The automotive manufacturing industry demands extremely high precision, consistency, and production efficiency from its parts. From engine components to drive shafts, the machining quality of each part directly affects the performance and safety of the entire vehicle.
Among these, the precision grinding of cylindrical parts such as shafts and pins is one of the core processes, and Centerless Cylindrical Grinding technology is the key equipment for achieving this goal. centerless grinding, as a key machining technology, can efficiently meet these requirements.
Centerless grinding is mainly used in the manufacture of automotive parts and engines, as well as components such as camshafts, crankshafts, needle rollers, input shafts, and fuel injector plungers.
These components require precision and high-standard tolerances to function perfectly in their respective applications.
By removing the grinding material during the grinding operation, precise polishing and surface finish can be achieved. In other words, centerless grinding differs from traditional grinding methods;
it does not require centers or fixtures to support the workpiece, offering advantages such as high machining efficiency and excellent roundness and dimensional accuracy. Therefore, it is widely used in the machining of automotive parts.
From a technical perspective, Centerless Grinding Machines offer advantages such as high precision, high rigidity, and high efficiency.
Their grinding accuracy typically reaches IT5 to IT6 levels, and the surface roughness Ra value can be controlled below 0.2μm.
Centerless grinding is widely used to achieve custom dimensions. To meet different size, shape, and surface finish requirements, centerless grinding is divided into two main forms:
Through-feed/Through-feed Grinding: For grinding long and round bars, through-feed grinding is the most efficient. This process is accomplished by feeding the workpiece into the machine, where it is pulled by adjusting wheels and fed out from the opposite side.
Through-feed (often called "through feed") methods are very efficient because they do not require a separate feed mechanism, although these methods are only suitable for simple cylindrical workpieces such as pistons, tubes, piston pins, and bars.
Feed/Dive Grinding: For grinding relatively complex parts and shapes to a very precise surface finish, feed/dive grinding is the most suitable.
Gear shafts, crankshafts, camshafts, and other highly complex automotive parts require feed grinding to achieve the desired grinding and surface finish.
In this case, the workpiece is loaded into the machine, allowing the adjusting wheels to move into place. The complexity of the part shape requires precise grinding to prevent axial feed of the workpiece through the machine.
1. Case Study: Machining Hydraulic Gear Pump Gear Shafts/Hydraulic Control Valve - Lifting Valve - External Cylindrical Grinding
For machining hydraulic gear pump gear shafts/hydraulic control valves - lifting valves, external cylindrical grinding and external cylindrical grinding machines have been maturely developed for grinding these high-precision workpieces.
Taking external cylindrical grinding machines as an example, when using a natural granite bed and a linear motor drive for the motion axis, it has excellent precision and thermal stability, making it suitable for applications with the highest requirements.
It is also suitable for grinding non-circular workpieces. With a water-cooled electric spindle, it can handle both conventional and high-speed grinding.
The maximum linear speed is 140 m/s, enabling both conventional grinding (60 m/s) and high-speed grinding (140 m/s) while maintaining maximum torque.
Direct-drive B-axis and multi-wheel applications achieve versatility and high flexibility. Integrated customized automatic loading and unloading systems enable fully automated production, ensuring minimal loading and unloading time (2-6 seconds).
2. High-Speed Motor Shafts: Longitudinal Grinding/Dive Grinding
Electric vehicle grinding technology presents new challenges. Speeds commonly found in internal combustion engines (approximately 2,500-8,000 rpm) increase 5-20 times in electric drives.
In the worst-case scenario, suboptimal gear grinding can lead to oil leaks, lubricant leaks, and engine damage. Therefore, precision machining of high-speed motor shafts is crucial.
Compared to other components, motor shafts involve more machining processes, including rough turning, finish turning, grinding, and milling.
Grinding areas include bearing locations, shaft extension locations, and wound rotor motor slip ring locations.
Motor shaft extensions can be cylindrical or conical; conical shaft extensions, in particular, represent a key area for advanced Grinding techniques.
Grinding, a type of finishing machining in mechanical processing, involves small machining operations with high precision.
The grinding process is performed on an external cylindrical grinding machine, used to grind the outer cylinders, outer cones, and shoulder end faces of shaft-type workpieces. There are two main types of grinding:
Longitudinal Grinding: The workpiece rotates at low speed, and simultaneously moves longitudinally back and forth. After each single or double stroke of the longitudinal movement, the grinding wheel makes a transverse feed relative to the workpiece.
Dive Grinding: If the width of the grinding wheel is greater than the length of the surface being ground, the workpiece does not move longitudinally during grinding; instead, the grinding wheel continuously makes a transverse feed relative to the workpiece.
Generally, dive grinding is more efficient than longitudinal grinding. If the grinding wheel is dressed to form a shaped surface, dive grinding can machine shaped outer surfaces.
In the modern automotive industry, which pursues lightweight and high-performance machining, higher requirements are placed on the machining precision of basic components.
YASHIDA, a manufacturer of high-precision centerless grinders, offers the CG-18S centerless cylindrical grinder, providing an efficient and reliable precision machining solution for automotive shaft parts thanks to its unique technological features.
For manufacturers committed to improving product quality and production efficiency, understanding and applying advanced centerless cylindrical grinding technology is undoubtedly a worthwhile direction to consider.
High-precision centerless grinders play a vital role in modern automotive manufacturing. With advanced technology and stable performance, they provide a reliable guarantee for the mass production of high-quality parts.
Learn more about centerless grinder：
How Roundness Is Achieved in Centerless Grinding
Centerless Grinding Solutions for Automotive Precision Shafts
The Role of Regulating Wheel Control in Centerless Grinding Accuracy
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