COLD FORMING MACHINE 12-NCT - Imponar - maszyny ... · PDF fileCold forming machines Slotting machines COLD FORMING MACHINE 12-NCT ERNST GROB AG

Cold forming machinesSlotting machines

COLD FORMING MACHINE 12-NCT

ERNST GROB AG

ERNST GROB AGCold forming machinesSlotting machinesRohrgasse 9, P.O. Box 830CH-8708 MännedorfSwitzerland

Phone +41 44 922 77 00Fax +41 44 922 77 88

[email protected]

Products and ServicesCold forming machines

ERNST GROB AG develops, designs and builds cold forming machines; from basic,

manually loaded units to fully automated production lines. The primary fields of

application for the sheet metal and solid components produced by cold forming

are to be found in the automotive industry. Our machines, however, are also opera-

tional wherever efficiency and quality are key considerations.

Slotting machines

Sheet metal parts that have been splined on GROB cold forming machines can be

transferred to our slotting machines for secondary operations, thereby ideally com-

plementing the cold forming process. Non-splined workpieces can also be slotted.

The design concept of our equipment is modular and can be optimally tailored to

suit the specific requirements of the application involved.

Subcontracting

At our subcontract facility we use our own cold forming and slotting machines to

produce components to customer order. We can take on your production

needs for individual components or small pilot runs. To overcome production

bottlenecks, we also process full-scale mass volumes. Our Quality Management

System is certified to ISO/TS 16949.

Engineering

A cornerstone of our success is the relentless search for optimal solutions to specific

engineering challenges. Our development department is key in this objective, as this is

where years of in-depth experience and the latest technological expertise are merged.

Close collaboration with our business partners invariably succeeds in generating innovative

results that our test department rapidly converts into prototype components, which

are already close to mass-production maturity.

ContentsPage

Company profile .................................................................................................. 2

Industries and products ................................................................................ 4

Production processes ..................................................................................... 6

Machine description ........................................................................................ 8

Layout, technical specifications ............................................................ 14

Installation, operation, service ................................................................ 16

Company profi le

CompetenciesERNST GROB AG develops, designs and

builds precision machines dedicated to

the cold forming of splined and non-

splined workpieces. The manufacture

of slotting machines for secondary

and finishing operations on cold

formed workpieces is yet another core

competence of the company.

From the initial idea through to its de-

velopment, and right up to the industrial

application – the entire concept is available

from a single partner: ERNST GROB AG

provides customer specific solutions,

from manually loaded single machines

to fully automated production lines.

GROB slotting processGROB slotting machines are employed to

finish cold formed splined or non-splined

hollow components.

Diverse slotting and coining

operations are undertaken at various

stations.

Separate stations for dedicated applica-

tions can also be integrated.

GROB cold forming processGROB cold forming machines are based

on the principle of the cold roll forming

in planetary type movement process.

The technology provides a solution for

the cost-effective production of splined

or reduction type cylindrical workpieces.

The founder of our company, Ernst Grob,

further developed and refined the

principle (see infobox «The GROB story»).

Diversity of finished productsApplications for cold forming machines

are highly flexible, for example, when

producing:

Clutch disc carriers

Splined shafts

Gearbox shafts

Drive shafts

Steering system parts

Pump shafts

Extruder shafts

Splined shafts for:

– Printers

– Medical instruments

– Communal vehicles

– Helicopters

– Food processing equipment

– Torsion bars and progressive coil springs

Gearbox shafts

Thin-walled tubular components, cold rolled without support mandrels

Components for a wide range of vehicles

Machines for the automotive industryGROB machines are primarily used in

the automotive industry. Typical compo-

nents are clutch disc carriers in auto-

matic transmissions and other splined

components within the power train.

Slotted workpieces

GROB cold forming technology

2 © ERNST GROB AG • 12-NCT • 8–2011

12-NCT

Dedicated partnershipsAt ERNST GROB AG the development

department is intensely focused on the

refinement of existing technologies,

plus the development of new processes

and applications. In close cooperation

with customers and other interested

parties, solutions are generated that

permit economic production of accurate

finished parts. When required, ERNST

GROB AG offers customer support

throughout the entire service life of

machines installed by our company.

