DISKUS Face Grinding Machines

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DISKUS Face Grinding MachinesPioneering since 1911.

DISKUS WERKE SCHLEIFTECHNIK2 3

Machine Tools & Automation

Tools & Components

Production

International Sales & Service

DISKUS WERKE Schleiftechnik GMBH

Headquartered in Dietzenbach near Frankfurt (Main), Germany, DISKUS WERKE Schleiftechnik GmbH has been pioneering the face grinding and double face grinding technologies - still referred to as »DISKUS grinding by the industry« - since 1911.

DISKUS WERKE Schleiftechnik is a leading supplier of CNC instal-lations for the machining of flat and parallel surfaces. Assisted by the proprietary IONIC18 measuring and control unit and other means, the face grinding machines of DISKUS WERKE excel in top-level precision and high metal removal performance.

DISKUS designs tailored tools or the appropriate technological extensions in a joint effort with the other member companies of the DVS TECHNOLOGY GROUP.

Doppel-Planseiten-Schleifen

Planseiten-Schleifen

DVS TECHNOLOGY GROUP – Machine. Tool. Production.

The DVS TECHNOLOGY GROUP is made up of ten ma-chining companies focussing on the turning, gear cut-ting and grinding technologies. The DVS TECHNOLOGY GROUP has more than 1.200 employees worldwide and is one of the leading system suppliers for machines, tools and production solutions for the machining of vehicle powertrain components before and after hardening. The DVS TECHNOLOGY GROUP is comprised of the following divisions: DVS Machine Tools & Automation: Manufactures and sells high-precision machine tools, automation equipment and the associated services. DVS Tools & Components: Develops, manufactures and sells customised machine components, tools and abrasives. DVS Production: Operates DVS machine tools for the series production of components for passenger cars and commercial vehicles.

DISKUS Grinding.PRECISE. EFFICIENT. RELIABLE.


Custom face grinding machines equipped with powerful DISKUS grinding technologies built by committed and expe-rienced employees – these are the hallmarks of DISKUS WERKE Schleiftechnik. Further services provided by the face grinding pioneers from Dietzenbach are:

DISKUS GRINDING – PLANAR PRECISION

LARGE VARIETY OF WORKPIECES – FROM PUMP VANES TO CONNECTING RODS

DISKUS WERKE SCHLEIFTECHNIK – YOUR APPLICATION IN GOODS HANDS

DISKUS grinding is grinding with the side faces of the grinding tools. A method for the efficient production of plane-parallel workpieces such as end faces of components like connecting rods, piston rings or bearing rings, which these days have to fulfil maxi-mum requirements in modern en-gines. The outstanding features of the method are high plane parallelism, evenness and extraordinary surface quality.

These allow machining precision to be achieved even with large-scale grind-ing tasks and high volumes of mate-rial removed by cutting, which previ-ously made lapping necessary in many cases. Since the workpieces are usu-ally ground without clamping, even very thin workpieces can be machined without any deformation whatsoever.

Whether small or large, thin or volu-minous – there are hardly any limits to the machining spectrum of plane-parallel workpieces with DISKUS ma-chines. The mass production of flat parts for the rolling bearing and ball bearing industry or the face grinding

of engine components in medium-sized series can be implemented with DISKUS technologies just as efficient-ly as the machining of components made of non-metallic materials such as carbon, ceramic or glass.

Machines: Vertical and horizontal grinding wheel layout Rotatory, linear and oscillating component transport Specially developed measuring technology for

controlling and optimising the face grinding process

System solutions: Application-specific development of grinding tools

with sister company NAXOS-DISKUS Schleifmittelwerke Combined machining such as turning and face

grinding in collaboration with DVS sister companies Upstream and downstream peripherals such as

brushing stations from a single source

Services: Implementation of grinding trials and production of

sample parts in the DISKUS application centre Development of special applications in cooperative

partnerships Global service network with local technicians on site

1911 DISKUS WERKE founded in Frankfurt am Main by engineer Dr. Carl Krug (*11.7.1881 in Stuttgart, † 19.12.1967 in Frankfurt am Main).

