Holroyd is advancing superabrasive machining technology

Holroyd is advancing superabrasive machining technology with the launch of its "next- generation" Edgetek SAturn Superabrasive Turning System. The new SAturn machines employ CBN wheels to achieve productivity rates far in advance of those obtained with hard turning. They are designed to remove stock from the OD of cylindrical parts (slot, groove, and forms) in all types of materials - including sintered - at rates up to 40% faster than conventional lathes.

"We already have major expressions of interest in our Edgetek SAturn machines from market leaders in both the automotive and aerospace industries," says Paul Hannah, Holroyd's Sales Director for Machine Tools & Rotors. "It's easy to see why: in one Beta site application we have reduced the cycle time for producing automotive sprockets manufactured from sintered metals from 1minute 10secs per component, to just 22 seconds. At the same time, the SAturn's CBN technology is cutting consumable parts costs, achieving a reduction from $1 US to just 3.3 cents per component."

"The above example illustrates how productivity with the Edgetek SAturn system goes far beyond that typically obtained with hard turning," says Hannah. "We are offering next generation machining, today: the ability to machine interrupted cuts - a process that destroys conventional tooling very quickly - on hard materials such as Inconel, and heat-treated powder metals. Typically, this type of machining is used in the production of impellers, gears and sprockets; however, it is just one of the facilities offered by our machine: the SAturn is equally expert at facing cylindrical parts and of machining slots and splines in the same hard materials."

The CNC controlled Holroyd Edgetek SAturn system provides cutting speeds of up to 12,200 metres/min, courtesy of a high power, variable speed 37kW spindle motor operating at 9,000 rpm max; and CBN electroplated wheels, which provide long wheel life. This combination is optimised by new design of coolant nozzle, which provides improved control of coolant direction and delivery rate to reduce the risk of any heat being transferred into a
workpiece.

The result of this synergy is a machine that allows heavy stock removal on straight outside diameters (OD's) or special form diameters to grinding machine tolerances on virtually any difficult material or Rockwell hardness.

Further extending the capability of the SAturn machines are options such as a high-speed (30,000 RPM) spindle version, which provides internal diameter (ID) capability for straight or spherical shaped bores, and a robotic automatic part loading/unloading function. For high production environments, the automated system can also feature dual workheads mounted on an index table, facing 180 deg from one another. The benefit of this arrangement is that it allows for in-cycle auto or manual loading to take place, delivering substantial reductions in machine idle time and increasing productivity.

Also aiding productivity, wheel changing on the SAturn machines can be performed using a simple hand-operated robotic arm, making the task quicker and easier for an operator to perform. The time saved by this operation means that machine downtime during wheel changes is minimised, with the resultant benefit of optimised production.

Holroyd manufactures the SAturn and SAM Edgetek machines in all types and configurations to suit specific applications. The machines can also be supplied as complete turnkey solutions as part of a manufacturing cell. In these applications machine integration is simplified by the universal Ethernet connectivity provided by Fanuc CNC controllers, and by Holroyd's wealth of software and hardware experience. This experience is also deployed to benefit customers in Holroyd's worldwide service network, and in the manufacturer-developed preventative maintenance plans the company provides.