Success factor employeesThe key success factor of ERNST GROB AG

is the professional competence and

dedication of its employees. A team of

highly qualified and experienced

specialists is the best guarantee for

meeting the most demanding challenges.

An innovative spirit coupled with an

inherent flair for technical solutions

are the foundation on which innumer-

able and unique developments are

based.

Headquarters in Maennedorf

LocationsERNST GROB AG plants are located in

Switzerland’s greater Zurich conurbation

where the company is able to benefit

from an outstanding infrastructure

with excellent transport facilities.

Headquarters (administration, research,

development, assembly) are located

in Maennedorf, while the subsidiary

(production, subcontracting) is to be

found in Oetwil am See.

Subsidiary in Oetwil am See

The GROB story

up to 1961 Dr. h.c. Ernst Grob develops cold forming machines at the machine tool works he founded in Munich in 1926. In 1948 already, he builds the first roller head with planetary type rotary roll forming tools.

1962 1962 Dr. h.c. Ernst Grob founds a company making cold rolling machines in Maennedorf and delivers the first one to Sulzer, Zuchwil, Switzerland.

1963 Further machine deliveries to Germany, Italy and Japan. Subsequent set-up of global sales and marketing network.

1979 Introduction of PLC technology and establishment of in-house electrical department including engineering for hardware and software development.

1984 Introduction of multiple axis CNC technology.

1985 Following death of Dr. h.c. Ernst Grob: establishment of ERNST GROB AG. Business continued and expanded by his grandson and current owner, Mr. Daniel Dériaz.

1991 Acquisition and expansion of a subsidiary plant of ERNST GROB AG in Oetwil am See, Switzerland.

1999 Quality Management Certification to ISO 9001.

2001 Expansion of product portfolio with type S8 slotting machine for hollow parts and delivery of first slotting machine to General Motors Strasbourg plant in May.

2005 Start-up of production at the newly constructed workshop in Oetwil am See.

2006 Certification of subcontracting facility in Oetwil am See to ISO/TS 16949.

2007 Introduction of torque drive technology (NCT).

2008 Modern centralised office building in Maennedorf is occupied.

2009 Market roll-out of newly developed stroke-stamping process.Quality inspection using state-of-the-art methodology

ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com 3

Industries and products

IndustriesMachinery from ERNST GROB AG is

installed primarily in the automotive

and vehicles industries. The majority

of OEM’s and their suppliers use GROB

technology to produce parts for

gearboxes, steering systems and

numerous other applications.

Splined components are also produced

by other sectors, for example, the

plastics and papermaking industries.

Large-scale and small volume productionWhereas ERNST GROB AG machine

customers essentially use their equip-

ment for mass production, the situation

for smaller volumes is different:

components for a wide range of applica-

tions are frequently subcontracted

direct and produced by ERNST GROB AG.

Finished productsIn the vehicles industry, splines are

mainly required on half-shafts,

gearbox shafts, universal joints, clutch

and steering shafts. In all these applica-

tions, high precision and surface finish

are essential.

The GROB cold forming process is also

highly suited to challenging compo-

nents, such as shafts for pump

construction or extrusion machinery.

Double clutch disc carrier Disc carrier processed by stroke-stamping

Here, even specifications for extremely

long and highly accurate splines of up to

10 metres in length or more can be met.

Materials and geometriesIn the majority of applications, steel is

the specified workpiece material. Also

steels for case-hardening, steels for

heat treatment and stainless steels are

suitable. However, other alternatives

such as titanium, non-ferrous metals

and light alloys can be processed by

GROB cold forming technology. Both

cylindrical thick-walled hollow shafts

and solid ones are suitable for cold

forming. The profile geometry of the

spline gap is virtually identical to the

profile of the rolling tool. Hence, all

common standard profiles and almost

any desired tooth geometry, e.g. parallel

flanks, involutes (including those with

undercuts), linear ball bearing or

buttress tooth profiles are feasible.


