superfinish for the antifriction bearing industry - · pdf filemodular concepts of the supfina...

Superfinish for theantifriction bearing industry

Linearoscillator

Rotaryoscillator

Superfinishing units

Handling

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Cup wheelspindle

Tape unit

Fullyautomatic

Semi-automatic

Manual RobotGantry

RollerShoes

Hydro-static

Supportrollers

Motorspindle

Friction

Supportrollers

Modular solutions

Modular solutions

The tasks defined by our customers are multifaceted – themodular concepts of the Supfina machines for the antifrictionbearing industry always offer the suitable solution.

Based on the given production environment and the incomingcondition, we combine the modular assemblies

• Superfinishing units • Centering systems • Workpiece drives • Handling systems

to a powerful Superfinishing machine.

Here, we rely on components which unite our decades of experience and the latest state of technology. Our modularsolutions guarantee fast return on investment, today andin the future.

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Superfinish improves the functionalityand the life of bearing componentsIncreasing quality demands on functionality,safe operation, service life, efficiency and redu-ced noise require a continuous improve ment ofmanufacturing technology. Here Superfinishingplays a crucial roll as the last and decisive stepfor the final product quality.

Improvement of bearing lubricationSuperfinish generates constant surface characteristics in a very consistent way. The resulting surface structure (plateau) with a high material ratio and optimum lubricationproperties will be maintained during the entireservice life of the bearing. The cross-hatch pat-tern generated by the Superfinishing processleads to a favorable distribution of the lubricant.Thanks to the 2-step process, plateaus with a large bearing ratio are generated while intersecting channels are maintained for theoil retention.

Improvement of the workpiece geometryIn Superfinishing, the contact between the tooland the workpiece is always defined by an arearather than a line or point as in grinding or turning.Consequently, roundness errors, waviness,form and profile are improved considerably.

Optimization of the workpiece boundary layerDuring grinding and precision turning, structuralchanges of the material can be triggered due tohigh temperatures and cutting forces. The result -ing soft skin has a negative effect on functionand wear of bearing elements. Superfinishinghowever removes the damaged surface layercompletely so that the sound, indelible materialwill become the supporting surface. At the sametime, a compressive stress is induced to theupper layer which prevents pitting and crackpropagation.

High profitabilityThe implementation of Superfinishing canmake expensive hard machining processes likeprecision turning, precision grinding or lappingobsolete. In addition to that, Supfina technologiesare able to finish fine- or hard-turned surfaces,eliminating the need for grinding.

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SuperfinishMachining of roller bearingsinner and outer rings

725Type:ABC

• Machining of any type of profile like e.g. con-cave, convex, straight, spherical and logarith-mic with the patented NC-controlled superim-posed stroke

• Infinitely adjustable oscillation frequency• NC-controlled pressure rollers• NC-controlled centering device• Automatic or manual loading and unloading• Control with digital drives for linear and rotarymotions

• One- or multi-step operation method with 2/3way stone indexing device

• Vertical spindles and actively controlled work-piece handling to avoid damages

• Optional flange, shoulder andIR bore operation

• Optional IR flange and OR outer diameterfinishing with tape


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725

Workpiece width:8 – 100mm20 – 200mm50 - 400mm

Workpiece∅:50 – 320mm100 – 650mm600 – 1200mm

constant

spee

dzo

nesp

eed

zone

track

track

finishing time

stock removal

Superfinishstone

Superfinishstone motion

Overlay speed

variable

finishing timestock removal

Comparison of profile error

before Superfinishafter Superfinish

2,00

1,80

1,60

1,40

1,20

1,00

0,80

0,60

0,40

0,20

0,00

Prof

ileer

ror[

µm]

Part number1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

31.268 µm

Ground Peak To Valley = 1.889 µm1.268 µm

-0.805 µm

31.268 µm

Peak To Valley = 0.658 µm1.268 µm

-0.805 µm

Superfinished

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The Supfina 725 combines the well-establishedvertical arrangement of the workpiece spindleswith Superfinishing units optimized for the variousmachining operations around cylindrical andtaper roller bearings. The ingenious design alsosupports Superfinishing of spherical rollerbearings.

Tape finishing units for flange or outer diameteras well as cup wheel spindles for the flange ope-ration can be combined with powerful linearoscillator systems for raceway finishing.

