Efficient grinding Okamoto expertise puts an end to wasteful ‘air grinding’

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One of the biggest efficiency killers in surface grinding is what is known as air grinding. But Okamoto kills the killer with MAP Grinding ...

In surface grinding, air grinding refers to certain movements of the grinding wheel over the workpiece without removing any material. The machine is still working, however, consuming energy and time without any productive effect, as Okamoto Machine Tools Europe explains. Particularly with large or warped plates, there are then quite long idle strokes because grinding must first be carried out from the highest point of the workpiece down to the actual machining zone, as it goes on to say. The consequences are extended machining times, unnecessary wheel wear, and thus increasing unit costs and cycle times that are difficult to calculate. But with MAP Grinding, Okamoto has now developed something that can completely eliminate air grinding for the first time, as it emphasises.

Okamoto halves the time required for surface grinding of large parts

Okamoto's MAP Grinding is based on an ‘intelligent’ interaction between measurement technology, NC logic and high-precision axis mechanics, as we have learned. The process is also fully automated. First, a tactile probe independently measures the workpiece. Meanwhile, the machine determines the actual surface geometry, automatically fixes the zero point and identifies the highest point of the component. The software uses the data to generate an optimised grinding programme. Material removal then begins precisely at this highest point of the workpiece. From there, the machine works its way step by step to the next higher areas until the lowest point is finally reached, Okamoto continues. Grinding is only carried out where material actually needs to be removed. Only when all height differences have been levelled out does the system automatically switch to classic pendulum grinding.

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The end result offers the following advantages: No empty strokes, no air grinding, no unnecessary loss of time. This is especially true for large or warped workpieces, where, according to Okamoto, MAP Grinding can save between 40 and 60 percent of the previous machining time. It also reduces machine running time and energy consumption per component. This also reduces the consumption of cooling lubricant.

Efficient surface grinding depends entirely on table positioning

A key prerequisite for the effective use of MAP grinding is the precise positioning of the machine table, says Okamoto. This is guaranteed by a servo-electrically controlled X-axis with a ball screw. The recirculating spindle converts the rotary motion of the servo motor into a highly accurate, backlash-free linear motion. This allows the table to be positioned with micrometre precision and stopped exactly at any measuring position. According to Okamoto, hydraulically driven tables are unsuitable for this process because they simply oscillate back and forth. They cannot be positioned precisely and, due to the nature of the system, exhibit drift and dead zones. The measurement accuracy required for automated measurement and a reproducible removal strategy from MAP Grinding would therefore not be achievable hydraulically.

Tackle flat grinding processes safely without specialist knowledge

MAP is fully integrated into Okamoto's tried-and-tested iQ control system, which follows a clear operating concept. This means that as little text as possible and maximum graphic representation make operation easier. Process steps, measuring points and grinding strategies are therefore shown visually and are thus intuitively comprehensible. The advantage of this is that even less experienced users can operate the machine safely and productively in a very short time. Complex programming skills or in-depth grinding expertise are therefore not required, which is an important enabler for stable production processes in times of skilled labour shortages.

Safe surface grinding possible with minimal manpower

Thanks to automatic measurement, a self-optimising grinding strategy and high process reliability, MAP Grinding is particularly suitable for low-manpower operation. The machine works reproducibly, avoids operating errors and delivers consistent quality – even during night and weekend shifts. This transforms the grinding machine from a pure machining centre into an autonomous process module that increases output without requiring additional specialist personnel. With MAP Grinding, Okamoto demonstrates how the combination of smart measurement technology, precise mechanics and user-friendly controls can deliver real added value for grinding practitioners.

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