kundenmagazin-2012-01-en

The JUNKER Customer Magazine • January 2012 Issue
MARKETS
Brazil – the future looks
bright
›› Page 6
c o m pa n y
The world of grinding
›› Page 4
te c h n o l o g y
Projects & Solutions
›› Page 8
in the field
Faster and more flexible production
with CBN technology
›› Page 10
“Being on location in Brazil means using German engineering
expertise to contribute to the development of the country.”
Dirk Huber, Regional Manager, Brazil
c o n te n ts
c o m p a n y .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
The world of grinding
Under this banner, the JUNKER Group made its appearance at the EMO 2011, where we
proved our versatility and innovative strength to the public.
markets .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Brazil – the future looks bright
In November of this year, the JUNKER Group opened its doors in Brazil. Now, the largest
industrial nation in South America has easier access than ever before to innovative
German grinding technology.
te c h n o l o g y .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
Projects & Solutions
With increasingly more productive grinding concepts, JUNKER offers its customers the
perfect solutions for constantly rising standards of efficiency and precision. JUNKER’s
leading technologies are the ideal foundation when it comes to this.
i n t h e f i e l d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
Faster and more flexible production with CBN technology
One of the largest German roller bearing manufacturers doubles its productivity with a
QUICKPOINT 5000/50 S.
legal notice
Publisher
Erwin Junker
Maschinenfabrik GmbH
Junkerstraße 2
77787 Nordrach, Germany
Concept, design, realisation
Marschner+Kühn GmbH+Co.KG
The B-to-B Brand Station
Werftstraße 12
76189 Karlsruhe, Germany
Phone: +49 (0)7838 84-0
Fax:
+49 (0)7838 84-302
E-Mail: [email protected]
www.junker-group.com
Image sources
Erwin Junker
Maschinenfabrik GmbH,
Nordrach, Germany
editorial
Dear readers,
2011 has been an eventful and strenuous year. The economy experienced highs and lows, Greece is challenged by an
unprecedented debt, and the Euro is being put to the test
more than ever before. Not an easy environment for a business, you might say. And yet the JUNKER Group has gone on
undaunted, pulling off one of the most successful years since
the company was founded.
New ideas and inventions – that is what has always been our
driving force in the past, and that is what will continue to be
our driving force in the future. Our unique innovations have
always led the way in the grinding industry. It is thanks to
them that we've been able to gain an edge over our competition. In order to maintain that edge, we have spent the last
few months launching new machine concepts and grinding
methods onto the market. One example is the JUSTAR, able
to grind a wide range of parts in a single clamping set-up.
Innovative machine concepts have made us into what we are
today: a grinding machine manufacturer capable of supplying every branch of industry. Our machines grind not only
automotive parts and tools but also high-precision parts for
wind generators, solar modules, pumps, electric motors and
more.
In 2012, the JUNKER Group will be celebrating its 50th anniversary. I’m happy to say that the path has been paved for
a successful future. JUNKER machines will continue their
successful production around the world. The network of sales
and service locations around the globe is expanding even
further, and Erwin Junker Machinery’s wealth of innovation is
far from being exhausted.
Please enjoy this overview of the latest and upcoming activities of JUNKER, your partner for precision.
Sincerely,
Erwin Junker
Founder and owner
of the JUNKER Group
Look&see 01/2012
3
The EMO in Hannover, Germany, was reflective of
our overall success in 2011
The world of
grinding
Under this banner, the JUNKER Group made its appearance at the EMO 2011,
where we proved our versatility and innovative strength to the public. With
our wide range of machines, JUNKER technologies have applications in a
whole variety of areas - from automotive manufacture and supply to the
renewable energy and pump industries.
4
Look&see 01/2012
c o m pa n y
Global tradeshow presence
Thanks to major growth in the East, JUNKER was represented at no less than two tradeshows in Asia in 2011.
In January at the IMTEX in Bangalore, India, and in April,
at the CIMT in the Chinese capital of Beijing.
In May, JUNKER participated in the METALLOOBRABOTKA
tradeshow in Moscow. At the same time as the exhibit in
Russia, the FEIMAFE took place in São Paulo, Brazil. But
the highlight of the 2011 tradeshow circuit was the EMO,
which was held in September in Hannover, Germany.
