Grinding solutions

02. INDEX

HIGH PRECISIONGRINDING MACHINES

03 YOUR PARTNER FOR MICRONS

04 LEADERS IN MACHINE TOOLS AND PRODUCTION SYSTEMS

05 GRINDING SOLUTIONS

06 IK4-IDEKO AND GOIMEK

07 INNOVATION AND TECHNOLOGY

08 EXTERNAL GRINDING

10 UNIVERSAL EXTERNAL & INTERNAL GRINDING

12 INTERNAL & EXTERNAL GRINDING

13 INTERNAL, EXTERNAL & RADIUS GRINDING

14 SIMULTANEOUS INTERNAL & EXTERNAL GRINDING

15 SURFACE GRINDING

16 CENTRELESS GRINDING

18 VERTICAL GRINDING

19 GRINDING CENTRE

20 AEROSPACE APPLICATIONS

22 HIGH-TECH RE-ENGINEERING

23 MAIN INDUSTRIES

26 SOME REFERENCES

27 OUR COMPANY, YOUR PARTNER

INDEX

GRINDING .03

YOUR PARTNERFOR MICRONS

15 SURFACE GRINDING

16 CENTRELESS GRINDING

18 VERTICAL GRINDING

19 GRINDING CENTRE

20 AEROSPACE APPLICATIONS

22 HIGH-TECH RE-ENGINEERING

23 MAIN INDUSTRIES

26 SOME REFERENCES

27 OUR COMPANY, YOUR PARTNER

04. GRINDING

LEADERSIN MACHINE TOOLS AND PRODUCTION

SYSTEMS

122 PRODUCTION SUBSIDIARIES WORLDWIDE

15TECHNOLOGY CENTERS

RESEARCHERS

1,679 4,000STUDENTS

OWN UNIVERSITY WITH

MONDRAGON

1,23774,060WORKFORCE

84%70%EXPORT RATE

22011,582TURNOVER (Million €)

DANOBATGROUP is the Machine Tool division of MONDRAGON Corporation, one of the most important European holding companies. Its production represents 40% of the total Spanish machine tooling market.

Founded in 1954, DANOBAT is part of DANOBATGROUP which is one of the largest machine tool and production system manufacturers in Europe and is specialised in different manufacturing technologies: grinding, turning, sawing, drilling, plasma cutting, punching and bending, boring and milling.

DANOBATGROUP’s strategy is to focus on niche applications for high-technology products and to deliver tailor-made solutions to customers in a wide range of industrial sectors.

DANOBATGROUP Headquarters

MONDRAGON Corporation Headquarters

GRINDING .05

DANOBAT is a global manufacturer with production plants in Spain, Germany and England and a sophisticated sales support and after-sales network covering 40 countries. Overseas sales in 2014 accounted for 84% of turnover.

In this catalogue, DANOBAT presents a complete range of grinding machines covering the machining of parts from smallest to heavy duty, single part batches to high production.

DANOBAT specialises in the construction of grinding machines suited to customer´s application.

The latest technologies are utilised to achieve the highest rigidity and precision. The modularity in the design makes it possible to achieve the shortest lead time and the optimum cost for a machine made to order. DANOBAT machines provide an ergonomic and quality solution with a user friendly and powerful software.

GRINDINGSOLUTIONS

Overbeck GmbH (Herborn - Germany)

Newall UK Ltd. (Peterborough - UK)

06. GRINDING

IK4-IDEKOIK4-IDEKO

AND GOIMEK

GOIMEK facilities Workshop at GOIMEK

IK4-IDEKO facilities Ultra-precision laboratory at IK4-IDEKO

Research & Development Centre dedicated exclusively to Machine Tools

Conscious of the need to develop and innovate its products to remain a market leader in Grinding solutions, DANOBAT is backed by IK4-IDEKO, whose main work consists of product development and optimisation as well as production process improvement.

Thus, DANOBAT subjects all components

and all machines to constant development at the IK4-IDEKO Technology Centre. This ensures that the design of its products and productivity can be continually improved and adapted to the latest technological innovations.

The high-precision laboratory IK4-IDEKO, which is both temperature and humidity controlled is dedicated exclusively to new projects and the development of machines, components and verification equipment necessary to

develop ultra precision applications and new prototypes.

