MK-400PLUS 5-Axis CNC Grinding Center High-Precision Machining Solution for Indexable Inserts

Product Description

MK-400PLUS 5-Axis CNC Grinding Center: High-Precision Machining Solution for Indexable Inserts

The MK-400PLUS represents a state-of-the-art advancement in the field of precision grinding, designed specifically to meet the rigorous demands of modern cutting tool manufacturing. This high-precision 5-axis CNC grinding center is engineered to handle the complex periphery machining of indexable inserts made from a broad range of advanced materials, including carbide, cermet, ceramics, cubic boron nitride (CBN), and polycrystalline diamond (PCD). These inserts are crucial components widely used in metalworking industries, such as automotive, aerospace, medical device production, and general manufacturing.

With the increasing complexity of cutting tool geometries and the push for higher productivity and tighter tolerances, the MK-400PLUS integrates precision mechanics, advanced control systems, and sophisticated automation technologies to deliver unmatched performance, flexibility, and reliability.

Key Features and Technical Specifications

1. Comprehensive 5-Axis Control System

At the core of the MK-400PLUS lies its fully integrated 5-axis CNC control system. This includes the traditional X, Y, and Z linear axes, complemented by two rotary axes, often designated as A (workpiece rotation) and C (table angle adjustment). The extended rotary range allows the machine to perform complex contouring and multi-surface grinding in a single setup, significantly reducing cycle times and eliminating the need for multiple reclamping.

X-axis (left-right oscillation): Employs direct-drive technology with automatic centralized lubrication, ensuring smooth, precise motion.
Y-axis (in-feed): Direct-drive and similarly lubricated for reliable operation.
A-axis (workpiece rotation): Enables full rotation of the workpiece, allowing grinding of peripheries and chipbreakers.
C-axis (table angle adjustment): Provides angular positioning from -90° to +90°, with a maximum travel from -91° to +91°, accommodating various grinding wheel sizes and insert shapes.
V-axis: Dedicated to online cleaning of the grinding wheel to maintain consistent grinding quality.
W-axis: Allows manual and automatic positioning of the insert core, enhancing precise alignment.

The maximum simultaneous control of 9 axes exemplifies the machine's ability to coordinate complex movements, a vital factor for high-precision machining.

2. Grinding Wheel and Spindle System

The MK-400PLUS is equipped with a 7.5 kW general flange-type, 3-phase induction motor operating at V3 level, providing robust and stable spindle power for high-speed grinding operations. The grinding wheel diameter is optimized at 400 mm, striking a balance between grinding surface area and machine compactness.

A 1.5 kW electric spindle dressing motor facilitates the dressing and conditioning of the grinding wheel, ensuring a sharp and clean cutting surface for extended wheel life and consistent surface finish on the workpieces.

3. Material Compatibility and Processing Range

The MK-400PLUS can handle a variety of hard and advanced materials that are essential in modern tool manufacturing:

Carbide: The standard for durable cutting inserts.
Cermet: Known for high wear resistance and thermal stability.
Ceramics: Suitable for high-speed machining of difficult materials.
CBN (Cubic Boron Nitride): Best for grinding hardened steels and ferrous alloys.
PCD (Polycrystalline Diamond): Ideal for machining non-ferrous metals and composites.

This wide material compatibility makes the MK-400PLUS suitable for diverse industries, enabling manufacturers to standardize their insert grinding operations on a single machine.

4. Automatic and Precise Positioning System

The MK-400PLUS employs an integrated core shaft device for center hole positioning on the left side of the insert, allowing precise alignment during grinding. The positioning device offers:

Manual fine adjustment for forward/backward positioning.
Automatic up/down positioning to improve workflow and reduce manual intervention.
Capability to install one positioning block.

5. Automated Workpiece Handling

To maximize throughput and minimize operator workload, the MK-400PLUS is equipped with a 3-axis linear coordinate robotic arm featuring:

B1-axis: Left-right tray transport.
B2-axis: Tray loading/unloading.
B3-axis: Up-down movement.

The robot is capable of handling multiple tray types:

Standard trays: Two trays, each 350 mm x 350 mm.
T-type trays: Two trays, each 190 mm x 370 mm.

A dedicated gripper facilitates the loading and unloading of workpieces, ensuring smooth and repeatable handling throughout the production cycle.

6. Advanced Detection and Quality Control

The system incorporates sophisticated detection devices for:

Measuring material dimensions prior to processing.
Inspecting the inscribed circle after grinding to ensure dimensional accuracy.
Automatic exclusion of defective workpieces.
Regrinding and automatic correction for subsequent workpieces, minimizing scrap and improving overall process yield.

7. Robust and Compact Design

Despite its complexity and high degree of automation, the MK-400PLUS maintains a compact footprint of 2,475 mm (W) x 2,250 mm (D) x 2,160 mm (H) and weighs approximately 5,500 kg. This design emphasizes mechanical rigidity and thermal stability, critical for maintaining grinding accuracy during high-speed operations.

Applications and Industry Impact

The MK-400PLUS is tailored for high-precision manufacturing environments where performance, accuracy, and automation are vital. Its key applications include:

Cutting Tool Industry: Grinding of standard and complex indexable inserts used in milling, turning, and drilling tools.
Automotive Manufacturing: Production of inserts for machining engine components, transmission parts, and structural materials.
Aerospace: Fabrication of high-performance inserts capable of machining superalloys and titanium alloys with strict dimensional and surface finish requirements.
Medical Device Manufacturing: Creation of inserts for machining medical implants and surgical instruments that demand high precision and consistency.

The machine’s ability to grind complex 3D shapes including dual-side lands, periphery contours, and chipbreaker geometries in a fully automated process makes it indispensable for companies aiming to reduce cycle times, improve quality, and scale production.

Advantages Over Conventional Grinding Machines

Increased Automation and Productivity: The integration of multi-axis CNC control and robotic workpiece handling minimizes operator involvement and allows for continuous, unattended operation, dramatically increasing production output.
Reduced Setup and Cycle Times: The machine’s ability to complete multiple grinding operations—periphery, dual chamfering, and 3D shaping—in a single clamping session cuts down machine downtime and improves workflow efficiency.
Enhanced Grinding Accuracy and Surface Quality: Direct-drive axes with automatic lubrication and precise positioning systems ensure consistent, repeatable accuracy within micrometer tolerances, critical for the performance of cutting tools.
Wide Material Capability: The MK-400PLUS supports the full range of modern insert materials, enabling manufacturers to switch between job types without needing extensive machine reconfiguration.
Integrated Quality Control: Automated measurement and rejection systems reduce human error, improve yield, and support the delivery of premium quality parts.

Summary

The MK-400PLUS 5-axis CNC grinding center stands as a premium solution for the modern tool manufacturer, combining the latest in automation, precision control, and material compatibility. By delivering fully automatic, multi-functional grinding capabilities, the MK-400PLUS addresses the evolving challenges of cutting tool production, offering:

Multi-axis flexibility for complex shapes.
Robust spindle and wheel systems optimized for diverse materials.
Intelligent robotic handling and integrated quality inspection.
Compact, reliable design suited for demanding industrial environments.

For manufacturers aiming to improve efficiency, accuracy, and product quality in their insert grinding operations, the MK-400PLUS offers an unbeatable combination of technology, versatility, and automation.