Grinding systems HG 204 HG 208
The HG series is designed for the cylindrical grinding of precision shaft-type components. This includes engine, transmission and hydraulics components as well as shafts used in electric motors, compressors and wind power generators. The HG series guarantees the flexibility needed to react quickly and efficiently to changes in workpiece.
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G R I N D I N G SY ST E M S
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Complete manufacturing systems from a single source.
The HG 204 and HG 208 grinders were
For example, in the machining of gear
designed for use in manufacturing
shafts, these shafts are pre-machined
systems. Customizing in this machine
on VTC vertical shaft turning machines
is very important. A wide range of
and finish-machined on HG grinders.
technology and production modules
Everything from a single source.
ensures that the machines can be
Complete manufacturing systems
customized for any manufacturing
from EMAG.
requirements. The integral loader allows for the machines to be linked up into a manufacturing system; and they can also be integrated into existing production lines.
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VTC 250 DUO
Complete-machining of a gear shaft: VTC 250 DUO: Cutting to length and centring, turning O/D and shoulders, milling the feather keygrooves HG 204:
Machine 1 Angular infeed grinding of O/D and shoulder on left side of workpiece
HG 204:
Machine 2 Angular infeed grinding of O/D and shoulder on right side of workpiece
HG 204, Machine 1
HG 204, Machine 2
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Perfectly ground – perfectly round.
The HG 204 and HG 208 provide
•• Corundum or CBN grinding wheels
solutions for the external and internal
•• B-axis with 2 grinding spindles
cylindrical grinding of medium to large component batches. The HG 204 accommodates shafts up to a grinding length of 400 mm. On the larger
for external grinding wheels of max. 500 mm dia •• B-axis with 1 grinding spindle for external grinding wheels of
machine, the HG 208, the limit is 800
max. 500 mm, plus 2 internal
mm. The modular design provides for a
grinding spindles
variety of machine configurations and therefore can provide the best possible adaptation to machining requirements:
•• B-axis with 3 grinding spindles for external grinding wheels of max. 400 mm dia •• work head with motor spindle or work head with belt-driven spindle
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•• tailstock slide
The arrangement of a number of
•• in-process measuring system
grinding wheels in B-axis allows for all
•• dressing attachment for CBN and
external cylindrical grinding operations
corundum grinding wheels •• touch-recognition for grinding and dressing
– for instance on a gear shaft – to be carried out in a single set-up. This ensures that the HG 208 can machine
•• automatic balancing unit
bearing seats, shoulders and grooves
•• workholding units
with the highest quality and flexibility,
•• various sizes of chucks and steadies
using the multiple-plunge grinding
•• automatic loading hatch for the
process.
connection of an automated workhandling system
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External and internal machining in a single set-up.
For hollow shafts and similar
The HG 208 CD machines hollow shafts
components when the bore and O/D
with a length of up to 400 mm. The
have to be precisely aligned, the
machine is equipped with two internal
workpieces are complete-machined –
and two external grinding spindles
i.e. ready to install – on the HG 208 CD
mounted on two compound slides that
Center Drive Grinder. Possible compo-
each feature a B-axis. This configuration
nents are the gear shafts used in
allows the internal grinding of bores,
transmission systems for modern
end faces and tapers.
passenger cars. The machine simultaneously grinds the hollow shafts internally and externally, in a single set-up. This method is considerably more precise than grinding the component on two separate machines.
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The two external grinding wheels can also be used to grind and groove diameters with adjoining flat shoulders. The machine may use traditional and/or CBN grinding technologies, depending on the machining requirements. To ensure that bearing seats are free of tool marks, a dressing attachment with profiled dressing roll is used. The work spindle is controlled by the state-of-theart, maintenance free direct drive technology. The O/D of the chuck is
Simultaneous machining of O/D and I/D in a single set-up
usually 160 mm.
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Simultaneous machining: HG 208 DW.
The four-axis HG 208 DW Simultaneous
The advantages from simultaneous
Grinder allows for two external
grinding on the HG 208 DW are:
grinding operations to be carried out
High component quality through
simultaneously on shaft-type
complete-machining in a single set-up,
components. This method is excellent
short cycle times, economic production
for workpiece families where the same
of component families and low capital
operations are carried out at varying
outlay per component.
distances to each other. It includes steering pinions, gear shafts, motor shafts and compressor shafts.
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The flexible grinding system with a high productivity rating: HG 208 DW
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Technical Data.
Capacity
HG 204
Workpiece diameter max.
mm
200
Workpiece length, max.
mm
650
CBN grinding wheel, max. dia.
mm
500
Corundum wheels, max. dia.
mm
610
in in
7.9
25.6
Grinding wheels in
19.7
in
24.0
X-axis travel
mm
360
Z-axis travel
mm
1,000
m/min
30 / 30
Feeds and speeds
X- and Z-axis speed
in in
14.2
39.4
ipm
1,181 / 1,181
Torque
Nm
95
Speed range Receptor
rpm KK
1 – 7,000 5
Torque
Nm
30
Speed range Receptor
rpm MT
1 – 1,000 4
Length
mm
3,410
Width
mm
2,400
Height
mm
2,490
Weight
kg
9,000
Work head with motor spindle ft-lb
70
Work head with belt-driven spindle ft-lb
22
Dimensions and weights
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The technical data refers to the basic machine only.
in in in
lb
134.3 94.5 98.0
19,841
Capacity
HG 208 HG 208 CD
HG 208 DW
Workpiece diameter max.
mm
200
100
200
Workpiece length, max.
mm
1,200*
400
600
CBN grinding wheel, max. dia.
mm
500
500
500
Corundum wheels, max. dia.
mm
610
610
600
in in
7.9
47.2*
3.9
15.7
7.9
23.6
Grinding wheels in
19.7
19.7
19.7
in
24.0
24.0
23.6
X-axis travel
mm
360
360
360
Z-axis travel
mm
1,600
600
800
m/min
30 / 30
30 / 30
30 / 30
Torque
Nm
Speed range Receptor
Feeds and speeds
X- and Z-axis speed
in in
14.2
63.0
ipm 1,181 / 1,181
14.2
23.6
14.2 31.5
1,181 / 1,181
1,181 / 1,181
95
–
95
rpm KK
1 – 7,000 5
– –
1 – 7,000 5
Torque
Nm
30
–
30
Speed range Receptor
rpm MT
1 – 1,000 4
– –
1 – 1,000 4
Torque
Nm
–
100
–
Speed range Chuck diameter
rpm mm
– –
1 – 500 160
– –
Length
mm
4,610
4,610
4,610
Width
mm
2,400
2,400
2,400
Height
mm
2,490
2,490
2,490
Weight
approx. kg
12,000
12,000
12,000
Work head with motor spindle ft-lb
70
–
70
Work head with belt-driven spindle ft-lb
22
–
22
Center drive ft-lb
in
–
–
74
6.3
–
–
Dimensions and weights in in in
approx. lb
181.5 94.5 98.0
26,455
181.5
94.5 98.0
26,455
181.5 94.5 98.0
26,455
* manual loading.
Subject to technical changes
13
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