The main activity of this 800 m2 prototype laboratory is to develop new machining technology and to collaborate with manufacturers and users to develop new machines. The laboratory, which is temperature controlled to +/- 0,5º, also serves as a demonstration facility for DANOBATGROUP´s technological capacity, carrying out trials, testings and optimising existing processes.

GOIMEKGOIMEK is DANOBATGROUP’s high-precision machining workshop, mainly dedicated to machining the group’s large-sized key components.

The workshop, located in the vicinity of the assembly plants, has state-of-the-art machining facilities: gantry milling machines, travelling column milling machines, double column surface grinding machines with

tangential and universal wheelheads, measuring machines in air-conditioned areas, painting cabinets, etc. It guarantees high precision supply of assembly components to the companies in the Group.

GRINDING .07

Measuring systems

We provide customised solutions for the most stringent grinding processes. Different commercial and in house measuring technologies are applied to our range of machines for in or post process applications.

Advanced software

The operation and programming of our grinding machines has been designed to meet the requirements of the users. The software has a modular design. The basic machine operating module software can be completed with other specific modules such as form and thread grinding, profiling of complex workpiece forms, monitoring , etc.

Hydrostatic technology

Our broad experience in grinding machine design & production allows us to provide the most suitable guideways and rotating solutions. Our machines can be supplied with hydrostatic linear motion and rotary technology to achieve the fastest and most accurate positioning for linear and rotation movements.

Digital & motion technology

Our grinding machines use digital drives in both linear and rotary axes, to ensure the most accurate positioning arrangements. Integrated linear motors are extensively used through our complete range of grinding machines.

INNOVATIONAND TECHNOLOGY

08. GRINDING

The compact design with small footprint combined with its high rigidity, make the CG the perfect machine to work in the most exigent industrial and production environments. A robust and reliable machine, the capacity to hold a grinding wheel of up to 760 mm in diameter, make this model the most attractive to those customers making high production series.The machine has as well flexibility to adequate more than one wheel, with the possibility to work with both internal and external grinding spindles.

In order to fit to the customers requirements, an automatic loading system can be easily incorporated, in the way of different technologies like robot, external or integrated gantry and custom made manipulation systems.For customers requiring the grinding of bigger parts, the PG model offers a production solution that can accommodate parts of up to 2000 mm length and wheels of max. 910 mm in diameter.

CHARACTERISTICS CG PG

Max. distance between centres mm 600 / 1000

Max. weight between centres kg 80 / 250 500

Max. diameter to be ground mm 440

Max. grinding wheel diameter mm 760 910

Max. peripheral speed m/s 60

EXTERNAL

CG PG

GRINDING .09

The LG range has been developed for high precision component grinding, such as cutting tools, hydraulic components and automotive parts. The machine’s natural granite base and the linear motor driven slides provide the high accuracy and thermal stability required for these high demanding applications. These specifications also allow the grinding of non-round components.The use of water cooled electric-spindle makes possible the combination of conventional and high speed grinding. This produces a maximum peripheral wheel speed of 140 m/s

and covers the range necessary for grinding with conventional abrasive (60 m/s) or superabrasives (up to 140 m/s) with maximum torque.In addition the machine is versatile and flexible with the direct driven B axis and the use of multiple wheels.Requirements of completely automated manufacturing processes are fullfilled with incorporation of customised automatic loading systems developed by DANOBAT, e.g. integrated gantry or robot solutions.

CHARACTERISTICS LG-200 LG-400 LG-600

Max. grinding length mm 200 400 600

Max. weight between centres kg 30 80 80

Max. diameter to be ground mm 200 300 300

Max. grinding wheel diameter mm 350 / 400 500 500

Max. peripheral speed m/s 35 / 140

EXTERNAL

LG

10. GRINDING

This moving table grinding machine range has been designed to fulfil the requirements of a wide range of applications that combine external, internal, face and taper grinding of components such as: transmission shafts, electric motor shafts, gas and wind turbine shafts, railway shafts, machine tools shafts, landing gear components, etc. Depending on the application corundum, CBN or diamond wheels can be used.