Regarding the Superfinishing operation, theSupfina 725 is the perfect choice – this alsoapplies to the auxiliary functions centering,workpiece drive as well as loading/unloading.In every case, precise and at the same flexiblemodules are available which can be adjusted toa new workpiece quickly while requiring only aminimum of type dependent tooling. Through theintelligent use of NC-controlled adjusting axes,set-up times of less than 15minutes are achieved.

With the patented

Supfina NC super-

imposed stroke, race-

ways with any given

profile (e.g. crowning

of 15 µm) can be

operated.

Tapered roller bearing outer ring, double row

Our system features� your benefit

NC-controlled Superfinishing units

�Adjustment of the oscillation frequencyoptimized for the respective cycle

�Patented superimposed stroke forSuperfinishing of any profile type

Stone indexing device fortwo- or three-step process

�Generation of optimizedbearing surface quality

�Extended tool live

One or optionally two operating stationswith servo driven spindles

� Improved torque and speed characteristics

�Reduced cycle time

�Additional productivity throughsecond station

Flexible, infinitely adjustable centering systems

�Fast setting process

�Range tooling with only few exchange partsLarge working range and versatilityfor different workpiece types

�Suitability for small andmedium size batches

�Built-in capability to cope with future changesin your product range

Ring outer∅ : 180mmRaceway∅ : 150mmRaceway width approx.: 42mm eachRing width: 150mm

Material: hardenedbearing steel

Roughness Ra: 0,07µmRoundness: < 1,5µm

725

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SuperfinishMachining of ball bearingsinner and outer rings

727


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• NC controlled rotary oscillator toproduce the desired surface (plateau)

• NC controlled, infinitely adjustableoscillating angle/amplitude optimizedfor the respective cycle

• Automatic infinitely adjustable contact angle• Infinite adjustment of oscillation frequency• NC-controlled pressure rollers• NC-controlled roller centering device• NC controlled hydrostaticmandrelsfor bore centering

• Automatic ormanual loading and unloading• Control with digital drives for linearand rotarymotions

• One- ormulti-step operationmethodwith 2way stone indexing device

• Vertical spindles and actively controlledworkpiece handling to avoid damages

• Optional IR flange andORouter diameterfinishingwith tape

727Type:AB

Workpiece width:8 – 100mm20 – 200mm

Workpiece∅:50 – 320mm100 – 650mm

Contactangle

Centre ofoscillation

IR OR

IR OR

IR OR

IR OR

Circumferential waviness before and after SUPERFINISH

5 10 15 20 25 30 35 40norm frequency

ampl

itude

[µm

] harmonics before Superfinishharmonics after Superfinish

0,60

0,50

0,40

0,30

0,20

0,10

0,00

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The versatile concept is

designed for IR and OR

of various bearing types.



�Fast setting through automaticcontact angle adjustment

�Optimumquality due to automatic adjustmentof the oscillation frequency and amplitude,optimized for the respective cycle

Stone indexing device for 2-step process

�Generation of optimized surfaces with highbearing ratio and good lubrication


One or optionally two operating stationswith servo driven spindles

� Improved torque and speedcharacteristics


�Additional productivity availablethrough second station

Flexible, infinitely adjustablecentering systems





Deep groove and angular contact ball bearingsare the domain of the Supfina 727. This machinecomes with vertical workpiece spindles andSuperfinishing units which have been tailoredto the demands of the application. Due tothe automatic contact angle adjustment, theSupfina 727 features multi-step Superfinishingof double row angular contact bearings andgothic profiles.

Tape finishing units for grinding shoe markremoval as well as cup wheel spindles for theflange operation can be added to the powerfulrotary oscillator raceway finishing systems.

The Supfina 727 is the optimum equipmentfor the requirements of today and tomorrow, alsowhen it comes to the auxiliary functions centering,workpiece drive and loading/unloading. Highlyaccurate and at the same flexible modules areavailable which can be adjusted to a newworkpiece quickly while requiring only aminimum of type dependent tooling. Throughthe intelligent use of NC-controlled adjustingaxes, set-up times of less than 15minutesare achieved. Themodular structure andhigh flexibility of themachine allow for theSuperfinishing operation of different racewaylocations and geometries in a single clamping.

