Erosion Efficiency: Inspection Efficiency

The machine can also measure the grinding wheels, electrodes and workpiece location within the machining environment. “The machine understands where everything is located and what the dimensions are,” Ries said, adding that the machine’s automatic toolchanger holds a combination of up to six wheels and electrodes. “It provides the versatility to run different geometries without having an operator change electrodes, change wheels or remeasure where they’re at because [the wheels and electrodes] were taken off and put back on.”

Because of the novel arrangement of the axes, a tool is machined in a suspended position, the company reports. Ries explained that Vollmer developed the vertical axis to improve tool runout because a tool can deflect due to its own weight when held with the conventional horizontal axis. That also helps keep the workpiece interface cleaner because debris is flushed down the tool. “It makes measurements more accurate as well,” he said.

To eliminate the need to tweak a 3-D model of a tool prior to producing it, Vollmer developed ExLevel software to create “an exact replica of that 3-D model” in which the manufactured tool’s tolerances don’t vary from the model, Ries noted. The virtual simulation program also enables end users to verify that a tool design is correct and, if not, modify it before production begins by importing the tool’s 3-D model into their modeling software, he explained.

The QXD 200 offers three options for delivering tools to the machine: a traditional magazine, a pallet system for 39 large-diameter workpieces and a pallet system for 64 small-diameter workpieces. The pallet systems are positioned on tracks outside the machine and enable integration of other parts of the manufacturing process, such as brazing and inspection, into the tool delivery system, Ries noted.

For more information about the QXD 200 and Vollmer of America Corp., Carnegie, Pa., call (412) 278-0655 or visit www.vollmer-us.com.