smooth, square, parallel and accurate workpi…" aria-label="Glossary: grinding machine">grinding machine from JUNKER offers an economical alternative to turning. From batch sizes of 200,000, short cycle times and a long workpiece service life can drive down costs per workpiece by up to 25 percent. Its high productivity makes the GRINDSTAR a particularly interesting alternative for large-scale series manufacturing in the automotive industry, according to the company.

The innovative grinding method enables the entire workpiece contour to be ground in a single processing operation. In addition, grinding involves much lower cutting forces than those occurring during turning, allowing for faster grinding of workpieces. Another advantage of the GRINDSTAR is the coordination it allows between workpiece, abrasive and machine. All three factors act together to enable a significant increase in productivity, up to three times faster than a lathe.

The automotive and supply industry demands high piece volume with the fastest possible turnaround. This is precisely where the strengths of the GRINDSTAR are brought to bear: From material cut-off through profiling to ejection, every work step is covered in a single machine. This enhances process reliability and minimizes machine downtime. As a result, GRINDSTAR achieves an impressive availability level of over 96 percent and an extended tool service life. Due to its innovative cooling system, the grinding wheels work precisely and to a consistent standard of quality – for up to 6 months or a production volume of 300,000 pieces and more.

Grinding instead of turning also impacts positively on the quality of workpieces, with significantly improved dimensional accuracy and excellent surface quality. The manufacture of burr-free parts during grinding is 100 percent guaranteed. Unlike turning, no chip impressions are created. The two profile grinding wheels in the GRINDSTAR require no dressing and use an innovative lubrication method. The flushing system prevents particles from being deposited on the grinding wheels, eliminating the need for the reworking process frequently required when turning. This reduces the production time required and saves the need to invest in additional machinery for surface grinding or polishing.