Here we are grinding a fluted Endodontic file from a long bar of raw material. The latest development in Extreme Profile Wire Grinding combines the rapid profiling of Centerless Mode with the Extreme Profile capability of Micro Machining. We have the best of both worlds in one grind process. Reduced cycle times while generating intricate shapes using a combined Centerless mode wheel and bushing mode wheel in one grind operation.
The machine is like the original Gen X but with the addition of a fully programmable 4th Axis System. The 4th axis wheel is for grinding intricate profile features like helical grooves, ring grooves, points, bumps and flats.
The footprint of this machine has been reduced significantly with the integration of the coolant filter and spool feeder below the base of the grinder. The machine enclosure contains all coolant and moving parts. The access doors allow for complete access when needed. The Lexan panels provide full visibility during process.
The original primary wheel with its 1/10 of a micron slideway and the new 4th Axis System secondary wheel with its 1/8 of a micron slideway are positioned very close to each other on the machine bed. The machine platform is our 8-inch-thick granite bed commonly referred to as BEDROCK.
In this set up we have a spool feeder with automatic pay out and cut, to work with a single length of wire. The feeder capstan delivers the wire to the open collet in the work head. The collet closes, and the linear motor moves the work head toward the grind zone. A sensor activates to close the grippers on the wire and the work head opens the collet and retracts to the start of grind position. The work head closes the collet and translates forward to position the wire in front of the 4th axis wheel. The tip of the new wire is trimmed to create a zero linear position. Next the work head passes the wire in front of the primary wheel to grind the taper length and calibration lines. When this is completed, the work head advances to the secondary grind zone and generates the flutes into the taper length. Finally, the part is positioned in front of the secondary wheel for cut to length of exact finish dimension. The finished file is deposited in the receptacle and the work head retracts to repeat the process. No secondary work is needed after this process on the Royal Master Model GEN X3.
This full part profile is ground and cut to length in one work holding in about 60 seconds depending on the part profile. This machine is completely automatic. It has CNC wheel dressing. It has two independent slide ways one for each grind zone. It has a coolant filter. It is available with an enclosure and a mist collection air filter. Raw material can be fed automatically from a spool.
The new Royal Master Generation X3 puts an end to the multi-operation process of producing complex part profiles. No more separate process for each part profile feature. No more cut to length and deburr. No more pre-pointing. No more taper grind. No more fluting. No more grinding calibration lines. No more grinding flats. No more grinding chamfer on back end. This is a single machine with capabilities to generate each of these features in a part with just one work holding.
The Generation X3 has a user-friendly 17” touchscreen control with simple Micro Soft Excel Point to Point programming language. No special skills are needed to program the most complex parts.
Look to Royal Master Grinders for centerless grinding solutions; from standard centerless grinders to total turnkey packages. Visit us at royalmaster.com. See us at Booth 6626 in Chicago.