12-NCT

Splined shaft with module 5Universal joint made of aluminium and steel

Example clutch disc carrierClutch disc carriers are typical finished

products. They are installed in automa-

tic transmissions and direct shift gear-

boxes (DSG). This clutch disc carrier

(p. 4, below) was first processed on a

GROB cold forming machine and sub-

sequently finished on a GROB slotting

machine.

Example universal joint shaftThe splines for both tubular drive shafts

were produced by the GROB cold

forming process. The weight savings

achieved also translate into reduced

fuel consumption. Moreover, safety

is enhanced as both hollow elements

telescope into each other in the event

of a crash.

Example solid materialSolid stock can be cold formed to ge-

nerate modules of up to 5 and above.Chrome steel workpiece

Clutch disc carrier

Bronze workpiece

Clutch disc carrier with reduced tooth tip


Production processes

The GROB cold forming process in briefIn the GROB cold forming process, the entire forming

sequence is broken down into numerous individual steps.

This procedure allows high degrees of accuracy and surface

finish to be achieved with relatively low force levels. The

tooling consists of two opposing rolling tools carried in

roller heads. During operation, the tools rotate in a

planetary motion within the roller heads and act on the

Forming of clutch disc carriersCold forming of sheet metal components from cup-shaped

preforms. The clutch disc carriers are formed by rolling tools

into the profile of a mandrel, thereby generating internal

and external splines.

ReductionThe preformed sheet metal cup is reduced by concave pro-

filed rolling tools so that splines are generated by the man-

drel. Internal splines are formed.

Direct reductionRelatively short splines can be formed out of a sheet metal

disc by direct reduction. The mandrel creates the internal

splines. The concave profile of the rolling tools defines the

outer diameter.

workpiece which is turning about its own axis. At the same

time, the workpiece moves in axial direction, thereby

generating the spline geometry along its length.

This process produces extremely precise components with

all the familiar benefits of chipless forming, e.g.: cold work

hardening, enhanced material microstructure, material

savings.


12-NCT

Reduction of bar materialBy the reduction, for example of torsion bars for chairlifts,

the diameter of the stock material is reduced without the

need for machining. Thanks to this chipless forming process,

the orientation of the grain flow remains unbroken; the

microstructure is homogenous and there are substantial

savings in weight and material.

Stroke-stampingWith the stroke-stamping process it is possible to form

splines close up to a shoulder. Splines on clutch disc carriers

no longer need to be continuous; a solid ring can remain

at the open end of the component to provide reinforcement.

Spin-grobingBy spin-grobing, a sheet metal disc is spun into a cup-

shaped preform. In the same clamping, the splines are formed

by the rolling tools and the mandrel.

Forming solid materialIndividual profiles can be generated on solid material used

to make, for example, hubs, flanges or fork shafts: invo-

lutes, buttress tooth, ball bearing or parallel flank profiles

are feasible. Tooth tips can be calibrated or chamfered by

rolling.


Machine description

Performance leap with new drive conceptERNST GROB AG has extended its technological

leadership by developing a new generation

of cold forming machines designated the

12-NCT series. At the heart of these

improvements is the main spindle drive

which is laid out as a torque motor,

offering numerous benefits such as

higher processing speeds, more accurate

profiles and reduced changeover times.

Cold Forming Machine 12-NCT

12-NCT under assembly: welded frame, cast iron bed and roller head carrier Forming zone


12-NCT

Electrical cabinet and controls of a custom-built 12-NCT (controls at rear, layout of electrical cabinet)

Control panelAll functions can be input and accessed

via the logically arranged control panel.

