1. Exceed with speed and precision
Timesavers International
Piet Kooman

2. Piet Kooman
Sales and marketing director at Timesavers international B.V.
24 years in the company
Fine mechanical engineer

3. Timesavers Int. B.V.
World leader in engineering, production and sales of wide belt grinders.
3 production facilities

4. Timesavers Int. B.V. 75 years experience 250 employees
Active in the world
80 distribitors

5. Proces
Example deburring
Example finishing

6. Proces
Example stockremoval
Example combi

7. Proces change over the years
Deburring
High stock removal

8. Deburring machine 1970

9. Evolution of the deburring process
Remove upstanding burr after punching
Sharp edge

10. Deburring machine 1980

11. Evolution of the deburring process
Remove upstanding burr after punching and remove sharp edge
Sharp edge

12. Evolution of the deburring process
Remove upstanding burr after punching and remove sharp edge and secondairy burr
Sharp edge

13. Disc machine 1995

14. Evolution of the deburring process
Remove upstanding burr after punching and remove sharp edge and secondairy burr and remove the burr from every side

15. Evolution of the deburring process
Introduction of the laser cutting machines
The Laser cutting machine will not leave a burr like the punching machine
No deburring machine needed any more ??
Actually more sold than ever
The start and stop point needs removing
Very sharp edge

16. Evolution of the deburring process
Remove upstanding burr after punching and remove sharp edge and secondairy burr and remove the burr from every side and remove the hard laser burr

17. Evolution of the deburring process
Remove upstanding burr after punching
Remove sharp edge and secondairy burr
Remove the burr from every side
Remove the hard laser burr
Multi materials
Pvc coating
Produce a radius at a specific value,
Remove oxide after laser cutting

18. Evolution of the deburring process

19. Evolution of the deburring process

20. Rotary brush machine 2010

21. New design 2014

22. High stock removal

23. High stock removal
Selection of material removal processes for plane surfaces
milling
broaching
honing
lapping
wide belt grinding
vertical grinding
horizontal grinding
abrasive jet

24. High stock removal Performances of the technological process
Customer demands
Materials to process at high productivity
At required surface integrity
At required tolerances
At lowest costs / part

25. High stock removal Costs Surface quality Productivity Specific energy
Tolerances
Belt Grinding
Milling
Wheel Grinding

26. High stock removal Specific energy Specific energy:
Energy required to cut a unit volume of work material (E)
(kWh/mm3)

27. High stock removal Specific energy Low specific energy results in
Less heating of material
Less negative influence surface
quality (finish)
Less metallurgical damage
Less residual stresses
Lower cutting forces
Lower costs
Lower energy consumption
Higher possible productivity
(because of reduced limitation by temperature rising of work material)
Lower tool wear rates
Higher geometric accuracy (tolerances)
(decreased deflections)

28. High stock removal Specific energy is of major importance
Cross reference of specific energy for various production technologies and materials (* kWh/mm3)
Yield strength
(MPa)
Material
Wheel
grinding
(kWh/mm3)
Belt
Milling 97
Aluminum
6,0
370
Cast iron
6,8
480
Steel (c45)
9,0
630
Stainless steel
43,3
690
Nickel alloy
77,4
750
Titanium
90,3
Belt grinding is a cool cutting process
37,5
60,0
68,2
214
375
441
3,8
4,2
5,4
30,0
53,5
62,5
Specific energy o ++
Belt Grinding
Milling
Wheel Grinding

29. High stock removal
Technological process of belt grinding is determined by
the machine tool
the grinding belt
The orientation and distribution of the abrasives are controlled
Orientation
aligning in accordance with the geometric longitudinal axis (sharp cutting edge perpendicular to the belt)
Distribution
easy reproducible and uniform distribution of the abrasives grains

30. High stock removal Explanation of the differences Milling vs. grinding
Rubbing energy (Elastic deformation)
Plowing energy (Elastic and plastic deformation)
Cutting energy (Chip) 1 2 3
Energy
Cutting energy
Friction energy (plowing, rubbing)
In grinding more friction than milling
Friction energy:
Cutting angle
Chip thickness
Chip chamber
Contact length

31. High stock removal Friction energy
Cutting angle Large positive angles reduces power consumption
Belt grinding
More energy required
Chip thickness Large chip thickness reduces power consumption

32. High stock removal Friction energy Chip chamber Contact length
Clearance of Chips: Easiness to remove chips out of cutting zone
High stock removal
Creep feed grinding
when chip production volume > space between grains, then:
Chips get involved in cutting process
Decrease of surface integrity
Increase specific energy
Contact length
(coolant flow, chip clearance)

33. Properties of the work material
Productivity:
Volume of work material removed
in an unit time (Q)
(cm3/min)

34. Properties of the work material
Productivity
500
1000
1500
2000
2500
Aluminum
Stainless steel
Nickel alloy
Cast iron
Steel (C45)
Belt grinding
Milling
Vertical grinding
Titanium
Productivity (cm3/min)
Mechanical properties
Physical properties
Machinability of:
SS, Nickel- Titanium-alloys limited by: Generation of heat
Aluminium, cast iron limited by: Clearance of the chips
productivity o + ++
Belt Grinding
Milling
Wheel Grinding

35. High stock removal Surface integrity Finish Roughness Visual
Horizontal Grinding
Vertical Grinding
0.01
0.02
0.04
0.06
0.1
0.4
0.25
0.16
1.6 1
0.63
2.5 10
6.3 4 16
0.001
Lapping
Honing
Polishing
Milling
Turning
Tumbling
Belt grinding
Rough
Fine
Average surface roughness (Ra) (µm)
Finish
Roughness
Visual
Metallurgical damage
Micro cracks
Residual stresses
According to DIN and -2
Surface quality + ++ o
Belt Grinding
Milling
Wheel Grinding

36. High stock removal Thickness tolerances and form tolerances Wheel
0.02
Sheet – 1000x800 (mm), According to DIN 876
Cross reference of tolerances for various production technologies
Wheel
grinding
High stock removal
Belt
Milling
Flatness (mm)
0,02
0.02
0,2 – 0,5
Thickness (mm)
0,01
0,1
Parallelism (mm)
t ± 0.02
0,02
tolerances ++ + o
Belt Grinding
Milling
Wheel Grinding

37. High stock removal Cost comparison Costs of machining (costs/product)
Wheel grinding
Belt grinding
7500 €/m3
6900 €/m3
Costs of machining (costs/product)
Tool costs, depend on wear:
C/P (mm3/ mm2) & tool costs (€/m2)
Additional costs:
labor & energy
Costs of machining tool
Similar investment costs:
depreciation
Material: C45
Product: 1 x 2 m
Costs + ++
Belt Grinding
Milling
Wheel Grinding

38. High stock removal + ++ o Wheel Grinding Milling Belt Grinding
Costs + ++
Surface quality o
Productivity
Specific energy
Tolerances
Belt Grinding
Milling
Wheel Grinding

39. Full project

40. Design 2017
Questions