Angular contact ball bearing inner ring

Ring∅ approx.: 220mmRaceway∅ approx.: 205mmRaceway radius approx. 21mmRing width: 50mm

Material: hardenedbearing steel

Roughness Ra: 0,03µmRoundness: <1,0µmProfile error: <1,2µm

727

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SuperfinishMachining of roller bearingsinner and outer rings

705


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715


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The Supfina Race 705 and Race 715 are desi-gned for the Superfinishing operationon raceways of roller bearing inner and outerrings up to 160mm in diameter. The track recordand benefits of the well established Supfina 725for larger ring diameters havebeen converted into this newly developedmachine concept.

The Race 705 and Race 715 cater to differentdiameter ranges. While the Supfina Race 705can machine rings of up to 90mm diameter, theRace 715 covers a range of up to 160mm.

Workpieces:• Cylindrical roller bearings• Tapered roller bearings• Needle roller bearings

Race 705Working stations: 2Workpiece diameters: 28 – 90mmWorkpiece width: up to 45mmTaper angle: 0 – 30°

Race 715Working stations: 2Workpiece diameters: 62 – 160mmWorkpiece width: up to 65mmTaper angle: 0 – 30°

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• 2 operating stations• 2 Superfinishing units• Vertical workpiece spindles• NC positioning of the Superfinishing units• NC-controlled spindle drives• Variable centering systems• Automatic loading and unloading• Multi-step process with automatic sequence• State-of-the-art control system• Integrated control cabinet• Multi-range tooling• High productivity due tominimized loading times

• Low tooling cost• Set-up times <15minutes• Operator friendly HMI design• Optimum accessibility• Small footprint• Swivel unit for tapered roller bearing operation• Superimposed stroke forcrowned / logarithmic raceways

• Optional attachment for flange operation

The modular structure of the machinessupports fast and easy customization.Depending on the combination of availableoptions, set-up times of < 15 minutes can beachieved. Setting up the machine for a newpart is accomplished with just a few, easilymanageable tasks.

Hardly any workpiece-dependent toolingis required, a typical feature of all Supfinamachines. The horizontally arranged feedingsystem supplies the parts to the vertical spindles.In combination with the actively controlledworkpiece handling, damages to the parts andwear on themachine are avoided.

The central part handling grips, lifts andtransports 3 bearing rings simultaneously.Compared to conventional systems, theloading time is reduced by more than 50%.

The two operating stations are located atthe front side of the machine and are readilyaccessible. Theworkflow can be easily monitoredby the operator. State-of-the-art electroniccontrols support themachine functions duringsetting, manual and automatic mode.To guarantee reproducible Superfinishingresults and consistent quality parameters,the machine offers extensive memory forthe technological know-how.

Taper roller bearing inner ring with simultaneous flange operation

Ring outer∅ approx.: 140mmRaceway∅ approx.: 120mmRaceway width approx.: 38mmRing width: 50mmMaterial: hardened

bearing steel

Roughness Ra raceway: < 0,08 µmRoughness Ra flange: < 0,08 µmRoundness: < 1,5 µm

Race 705715

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SuperfinishMachining of ball bearing racewaysinner and outer rings

707


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717


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The innovative Supfina Race 707 and Race 717are setting new standards in Superfinishing ballbearing inner and outer rings. Both have beenoptimized to meet the highest productivitydemands, while achieving best quality results,fast set-up times and superior reliability.

Valuable input from our customers, combinedwith extensive experience of the Supfina 727machine types for the large diameter range, arethe cornerstones of this newly developedmachine concept.

The Race 707 and Race 717 cater to differentdiameter ranges. While the Supfina Race 707can machine rings of up to 90mm diameter, theRace 717 covers a range of up to 160mm.

Workpieces:• Deep groove ball bearing• Angular contact ball bearing• Spherical roller bearing• Wheel bearing

Race 707Working stations: 2Workpiece diameters: 28 – 90mmWorkpiece width: up to 45mmContact angle: 0 – 55°

Race 717Working stations: 2Workpiece diameters: 62 – 160mmWorkpiece width: up to 65mmContact angle: 0 – 55°

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Raceway

Superfinishing of

an inner ring on a

Supfina Race.