Legend

Forming zone Spinning heads Radial depth positioning motors Countercenter Carriage guides Carriage with torque motor Feed drive

Salient features of the 12-NCT at a glance• Reduced changeover times by elimination

of mechanical interchange elements

• Number of splines freely selectable in continuous and indexed pitch mode

• Dynamic drives provide higher speeds and feed rates

• Option of using 2 rolling tools per head reduces processing times

• Greater accuracy through prismatic guideways and more rigid main spindle

• Smaller numbers of splines can also be formed at higher speeds

• Spline alignment corrections possible

• Wider range of applications, e.g. reduction, spin-grobing and stroke-stamping

• Minimal maintenance costs

• Lower tooling costs

Primary elements

ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com

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3

21

5

4

6

7

9

In place of a conventional main spindle

drive for workpiece rotation, the 12-NCT

features a torque motor. This direct

drive system is free of backlash and

operates at high peak, nominal and

standstill torque ratings. The transition

Roller head and carriage zone

Carriage with torque motor

Oil filtering system

has allowed the further development

of the entire drive and control concept.

Elimination of the indexing plate

and other mechanical elements has

permitted the bedding of the main

spindle to be optimized. The self-cen-

tering effect of the prismatic guideways

has also enhanced accuracy. Two lead

screws are arranged in the same plane

as the main spindle, thereby ensuring

ideal force application conditions.

Hydraulic systemThe separate hydraulic power unit

with integrated cooling supplies the

torque motor, the counterplate, the

roller head retraction cylinder and the

ejector cylinder, as well as those for

the splash guard movement with its

corresponding coolant.

Legende C axis: Workpiece rotation drive Z axis: Workpiece feed X axis: Roller head depth movement B axis: Roller head rotation drive A axis: Swivelling angle

Electrical controls and drives, axis functions

CZXBA

CX

A

A

X

Z

B

B

10 © ERNST GROB AG • 12-NCT • 8–2011

12-NCT

Gantry loaderDouble gripper flexible gantry loader

and transport conveyor, for example,

are used for handling workpieces within

the production system. In the majority

of cases, the entire workpiece spectrum

can be catered for via the program

selection, without a need for manual

changeovers or adjustments.

The gantry loader features a horizontal

and a vertical NC axis, plus a pneu-

matically actuated double gripper unit

incorporating a swivelling module for

blanks and another for finished com-

ponents.

Conveyor beltsArrangement of conveyor systems is

customer specific and depends on the

integration potentials of the production

line. Conveyor belts and tracks, robots

or other handling equipment can be

installed.

Infeed and outfeed conveyor belt

Gantry loader with blank and finished component

Automation solutions


Special purpose stationsTo complement the forming process,

other production processes can be

carried out before or after the splining

operation. Typically, these are creating

preforms or various slotting operations,

undertaken on integrated special

purpose stations.

Example of an integrated slotting stationThanks to the compact design concept,

it is possible to integrate a slotting station

inside the noise reduction cabin of a

GROB cold forming machine. Hence,

a slotting operation can follow spline

forming in one and the same produc-

tion cycle.

As handling is done by the same auto-

mation system, the processing times are

held to a minimum.

Potential operations: trimming to length,

punching holes or slots, coining in snap

ring grooves, plus a wide range of other

features.

Integrated slotting station

Clamped and slotted workpiece Tooling with finished workpiece

12 © ERNST GROB AG • 12-NCT • 8–2011

12-NCT

Characteristics of the 12-NCT

The 12-NCT machine generation incorporates the following technical and design improvements*:

Prismatic guideways The self-centering effect of the prismatic guideways helps to achieve greater accuracy.

Lead screws Twin lead screws are arranged in the same plane of forces as the main spindle.

Torque motor The main spindle drive has been laid out as a torque motor.

2 Drives Roller head approach (X axis) is achieved through two electronically coupled drives.

Improved space conditions The use of the torque motor has improved the space conditions within the carriage, thus allowing optimized bedding of the main spindle.

Advantages of this drive concept

– A substantial number of expensive changeover elements is eliminated.

– For many applications, it is now possible to operate with two rolling tools per roller head, significantly reducing processing times.

– The number of splines or teeth is freely selectable.

– Changeover from continuous to indexed pitch mode is electronic.

– Smaller numbers of splines or teeth can also be formed at higher speeds.