Fan Ming, Technical Director,
Chengdu Xiling Autoparts Co. Ltd., China
2012 tradeshow schedule
GRINDTEC
14.03. – 17.03.2012
Augsburg
GER
MECANICA
22.05. – 26.05.2012
São Paulo
BR
METALLOOBRABOTKA
28.05. – 01.06.2012
Moscow
RU
MSV
10.09. – 14.09.2012
Brno
CZ
IMTS
10.09. – 15.09.2012
Chicago
USA
AMB
18.09. – 22.09.2012
Stuttgart
GER
Latest new developments
JUSTAR: The JUSTAR concept is the perfect grinding
machine for complete grinding of a wide range of parts
for high-precision cutting tools of all kinds. It offers maximum flexibility, coupled with top productivity, as well
as practical programming software.
JUPITER 250: Like the other JUPITER platforms, this
centerless cylindrical grinding machine features a workrest blade with its own internationally patented height
adjustment CNC axis. This machine concept has applications in grinding and fine grinding, examples: for needle
rollers and hydraulic pistons.
6XL platform: The 6XL platform offers JUNKER customers a whole new set of possibilities. The 6XL easily carries out grinding operations on parts such as ship engine
crankshafts, with a clamping length of up to 3 meters.
JUNKER Service – above and beyond
One of the best-known automotive suppliers in
China is Chengdu Xiling Autoparts Co. Ltd. from
Sichuan Province. For some time now, the company has relied on JUNKER grinding technology for
its camshaft production. Fan Ming, the company’s
technical director, explains why: “In order to manufacture high-quality camshafts, we need top quality
production machines with excellent after-sales service. We tested a number of manufacturers, including foreign companies, but no one could match
the JUNKER Group. In 2010, we started using our
first JUNKER grinding machines and were immediately won over by them. Perfect quality coupled
with first-class service. Whatever the problem may
be, the JUNKER Service team always delivers the solution, whether it’s by phone, teleservice or directly
onsite on the machine. JUNKER makes us feel like
more than just a customer; they treat us like a business partner. And with their large spare parts stock
in Shanghai, any type of repairs and maintenance
can be taken care of quickly and easily.
All of this has made us believers in JUNKER as a partner – perfect quality and unmatched service. The
next JUNKER machines have already been ordered
and are soon to be shipped to our plant. We look
forward to continued cooperation with JUNKER
and hope that our partnership will result in mutual
growth."
JUSTAR
JUPITER 250
6XL platform
Complete grinding of cutting tools
Centerless cylindrical grinding
Grinding of large parts
Look&see 01/2012
5
JUNKER now has its own
location in the booming
country of Brazil.
Brazil – the future
looks bright
In November of this year, the JUNKER Group opened its doors in Brazil. Now, innovative German grinding technology has an even bigger presence in the largest industrial nation in
South America.
In November, JUNKER celebrated yet another step towards global player status: our first subsidiary in Brazil.
With this new footing in São Paulo, JUNKER’s high-capacity grinding technology is now more present and readily available than ever on the South American continent.
With his highly motivated sales and service teams, Dirk
Huber is setting out for a promising future. Huber, who
previously worked at JUNKER’s Nordrach location and
has intimate knowledge of the company, started his own
business in Brazil in 2003. Since then, he has acted as an
able spokesperson for JUNKER on the Brazilian market
and has contributed to the trustworthy reputation that
JUNKER has already built up with Brazilian businesses.
Thus, it is no surprise that Huber only sets clearly defined
goals: “We are prepared to take on the demands of a
booming economy and work hard for this market.”
6
Look&see 01/2012
Leading the way
Nordrach loves to see this much competitive energy, in order to reach
a wider market and in order to improve both our service quality and
availability. This way, JUNKER can offer its customers maximum reliability
and convenient locations. And this, according to Huber, is what's most
important to a company that puts precision and excellence at the top
of its list.
The car and truck industry is on the move
JUNKER is not the only one thinking in this direction. Brazil is already
home to many companies in the automotive industry. Many Chinese
manufacturers have joined the club over the course of this past year.
And they are thinking about starting production in Brazil. The word in
the industry is that, starting in 2012/2013, Brazil is expected to attain a
production volume of approximately 4.5 million automobiles. In comparison to 2008/2009, in which a mere two million vehicles rolled off the
lines, this would mean an increase of over twice the output.
markets
In 2010/2011, Brazil also produced only about three
million vehicles. But the 4.5 million figure is expected to
be just the beginning. Starting 2015/2016, forecasts say
that production volume should grow to nearly six million
vehicles a year. BMW, for example, has plans for an onsite
car manufacturing plant entirely of its own. In the state
of Perambuco in northeastern Brazil, near the city of Recife, work is underway on a new industrial zone, in which
Fiat is planning to construct a new engine and transmission plant, expected to begin production in mid-2014.