• 2 operating stations• 2 Superfinishing units• Vertical workpiece spindles• NC positioning of the Superfinishing units• NC-controlled spindle drives• Variable centering systems• Automatic loading and unloading• Multi-step process with automatic sequence• State-of-the-art control system• Integrated control cabinet• Multi-range tooling

• High productivity due tominimized loading times

• Low tooling cost• Set-up times < 15minutes• Operator friendly HMI design• Optimum accessibility• Small footprint• Swivel unit for angular contactball bearing operation

• Optional attachment forOR outer diameter finishing

The optimummodule for every task:In the highly productive Supfina Race 707and Race 717 the highlights are the rotary oscil-lators with unmatched efficiency and a very fastloading system.

At the same time, setting the machine is easy,changing to another workpiece takes less than15 minutes.

Versatile multi-range tooling makes the machineflexible while limiting additional expenses,making the Supfina Race a very reasonableinvestment.

Supfina Race 707 and Race 717 are fully inte-grated machines designed for simple transpor-tation by crane or fork lift.

Installation and starting-up are fast, making themachine ready for operation in just a few hours.

The integrated part handling system offerstwo external loading /unloading positions forinterfacing with the production part flow viaconveyors, robots or gantry loaders.

Excellent accessibility and state-of-the-art con-trols are contributing to the operator friendlinessof the concept. Via the control panel with LCDcolor display, setting, manual and automaticmodes are monitored. The Superfinishing know-how is stored in the vast technology memory.This guarantees reproducible Superfinishingresults and consistent quality parameters at alltimes.

Angular contact ball bearing inner ring, double row

Ring outer∅ approx.: 64mmRing width: 36mmMaterial: hardened

bearing steel

Roughness Ra: < 0,04µmRoundness: < 1,2µmProfile error: < 1,2µm

Race 707717

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SuperfinishMachining of ball bearing and roller bearinginner and outer rings

• NC controlled rotary oscillator to producethe desired surface (plateau)

• NC controlled, infinitely adjustableoscillating angle /amplitude optimized forthe respective cycle

• Automatic infinitely adjustable contact angle

725-727


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• NC-controlled linear oscillator formachining of any type of profile like e.g. con-cave, convex, straight, spherical and logarith-mic with the patented NC-controlled superim-posed stroke

• Infinitely adjustable oscillation frequency• NC-controlled pressure rollers• NC-controlled roller centering device• NC controlled hydrostatic mandrelsfor bore centering

• Manual or optional automatic loadingand unloading

• Control with digital drives for linearand rotary motions

• One- or multi-step operation method with 2/3way stone indexing device

• Vertical spindles and actively controlled work-piece handling to avoid damages

• Optional flange, shoulder andIR bore operation

• Optional IR flange and OR outer diameterfinishing with tape

725-727Type:ABC

Workpiece width:8 – 100mm20 – 200mm50 - 400mm

Workpiece∅:50 – 320mm100 – 650mm600 – 1200mm

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

abbot curve grinding

abbot curve plateau II

Mr1 grinding

Mr2 grinding

gauged length lm material ratio Mr

abbot curve plateau I

Rpkgrinding

Rkgrinding

Rvkgrinding

Rpk Plat. IRk Plat. II

RVk Plat. II

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The Supfina 725-727 is designed to achieveconsistent top quality and highest flexibility inSuperfinishing Aeroengine bearings, prototypesor other small production batches. Unmatchedversatility is based on the combination of upto four different Superfinishing units in onemachine.

The powerful rotary and linear oscillatorsystems for the raceway finishing operationcan be complemented with tape finishing unitsfor outer diameters and flanges as well as cupwheel spindles for lip and thrust face operations.

Clamping and centering systems as wellas the workpiece drive are just as flexible.Supfina relies on state-of-the-art modulesthat have been optimized over decades andthat can be adjusted to a new workpiecequickly while requiring only a minimum oftype dependent tooling. Due to the intelligentdesign, set-up times of less than 20 minutesare achieved, supported by NC controlledadjusting axes.