1913 First DISKUS grinding machine

1948 First DISKUS grinding machine with analogue IONIC measuring control for automatic grinding wheel wear compensation.

1969 First grinding machine with machine frame with portal design.

1984 First CNC-controlled DISKUS grinding machine

2017 Presentation of the DFine machine series

2011 Centenary celebrations of DISKUS WERKE at the new Dietzenbach plant.

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rnFace grinding machines from DISKUS WERKE Schleiftechnik stand out through high capacities thanks to ex-tremely short cycle times. To make the very most of this potential, DISKUS automation solutions are customised to the process and developed in line with customer requirements. The spec-trum of automation options ranges from manual loading by hand to fully automatic loading by robot arm.

AUTOMATION – KEY TO HIGH PRODUCTIVITY


Compact and modern on the outside, individu-ally configurable on the inside, a precise match for your face grinding or brushing application – the DFine machine platform from DISKUS WERKE Schleiftechnik.

The broad-based DFine technology module has been designed for ma-chining a wide range of different plane-parallel components with a diameter of up to 250 mm. One-sided or two-sided face grinding, the grinding of shouldered surfaces or even brush machining – the DISKUS DFine can do it all. Even complex requirements such as the precise incorporation of defined step dimen-sion and evenness as well as the exact production of run-ning qualities, parallelism in the µm range and perpen-dicu-larity can be realised in a reliable process thanks to integrated DDG technology.

Diskus DFine – Face Grinding redefined.

THE TECHNOLOGYDISKUS DEFINED GRINDING – or DDG for short – describes the grinding tech-nology that makes the defined production of dimension, shape and position of shouldered and non-shouldered faces pos-sible on plane-parallel compo-nents for the first time. The offset and angle of inclination of the work-piece axes can be adjusted to produce a defined grinding pattern or a crowned or convex surface. Offsetting the axes to one another provides the choice be-tween aligned grinding or cross-grinding. Inclining the axes to one another results in concave or crowned faces.

Workpiece geometry

Single-spindle Multiple-spindle

Height [mm] 3-80 3-80

Diameter [mm] 100 (-8), 170 (-4), 250 (-2), 10-170(Number of tool spindles)

Ø Grinding wheel [mm] 20-100/310-400

Dimensions/weight

H/W/D [mm] 2.350/1.480/1.970

Total net weight without automation [kg] 3.500

One- and two-sided face grinding

Max. workpiece Ø 250 mm

Number of workpieces 2

Workpiece carrierfloating or clamped

Number of tool spindles

1

1-2Max. workpiece Ø 170 mm




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Face grinding of shouldered surfaces and brushing

Max. workpiece Ø 170 mm




4

B 1-4Max. workpiece Ø 170 mm


Workpiece carrier clamped


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Through-feeding face grinding with straight workpiece feeding

THROUGH-FEED GRINDING Especially suitable for large batch sizes

Offers a high degree of application flexibility

THROUGH-FEEDING PLUNGE-CUT GRINDING Suitable for medium batch sizes

Extremely flexible in application

Ideal for high allowances

CONTINUAL THROUGH-FEEDING PLUNGE-CUT GRINDING Medium to large batch sizes

Flexible for sensitive workpieces

Suitable for high allowances

PLUNGE-CUT GRINDING Small to medium batch sizes

Extremely flexible in application

Suitable for high allowances and high quality requirements

With the DDS XR range, the workpiec-es are conveyed on a transport plate through the grinding gap. This method allows workpieces with widely differ-ing geometries to be ground coplanar. Depending on the machine equip-ment, there are four different grinding methods available for machining. This makes the DDS XR range ideal for ma-chining a wide workpiece spectrum flexibly, economically and in top quali-ty. Thanks to the compact design and only one loading side, the grinding ma-chine is easy to automate and also suit-able for the manual loading of smaller batch sizes.

The technology of through-feeding face grinding with straight workpiece feeding was developed especially for the cost-efficient machining of large quantities of flat workpieces. Thanks to the straight workpiece supply, a very high material removal rate and very short cycle times can be achieved. This design can be used for machining workpieces with a width of up to 500 mm.

DDS XLThrough-feeding grinding for large quantities

Machine DDS 457 XR/E

DDS 600 XR/E DDS 750 XR/E

Workpiece geometry

Height/width [mm] 0,8-80/8-0 0,8-80/8-250 1-80/8-405

Ø Grinding wheel [mm] 457 600 750

Dimensions/weight

H/W/D [mm] 3.100/3.300/2.800 3.300/3.500/3.000 3.300/3.500/3.000

Total net weight without automation [kg]

10.000 14.000 14.000Machine DDS 600 XL DDS 900 PL

Workpiece geometry

Height/width [mm] 0,8-80/15-210 2-80/30-500

Ø Grinding wheel [mm] 600 900

Dimensions/weight

H/W/D [mm] 3.000/2.600/3.300 3.600/4.400/4.700


11.000 21.000

DDS XRRotating feed for high requirements

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DISKUS DDW XRMaximum precision for large quantities

DISKUS DDW XLThrough-feeding grinding for mass production

If high quality requirements have to be met for large batch sizes, there is no alternative to a DISKUS DDW XR.