And it’s rumored that VW is soon to follow suit. Things
have been happening in the utility vehicle area, as well.
MAN is planning to manufacture trucks in Brazil in 2012.
The reason for this economic upshot is clear and simple:
Brazil is hosting the 2014 soccer world championship, as
well as the 2016 Olympic Games, making it the focus of
much more attention around the world.
Huge possibilities for the tool industry
Aside from automotive manufacturers there are other
industrial sectors that play an important role for JUNKER
in Brazil: the aviation industry, as well as the energy generation and agriculture. The JUNKER Group expects significant potential for expansion in all these sectors in the
coming years. The logical conclusion: there is demand
for the tooling industry in the region as well. This applies
most of all to the high-tech sector, where substantiated,
long-running experience is required as a guarantee for
success. This is where JUNKER has a special role to play.
Sophisticated, high-quality tools are still currently in
short supply in Brazil.
Manaus
AMAZONAS
PERNAMBUCO
Recife
MINAS
GERAIS
Belo Horizonte
SÃO PAULO
“Being on location in Brazil means using German engineering expertise to contribute to
the development of the country.
And what could be better than
actively growing along with and
within a region?"
Dirk Huber,
Regional Manager, Brazil
Erwin Junker Máquinas Ltda.
Centro Administrativo Rio Negro
Edifício Jaçari – Bloco A
13º andar cj. 132/133
Alameda Rio Negro 585
CEP 06454-000 Alphaville – Barueri
São Paulo, Brazil
Phone: +55 (11) 4153-9645
Fax: +55 (11) 4153-8954
E-Mail: [email protected]
Web: www.junker-group.com.br
PARANA
São Paulo
Curitiba
RIO GRANDE
DO SUL
SANTA CATARINA
Porto Alegre
The current biggest industrial zones in Brazil
Working with strong partners
A good example of this is our partnership with
ThyssenKrupp. ThyssenKrupp purchased the first
JUNKER machines in Brazil four years ago, and today,
the corporation relies more and more on JUNKER
technology. One of the driving forces behind this
dynamic development is the high level of customer
satisfaction with JUNKER machines, as well as outstanding onsite service. On the other hand, the huge
professional, technological and commercial push the
Brazilians have experienced in the last few years has
also played a major role. For JUNKER, this means more
mutual projects are on their way, and the JUNKER
Group will continue to work closely with ThyssenKrupp in the coming years.
Look&see 01/2012
7
QUICKPOINT 5000/50 S for
maximum flexibility for the
manufacture of axially symmetrical precision
components.
Projects & Solutions
JUNKER offers its customers the perfect solutions for constantly rising standards of efficiency and precision, with increasingly more productive grinding concepts. JUNKER’s leading technologies are the ideal foundation when it comes to this.
Maximum flexibility for shaft production
One of the largest Chinese manufacturers of tobacco
packaging machinery uses a QUICKPOINT 5000/60 to
produce over 1,000 different axially symmetrical precision components in small batches of 1 to 5 or at the most
20 pieces. The motto is “plug & grind“: fast changeover
times and minimal downtimes guarantee flexibility and,
as a result, efficiency, as well. The QUICKPOINT grinding
method ensures that the necessary level of quality is
reached. The method involves a horizontal workpiece
axis and an extremely wear-resistant CBN grinding wheel
only a few millimeters wide, which grinds the part surface at a high infeed rate and using a point-sized contact
zone.
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Look&see 01/2012
te c h n o l o g y
Grinding concept for brake discs
A new concept for brake discs grinding is currently being
developed in cooperation with an automotive supplier.
The platform 6 JUMAT uses two grinding wheels to grind
the brake discs faces in parallel. Simultaneously grinding
both faces naturally results in major time-savings. Using
extremely low-wear diamond grinding wheels allows
JUNKER to attain the best possible results.
Grinding large crankshafts
The new JUCRANK 6XL is able to grind crankshafts 350 mm
in diameter, up to 3 meters in length and weighing 300 kg
in a single clamping set-up. The single clamping grinding
method and mineral concrete machine base with its
high vibration-reduction and warp resistance properties
allows for maximum accuracy. In-process gauging assures dimensional accuracy. The large crankshafts that
are ground on the JUCRANK 6XL have applications in
marine and aircraft engines, as well as locomotives and
other types of engines and energy generation systems.
