PG4 - SCD/MCD Tool Production

CNC Planetary Grinding Machine
Tooling Production

PG4

Ultra-high precision, CNC grinding machine for single crystal diamond tool manufacture. The new PG4 enables the automated production of ultrahigh precision diamond tools.

Launched in 2016, the PG4 is an automatic, ultra-high precision grinding machine designed to meet the most sophisticated of demands from toolmakers working with natural or synthetic single crystal diamond (SCD), manufactured by either high pressure high temperature (HPHT) or chemical vapour deposition (CVD).

Drawing on our 75 years of experience in designing machines for grinding and polishing diamond and related ultra-hard materials, the PG4 now enables many of the laborious and time consuming processes, such as blocking out, to be fully automated and the subsequent final radius polishing to be completed without human intervention.

The PG4 uses high quality air bearings for both wheel spindle and the pivot which are essential pre-requisites for controlled and low waviness SCD tools. Programming is extremely simple and minimal training is required.

The PG4 is an ideal machine for SCD tool manufacturers who are looking to minimise production costs and use their skilled operators in more demanding areas.

Features

PG4 machine in factory
• Simple programming via menus
• Machine operation training in one day
• Rotary axis training in one additional day
• High resolution touch-screen
• Tool profiles generated from tool program
• Digital zoom and image dragging facility
• Fast Windows-based PC and associated drives
• Connects to grinding machine by umbilical harness to avoid vibration transmission
• All units pluggable
• Remote diagnostics via internet
• 3 phase, multi voltage/multi-frequency supply
• X,Y tool position adjustment via micrometers
• Tool height adjustable
• +/-20° tilt cylindrical clearance
• Nest accepts round and square shank tools
• High precision linear bearings
• Constant load, dead weight systems, 0.5-3.0kg
• 0.1μm in-feed scale
• Precision ground and dynamically balanced to gyroscope tolerances
• Allows wheels to be removed and replaced from spindle nose quickly and easily
• GigE camera for fast image capture
• High resolution pixel count
• X, Y micrometer adjustment for camera alignment
• Extra long facial length for in-process inspection
• x60 - x600 magnification
• x1000 magnification - optional extra (inspection only)
• Coborn, high precision planetary with rolling element design
• 0.1° planetary position resolution
• AC servo motor drive via non-influencing motor and non-influencing belt
• Speed, direction angular position programmable
• 0 - 20° tilt for conical clearance
• Ultra-high precision air-bearing
• Water cooled to provide thermal stability
• Speed up to 12,000 rpm programmable
• Rotation direction programmable
• Brushless, vibration free integral drive
• Non-influencing linear drive
• Can be synchronised
• Fully programmable speed, and stroke
• Sinusoidal acceleration / deceleration
• For optimum vibration damping and thermal stability
• High intensity LED
• Electronically dimmable
• Cover glass easily replaced
• Ultra high precision air-bearing pivot
• Brushes, vibration free integral drive
• ‹50nm rotational error
• Maximum arc of rotation 182°
• Position resolution 0.001°
• Position & speed programmable

Machine dimensions (w x d x h) – 790mm x 1310mm x 1900mm

Control tower dimensions (w x d x h) – 680mm x 610mm x 1910mm

Machine weight – 800kg

Control tower weight – 160kg

CNC control system – CNC control with Intel i7 processor running Coborn .net software on a Windows platform

Grinding wheel spindle – 2.0kW 0 – 12000 rpm programmable liquid cooled high-precision air spindle

Grinding wheel – Ø 85mm Metal bond wheel or cast iron lap

Pivot spindle – High-precision air spindle with radial error ≤ 0.00005mm

Lubrication – Manual grease lubrication system

Process inspection – Coborn integrated camera inspection system X60 to X600 magnification

Electrical requirements – 380 / 220 3phase 50/60 Hz 16amps

Mechanical options – Rotary axis (RM) programmable, Coning spindles (CS) manual, Work piece clamping systems

Software options – Rotary module, Profile contour deviation, Controlled/low waviness, Dxf.import (profile grind)

  • RM76 – Rotary Axis
    • For coning, cylindrical grinding and index positioning • Programmable rotation to 0.001° • Collet chuck to suit tools up to Ø16mm • Other adaptors available
  • SAM – Metal Bond Wheels
    • High quality, porosity free • Extremely long life, designed for dry grinding • Dynamically balanced to gyroscopic tolerances
  • TCS1 – Tool Cooling Unit
    • Cools tool shank using sub-zero compressed air • Removes thermal expansion effects • Programmable ‘on/off’
  • PS2B – Planetary Scaife Bench
    • For top lapping of SCD tools after radius grinding • Re-sharpening worn tools and general facet work • Adjustable planetary motion allows ‘set and leave’ operation
  • TRC – Tool Radius Check
    • Microscope with image analysis software to measure tool radius and radius waviness • Generates custom designed QC graphical data sheets which can then be supplied with the associated tool
  • Optional Software Modules
    • Synchronized pivot, planetary, traverse, infeed and rotary (RM) motions • Profile contour deviation

PG4 footprint and dimensions

PG4 Brochure and datasheets

The brochure including data sheets for the PG4

PG-Brochure.pdf

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