A transport plate guides the work-pieces into the grinding gap, where they are machined to the re-quired dimension by rotating movements on both faces.

The horizontal alignment of the grind-ing wheels and the extremely rigid machine bed are the basis for excel-lent machining results with high plane-parallelism.

The DISKUS DDW XL was developed for mass and class, being able to pro-duce extraordinarily high quantities at consistent surface quality in minimum cycle time.

Different workpieces can be machined at one and the same machine. This flexibility is particularly useful for ball and rolling element manufacturers.

THROUGH-FEEDING OR PLUNGE-CUT GRINDING WITH TRANSPORT PLATE For high output and medium allowance

Especially for non-shouldered connecting rods or pre-shouldered shouldered connecting rods

THROUGH-FEEDING OR PLUNGE-CUT GRINDING WITH CLAMPED COMPONENTS For high output with medium allowance

Clamped grinding with high perpendicularity requirements

Especially for pump vanes or rolling elements

Machine DDW 400 XR DDW 600 XR DDW 900 XR

Workpiece geometry

Height/width [mm] 0,8-80/8-205 0,8-80/8-250 1-80/8-405

Ø Grinding wheel [mm] 400 600 900

Dimensions/weight

H/W/D [mm] 3.100/3.300/2.800 3.300/3.500/3.000 3.300/3.500/3.000


8.000 9.000 18.000

Machine DDW 660 XL DDW 760 XL

Workpiece geometry

Height/width [mm] 0,8-80/8-250 1-80/8-405


Dimensions/weight

H/W/D [mm] 4.300/2.100/3.000 3.300/3.500/3.000


10.000 10.000


DISKUS DHS Machine engine blocks more efficiently and precisely

Engine blocks (cylinder crankcases) are made of aluminium or cast iron, in rare applications a magnesium-alu-minium compound structure is used. The piston does not always run di-rectly in the engine block material, however, since this material does not fulfil higher tribological requirements. The re-placement of pistons and cyl-inders as the main wearing parts is also significantly more complicated. For this reason, a cylinder liner is often

fitted. The inner surface of this liner is generally drilled after fitting (in the case of “wet” cylinder liners before fitting) and then honed to precision. This guarantees the geometrical shape and surface roughness required by the manu facturer to meet the technical and ecological characteris-tics required. Cast iron or aluminium alloys have proved their worth as ma-terials for cylinder liners.

Maschine DHS XOZ

Workpiece geometry

Height/width [mm] 5-240

Ø Grinding wheel [mm] 457

Dimensions/weight

H/W/D [mm] 3.200/3.000/2.250


10.000

Machine DDW 900 DDW 1060

Workpiece geometry

Height/width [mm] 20-850/20-240 120-1000/20-240


Dimensions/weight

H/W/D [mm] 3.200/5.400/5.700 3.400/5.400/5.800


18.000 22.000

DISKUS DDW XOZOscillation for precision

Specially designed for very solid com-ponents whose weight does not al-low them to be supplied to the ma-chine by transport plate, as well as for components with machining sur-faces on different levels, such the shouldered connecting rod installed in the engine, the DDW XOZ excels with top marks for precision. The

Plunge-cut grinding withoscillation movement

components are supplied to the work chamber using a slide which creates an oscillation movement during the plunge-cutting of the grinding wheels. During machining the work-pieces rotate non-clamped between the grinding tools.


Local service for international markets

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International DVS locations

International DVS representatives

Repairs

Maintenance

Remote diagnosis

Spare parts supply

Training

Production support

Retrofit

To make your machine life cycle as long as possible, we offer the following services:

DISKUS IONIC18The process under control for 100% safety

Process safety and consistent machining quality form the basis for a zero-error strategy during grinding. To achieve this, DISKUS WERKE Schleiftechnik has developed the process controller IONIC18 which communicate with the machine control. In the case of tolerance deviations at the workpiece caused by grinding wheel wear, for example, the IONIC18 adapts the distance between the grinding wheels during operation, thus guaranteeing consistent machining results.