– Non-productive times between combined processes from spin-grobing and spline forming have been reduced by more than half.

Speeds The new dynamic drives permit greater rapid traverse speeds, plus higher rotary speeds and feed rates.

Cycle times Depending on the application, cycle times can be reduced by 20% to 50%.

The design and constructional measures described above have led to the further enhancement of an already elevated level of quality:

Accuracy Both runout and pitch error have been further reduced.

Spline alignment correction Spline alignment correction is possible.

Wall thickness variations Variations in wall thickness within splines resulting from material deviations are significantly reduced thanks to the short clamping mandrel, the new spindle bedding concept and the prismatic guideways.

* Compared to earlier machine generations


Layout, technical specif ications

3580

2800

1215

2505

Z

6225

LW

LZX

C

X

B

8085

2400 DR

DA

F

A

3580

2800

1215

2505

Z

6225

LW

LZX

C

X

B

8085

2400 DR

DA

F

A

14 © ERNST GROB AG • 12-NCT • 8–2011

12-NCT

Technical Specifications 1)

Controls Fanuc or Siemens

Roller head speed (min-1) 0–1600

Carriage rapid traverse (mm/min) 30000

Roller head fast approach (mm/min) 1600

Electrical power supply (V AC) 3x400

Power consumption (kW) up to max. 50

Compressed air (bar) 3.5

Total weight (kg) 22500

1) As GROB machine concepts undergo continuous development refinement, all technical specifications are subject to change without notice.

2) Workpiece and its related accessories can influence this dimension.3) Greater lengths possible with extended machine bed or follow-up reclamps.

Machine specific data: solid material

Spline forming with countercenters

Workpiece diameterLower range (mm) 50–250

Intermediate range (mm) 100–300

Upper range (mm) 150–350

LW – Space between spindle nose and roller head carrier (mm) 1000

LZ – Max Spline length (mm) max. 2502)

Spline forming with guide bushes on roller head side

Workpiece diameter (mm) 50–150

LW (mm) 1000

LZ (mm) max. 6002)

Spline forming with guide bushes on roller head side and follow-up reclamp3)

Workpiece diameter (mm) 50–100

LW (mm) 1000

LZ (mm) from 600

Machine specific data: sheet metal workpieces

Workpiece diameterLower range (mm) 50–250

Intermediate range (mm) 100–300

Upper range (mm) 150–350

Stroke-stamping range (mm) up to 2502)


Instal lat ion, Operation, Service

Up to transfer to enduserCustomized installations are built and

set up at the GROB facility by a team

of specialists. Our experienced service

engineers participate in every prelimi-

nary acceptance procedure together

with the customer. Following delivery

to the customer’s plant, they ensure

seamless installation and handover of

the equipment.

Assembly shop Machine assembly

Operation and serviceGROB machines are renowned for their

durability under full production condi-

tions. Virtually all machines produced

since 1962 are still fully operational

across the globe.

ERNST GROB AG offers its customers

competent, prompt and comprehen-

sive repair and spare parts services

during the entire lifetime of the

machine.

The cold forming machine stands on

anti-vibration pads and can be installed

without the need for foundations.

Spare parts available to orderNo foundation required

16 © ERNST GROB AG • 12-NCT • 8–2011

12-NCT

ERNST GROB AGCold forming machinesSlotting machinesRohrgasse 9, P.O. Box 830CH-8708 MännedorfSwitzerland

Phone +41 44 922 77 00Fax +41 44 922 77 88

[email protected]

8–2011 • v1.3 • ks

Rapperswil

Männedorf

WinterthurAirportZürich-Kloten

A1

Chur

Bern/Basel

St. Gallen

Kreuzlingen

SchaffhausenSchaffhausen

Zürich

Horgen

Meilen OetwilA3

A3

A53

A1

A1

A7

A4

A51

ERNST GROB AGUster

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COLD FORMING MACHINE 12-NCT - Imponar - maszyny ... · PDF fileCold forming machines Slotting machines COLD FORMING MACHINE 12-NCT ERNST GROB AG