NC-controlled rotary and linear oscillatorSuperfinishing units

�Highest possible flexibility to machineany given raceway geometry

�Reproducible top quality also insmall batch production

Stone indexing device fortwo- or three-step process



Machine can be upgraded with one or two auxi-liary Superfinishing units

�Tape unit for OR outer diameter

�Tape unit for tapered roller bearing IR lip

�Cup wheel unit for cylindricalroller bearing flange

�Cup wheel unit for spherical rollerthrust bearing flange

Flexible, infinitely adjustable centering systems





725-727

Plateau finishing: Comparison of surface properties (Abbot curve) of grinding and Superfinish results

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SuperfinishMachining of cylindrical rollers and tapered rollers

470+478


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• Continuous Superfinishing process forhigh volume production of rollers

• Dynamically balanced pneumatic oscillator• Vertical Superfinishing unit adjustment forstone and roller change

• Optional superimposed stroke

• Connection of up to 14 stone guideswith fast change system

• Infinitely adjustable and individuallycontrollable stone pressure

• Stone wear indication supportingfully automatic operation

• Infinitely adjustable transport rollers,optionally automatic

• Transport rollers with an effectivelength of 900 and 1100mm

• Profiled transport rollers available togenerate specific workpiece geometries

• Automatic workpiece feed

470Workpiece diameter: 6 – 100mmWorkpiece length: up to 250mm

478Workpiece diameter: 5 – 24mmWorkpiece length: up to 65mm

Cylinder rollers


Powerful pneumatic oscillator carryingup to 14 stone guides

�High production output throughlarge stock removal

�Long service life and low wear

�No undesired vibrations

�Short set-up time due to quick changesystems and automatic vertical adjustment

Flexible transport roller adjustment

�Workpieces with varying dimensionscan bemachined

�The setting time can be further reduced byutilizing the optional NC adjustment

Transport rollers with an effective length ofup to 1100mmwith optimized profiles

� Increased productivity with productionspeeds to 9m/min and beyond

�Generation of fully crowned,cylindrical / convex and logarithmicworkpieces

Safety and monitoring devices

� In case of stone wear, the machinestops automatically to avoid damage

�Parts with incorrect orientation ordimension can not enter the machine

�Operator supervision required isreduced to a minimum

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Superfinishing operation

of cylindrical rollers

The Supfina 470 and Supfina 478 are thesprinters among the Superfinishingmachines.Dependingon theworkpiecedimensions, hundredsof rollers perminute canbemachined in the center-less through-feed process. At the same time, thehighest demands regarding geometrical andsurface quality aremet.

Modular options available are designed fordifferent levels of automation.

Through the intelligent use of NC-controlledadjusting axes, very short set-up times areachievable. Transport rollers with an effectivelength of up to 1100mmand specific profiledesigns open up new potentials.

On the raceway of antifriction bearing rollers,the centerless through-feed Superfinishingprocess generates defined crowned orlogarithmic profiles.

Roller∅ approx.: 13mmLength approx.: 18mmRoughness Ra: 0,04µmProduction rate: 400 parts per min.

470478

Roundness before/after Superfinishing (filter 1-15) Roundness before/after Superfinishing (filter 15-500)

ampl

itude

[µm

]

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,0

0,5

1,0

1,5

2,0

2,5

Roundness before SuperfinishingRoundness after Superfinishing

Rpk = reduzierte Spitzenhöhe R

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The two-step Superfinishing process of theSupfina 778 generates plateau surfaces with adefined cross-hatch pattern, an optimum profileand roundness as well as a high bearing ratio.

The integrated loading system is very versatileand can be adjusted to different workpiecedimensions quickly. Through the intelligent useof NC-controlled adjusting axes, set-up times ofless than 20 minutes are achieved.

• Two or four operating stations• Two or four Superfinishing units• Workpiece drive and centering byhorizontally arranged support rollers

• NC-controlled adjustment• Digital drives for tools and workpiece• Integrated loading and unloading,NC controlled

• Two-step Superfinishing process• State-of-the-art control system• Multi-range tooling• Set-up times < 20minutes

SuperfinishMachining of bearing rollers

778


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778Type:AB

Workpiece length:12 – 60mm50 – 200mm

Workpiece∅:14 – 50mm50 – 120mm

The Supfina 778 marks the industry standard forthe Superfinishing of bearing rollers.In the most recent generation of roller bearings,the improvements in performance and permissibleload are based on the consistent reproduction ofexactly defined surface parameters. Here, thehighly productive Supfina 778 plays a crucialroll. The machine's dynamically balancedSuperfinishing units are designed for highfrequencies and amplitudes. The resultinglarge stock removal rates lead to shortmachining times.