DVS UGrindCustomised hard-fine machining for shafts and chuck parts

Job order production and shops within larger mechanical engi-neering companies often face one and the same challenge: How can the metal-cutting machining of metal com-ponents be made more efficient even for small batch sizes? The focus is particularly on reducing the work required be-tween initial clamping of

the workpiece and achievement of the final dimensions.

The UGrind was specially developed for the hard finishing of small series of shafts and chucking components. Thanks to the smart operating inter-face, combined processes and high thermal and dynamic stability, overall machining time can be reduced by more than 50% with the UGrind.From the outset, the machine was de-veloped with the objective of achiev-ing optimised reproducibility taking the requirements of shop fabrication into account.

Radial grinding

Cylindrical grinding Face grinding

Cone grinding

Internal grinding

Internal turning

Groove turningFace turningExternal cylindrical turning

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Mitglieder der DVS TECHNOLOGY GROUPMembers of the DVS TECHNOLOGY GROUP

DVS MACHINE TOOLS & AUTOMATION

DVS TOOLS & COMPONENTS

DVS PRODUCTION

DVS INTERNATIONAL SALES & SERVICE

BUDERUS Schleiftechnik GmbH | www.buderus-schleiftechnik.deInnenrundschleifen – Außenrundschleifen – Gewindeschleifen – Bohrungshonen – HartdrehenI.D. grinding – O.D. grinding – Thread grinding – Bore honing – Hard turning

DISKUS WERKE Schleiftechnik GmbH | www.diskus-werke.dePlanseiten-Schleifen – Doppel-Planseiten-Schleifen – SonderbearbeitungFace grinding – Double face grinding – Special machining

DVS Universal Grinding GmbH | www.dvs-universal-grinding.de Kombinierte Hartfeinbearbeitung für Klein- und MittelserienCombined Hardfine Machining for small and medium size batches

PITTLER T&S GmbH | www.pittler.deVertikal-Drehbearbeitungszentren & Pick-up-Systeme – VerzahnungszentrenVertical turning centers and Pick-up systems – Gear cutting centers

PRÄWEMA Antriebstechnik GmbH | www.praewema.deVerzahnungshonen/-schleifen – Verzahnungsfräsen – Anspitz-/HinterlegungsfräsenInternal and External Gear honing – Gear grinding – Hobbing/Fly-cutting – Chamfering

WMS Werkzeugmaschinenbau Sinsheim GmbH | www.wms-sinsheim.deService-Dienstleistungen – Generalüberholungen – Reparatur von BaugruppenMaintenance – Machine Retrofit – Repairs

WMZ Werkzeugmaschinenbau Ziegenhain GmbH | www.wmz-gmbh.deDreh- & Kombinationsbearbeitung wellenförmiger Bauteile – MotorspindelnTurning & Combined machining of shafts – Motor spindles

DVS TOOLING GmbH | www.dvs-tooling.de Werkzeuglösungen und Technologiesupport für das PRÄWEMA VerzahnungshonenTool solutions and technology support for PRÄWEMA gear honing

NAXOS-DISKUS Schleifmittelwerke GmbH | www.naxos-diskus.deKonventionelle Schleifwerkzeuge – CBN & DiamantwerkzeugeConventional grinding tools – CBN & Diamond tools

DVS Production GmbH | www.dvs-production.deDVS Technologien in der Serienfertigung für PKW-KomponentenDVS Technologies in mass production for passenger car components

DVS Production South GmbH | www.dvs-production-south.deDVS Technologien in der Serienfertigung für Nutzfahrzeug-KomponentenDVS Technologies in mass production for commercial vehicle components

DVS Technology America, Inc. | www.dvs-technology.com DVS Sales & Service in USA, Canada & Mexico

DVS Technology (Shenyang) Co., Ltd. | www.dvs-technology.comDVS Sales & Service in China

DVS Technology Europe GmbH | www.dvs-technology.comDVS Sales & Service in Europe

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DISKUS WERKESchleiftechnik GmbHJohannes-Gutenberg-Straße 163128 DietzenbachGermany

www.dvs-technology.com

Tel +49 (0) 6074.48402 - 0 Fax +49 (0) 6074.48402 - 36Mail [email protected]

Documents

DISKUS Face Grinding Machines