'Not possible' is not an option

It’s not without reason that the machine tool is considered the forerunner of all machines. It constitutes the basis for building other machines and tools. Grinding machines play a key role in this context, as they are the undisputed masters of absolute precision, precision that extends to the most minute micrometer range. Since the introduction of the first grinding machine, the research and development objectives for machines have not changed: always more precise, faster, more efficient and, of course, more economical. These were, and remain the requirements. Repetitive, almost redundant to the point of boredom, the demands are ever the same, and ever more difficult to realise. Where is there still room for true innovation – for true invention? Perhaps, in the introduction of a “true fifth axis” for highly productive grinding of indexable inserts, as the WAC 735 CENTRO demonstrates, or maybe the devising of a completely new technique for the creation of three-dimensional profiles on machining tools, like the laser machining centre SPECTRA 820 displays, an innovation that takes laser micromachining into a fully new dimension.

Both machines clearly demonstrate that the limits of technical feasibility, even today, can be pushed a great deal further. However, machine design at this level always likens a walk on a tightrope in which even the slightest misstep is fatal. Since the engineering of the machines devours enormous amounts of resources, courage is required in addition to skill to venture into the vastly uncharted territory. But only those who constantly teeter on the brink of what is technically difficult, even impossible, can remain a decisive step ahead of the competition, can maintain their market position and continue to turn a profit while producing in a high-wage country like Germany. All WENDT’s engineers have to hear is “that’s not possible” and they begin to get excited. That’s exactly the point where the idea for a new product is born, where the limits get pushed back and finally a new market niche appears. CENTRO is a prime example of this. It incorporates technical advances that once seemed impossible. Although extensive tests and improvements were necessary along the way, the product is now in regular production. WENDT’s engineering team had seldom received such enthusiastic feedback as it did during the first demonstration. The customers were, simply put, flabbergasted upon seeing all that is technically possible. No one, neither WENDT nor the customers had previously imagined this before.

Such experiences capture the essence of research and development and stimulate to new, previously unconquered innovative heights. Currently, WENDT’s engineers are working on taking the productivity and quality of ultra-hard materials like PCD and CBN, machined on peripheral grinding machines, such as CENTRO, into a fully new dimension. To date, the work has produced a double-wheeled grinding tool consisting of a peripheral grinding wheel configured with coarse grit and a fine-grit cup wheel. At a rapid feed rate, the peripheral wheel premachines the workpiece. The line contact keeps the grinding force low and provides the contact area with ample coolant. Finally, the cup wheel is used for finishing. The machine’s ability to allow the workpiece position to be adjusted guarantees the highest cutting edge quality. To maintain the consistent cut quality of the peripheral grinding wheel, the CENTRO has an additional, integral dresser spindle for diamond form rollers.

Even the workpiece-specific accessories are subject to constant innovation. Often, experience acquired in actual industrial applications is integrated into advanced engineering efforts. An example is the recent development of the CENTRO’s AXR clamp with separate thrust and radial travel, which, thanks to the improved rigidity and reduced vibration, offers new potential in the grinding of ultra-hard materials, such as PCD and CBN. New software for the grinding of ultra-hard materials complements these solutions, significantly increasing the feed rate and guaranteeing the preciseness of the finished part’s dimensions.

The latest SPECTRA is a case in point of the constant utilisation of optimisation potential. The worktable, upgraded to a carbon fibre table, shortens cycle times. Boosting the material removal capacity, the machine is now available with an optional, integral laser beam source with higher power. Demands for even shorter set-up times were met with a modular clamping system that accommodates different types of workpieces with much less effort. 

A major source of the research and development stimuli is feedback obtained through close customer contact. Often, customers are the first to stumble on an idea: “If only ….. were possible. But that’s expecting too much.” Usually, within just a couple of months, the very thing thought to be unimaginable is “possible”.