Rk = Kernrautiefe

Rvk = Riefentiefe (Ölrückhaltevolumen)

Measuring range: 1,000mmMeasuring interval: 0,10° 15–500

1,00µm

1,00µm

1,00µm

1,00µm

Measuring range: 1,000mmMeasuring interval: 0,10° 15–500

1,00µm

1,00µm

1,00µm

1,00µm

Spherical rollers

Spherical rollers∅ approx.: 20mmRoundness: 0,41µmRoughness Ra: 0,038µm

Rpk: 0,049µmStock removal: 6µmCycle time: 3,5Sek.

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Operation of

asymmetrical

spherical rollers

Plateau-like functional

surface to DIN 4776



�Fast setting through automatic adjustmentof the oscillator

�Optimum quality due to automatic adjustmentof the oscillation frequency, optimized for therespective cycle

�Patented superimposed strokefor Superfinishing of any given profileon parts >∅ 50mm

Two-step Superfinishing process



Two or optionally fouroperating stations withdigital drives

� Improved torque and speed characteristics


�Additional productivityFlexible, infinitely adjustable support rollers



�Suitability for small, medium andlarge size batches

�Optimized for spherical, cylindricaland tapered rollers

778

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SuperfinishService

Service is one of the key foundations of ourcorporate philosophy. We consult our customersextensively and engineer in close collaborationthe best-possible solution for their individualsurface design.

Our pre-sales-service with process consultingand prototype production is a matter of coursefor us as well as our after sales service withmaintenance, repairs and rebuilds of machinesand the supply of custom-made perishableSuperfinishing tooling.

Our modular machine concepts with itsoutstanding versatility stand for easy and quickchange-over in case of multiple workpiecesand/ or different surface parameters.

These flexible concepts allow our customersto quickly respond to new demands from theircustomers which can be of an essentialcompetitive advantage for them.

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We offer continuous development for newprocess technologies to meet increasing qualityrequirements with regard to complex geometriesand newmaterial specifications.

The Superfinishing of prototypes or smallproduction runs closes the loop in our processdevelopment chain.

Process Development

We thoroughly analyse the requirementsof our customers to demonstrate solutions andalternatives with focus on cost-effectiveprocess integration.

Application consulting

We offer training either on customer's flooror at Supfina. We have customized programsfor operators, maintenance personnel orsupervisors.

The contents of our outstanding manualsserve as baseline for our theoretical and practicaltraining classes.

Training

We offer production support during start-up orrunning production as well as fast process devel-opment for changed production requirements(cycle time, tolerance, stock removal)

Production Support

With our 24h-service support a Supfina technicianwill be at your site within 24 hours, even duringweek- ends or holidays. With our Supfina OnlineSupport via Telefone, Online and Videocamerawe

are able to circle in potential problems so that theservice trip can be better prepared or the problemcan be resolved without being on-site.

24h-Service

The majority of our standard spare parts andconsumables can be shipped directly out of ourextensive part inventory within 24 hours. With thedelivery of every machine we will supply you with

a first set of high quality tools designedfor your application to ensure a smooth andsuccessful start-up.

Consumables and Spare parts

With our three-step service concept scheduledrepairs and preventative maintenance are easilycarried out. Minimizing downtimes, increasingthe machine reliability and an extension of the

lifetime of the main wear components will resultsin a production tool you can count on.

Maintenance

Supfina Grieshaber GmbH & Co. KG

Schmelzegrün 7 · 77709 Wolfach / Germany

Tel. +49 (0)78 34 866-0 · Fax +49 (0)78 34 866-200

www.supfina.com · [email protected]

Supfina Machine Company, Inc.

181 Circuit Drive · N. Kingstown, RI 02852 / USA

Tel. +1 401-294-66 00 · Fax +1 401-294-62 62


Supfina Grieshaber GmbH & Co. KG

Bejing representative Office

DiYang Tower 1202B · Chaoyang District Bejing

100027 P.R. China

Tel. +86-10-84536-669 · Fax +86-10-84536-670


superfinish for the antifriction bearing industry - · pdf filemodular concepts of the supfina...

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