Efficient camshaft grinding
New on the market is the Lean Selection cam – an efficient and flexible machine for camshaft grinding, reduced
to the essentials. This machine from the JUNKER Lean
Selection – a range of standard machines – is highly
user-friendly and is truly a great value. It boasts minimal
processing times and high availability. The Lean Selection
cam is particularly well-adapted for medium-sized and
large series production.
Look&see 01/2012
9
Faster and more
flexible production
with CBN technology
One of the largest German roller bearing manufacturers has doubled its productivity
with a QUICKPOINT 5000/50 S. The company manufactures roller bearings with different
dimensions and lengths, with the help of sophisticated CBN technology and a customized machine concept.
The QUICKPOINT platform offers an
excellent grinding concept for the
production of roller bearings
.
10
Look&see 01/2012
p ra x i s
Flexible grinding
The QUICKPOINT 5000/50 S grinds both the casing profile
and faces of various roller bearings having a length of
40-220 mm and a diameter of 50-170 mm. In addition,
it grinds radi on the surface of the end faces, as well
asymmetrical barre rollers and attains a rate of availability
of >95 %.
The grinding process
Jobs that once required two machines can now be done
with just one. The outer diameter used to be ground
with corundum plunge-grinding wheels and the end
faces with twin face grinding wheels.
The QUICKPOINT, however, works with just 2 thin CBN
grinding wheels, mounted on one wheelhead. Wheel
1 carries out rough grinding using the peel grinding
method with a cutting capacity of up to 1 mm. Wheel
2 takes care of the finish grinding. In order to grind the
outer diameter, the QUICKPOINT 5000/50 S was given a
B-axis mounted on a hydrostatic bearing. Compared
to the methods used until now, the JUNKER grinding
method gets far more accurate results on the profile
position on the face side. Advantage: This results in a
roller that runs much more smoothly and lasts significantly longer. Thanks to the minimal wheel contact zone,
the grinding forces are significantly reduced, which is
reflected by a fast warm-up cycle and high finish quality
of the workpiece.
Symmetrical cross-section of a barrel roller bearing. The JUNKER grinding
method results in a roller that runs much more smoothly and lasts significantly longer.
Newly developed gauging system
The QUICKPOINT 5000/50 S features a newly developed,
fully automated in-process gauging system which monitors the diameter and profile contour of the bearing
exterior. The system consists of a descending gauge with
2 measuring probes. This entirely eliminates the need for
painstaking post-measurement and manual correction,
and the machine only produces good parts. In addition,
the machine features a built-in length positioning device
and diameter gauge. The warm-up cycle, which is minimized through point-sized wheel contact as it is, can
also be continually monitored.
Benefits to the customer
• High flexibility with maximum final part quality
• Low tool costs thanks to long tool lives
• Low changeover costs, since no carriers are required
• Fast and accurate centerpoint changeover thanks to the JUNKER 3-point mounting system
• High machine availability: >95%
• No bad parts thanks to innovative in-process gauging device
• Customer-friendly and intuitive operating system
Profile grinding between centers on a symmetrical barrel roller bearing.
Look&see 01/2012
11
Grinding is our world
Machines and solutions for every industrial sector
www.marschner-kuehn.de
• Grinding of any workpiece contours and
material combinations
7509470 E January 2012
We reserve the right to make changes in the interest of technological progress.
• Individual solutions for maximum quality, productivity and efficiency
Erwin Junker
Maschinenfabrik GmbH
77787 Nordrach, Germany
www.junker-group.com
Junker Machine Tools &
Technology (UK) Ltd.
Sheffield S10 3TP , U.K.
www.junker-group.com
Erwin Junker Maschinenfabrik GmbH
Shanghai Representative Office
Shanghai 200070, P.R. China
www.junker.com.cn
Erwin Junker
Grinding Technology a.s.
534 13 Holice, Czech Republic
www.junker-group.com
Erwin Junker
Machinery, Inc.
Elgin, IL 60124, USA
www.junker-usa.com
Erwin Junker Maschinenfabrik GmbH
India Branch Office
Pune 411 001, India
www.junker.in
Erwin Junker Máquinas Ltda.
CEP 06454-000 Alphaville – Barueri
São Paulo, Brazil
www.junker-group.com.br
www.junker-group.com