The machine base and sub-assemblies are made of stabilized perlitic cast iron. HG grinders can be equipped with a wide range of wheelhead configurations: straight, angular and “B”-axis which is driven by an integrated torque motor. Wheels are assembled on

hydrostatic bearing spindles,roller bearing or on DANOBAT designed electric-spindles.

In order to obtain the maximum machine performance HG machines can be equiped with in-process measuring systems, automatic wheel balancing system incorporating gap and crash, axial positioning system and taper correction, etc.

Depending on the application the machine can be equipped with an absolute multi-diameter measuring system MDM 300 or MDM 500, as an option.

HG series is a very flexible, ergonomic and easy to use machine with a wide range of configuration in order to suit the customer’s needs.

UNIVERSAL EXTERNAL & INTERNAL

HG

CHARACTERISTICS HG-62 HG-72 HG-92

Max. distance between centres mm 2000 4000 5000



Max. grinding wheel diameter mm 760 915 1060

Max. wheelhead power kW 30 45 45

Max. wheel peripheral speed m/s 45 / 60

GRINDING .11

The medium and heavy duty WT grinding machine range has a cross slide configuration to optimise the machine foot print. Machine main groups like weighting, workhead and tailstock are designed to grind components weighing up to 8 ton and 8 meter length. Gap bed option is available for large diameter swing components.

The machine base and sub-assemblies are made of stabilized perlitic cast iron. WT grinders can be equipped with a wide range of wheelhead configurations: straight, angular and “B”-axis which is driven by an integrated torque motor. Wheels are assembled on hydrostatic bearing spindles, roller bearing or on DANOBAT designed electric-spindles.

Depending on the application, corundum, CBN or diamond wheels can be utilised.

In order to obtain the maximum machine performance HG machines can be equiped with in-process measuring systems, automatic wheel balancing incorporating gap and crash, axial positioning system and taper correction system, etc.

Different wheelhead configurations can be installed combining ID and OD spindles for all kind of universal applications for the most demanding industries such as aviation, railway and power generation among others, offering the maximum flexibility to the customer.

Depending on the application the machine can be equipped with an absolute multi-diameter measuring system MDM 300 or MDM 500, as an option.

CHARACTERISTICS WT-62 WT-72 WT-92

Max. distance between centres mm 2000 8000 10000



Max. grinding wheel diameter mm 610 1060 1220

Max. wheelhead power kW 15 45 45

Max. wheel peripheral speed m/s 45 / 60

UNIVERSAL EXTERNAL & INTERNAL

WT

12. GRINDING

High precision machines for internal, external and face grinding, suitable for single part manufacturing and high production. The ID can also incorporate spindle turret, measuring head and automatic loading system.

Designed for the grinding of gear parts, cutting tools, bearings, unround discs and hydraulic components.The ID-400 L is prepared for the grinding of spindle shafts, spindle housings, tool adapters and heavy duty.

INTERNAL & EXTERNAL

CHARACTERISTICS ID-200 ID-400 ID 400L ID-600

Max. internal grinding diameter mm 100 200 300 700

Max. part length mm 100 190 1300 600

Work swing mm 200 400 500 900

Max. workpiece weight kg 30 70 / 170 170/350 500

X and Z axes stroke mm 400 / 200 400 / 450 400 / 450 650 / 650

ID ID-400 L

GRINDING .13

High precision grinding machines with integrated rotary axis in the workhead base.The CNC controlled motor and the 3 axes interpolation software allow the grinding of different radii without manual resetting of the pivot points.

Spindle turret for highest versatility with up to 4 spindles.Prepared for internal, external, radius, face and unround grinding, ideal for the machining of forming and cutting tools.

IRD

INTERNAL, EXTERNAL & RADIUS

CHARACTERISTICS IRD-200 IRD-400 IRD-600

Max. internal grinding diameter mm 100 200 460

“B0” axis swivelling range º +95 / -15 +95 / -15 +95 / -15

Work swing mm 200 400 600

Max. workpiece weight kg 30 70/170 170/350

X and Z axes stroke mm 400 / 200 400 / 450 650 / 650

14. GRINDING

Simultaneous machines for internal and external diameter or face grinding. The machines are equipped with best quality components, produce with the highest accuracies and reduce the idle times to the minimum.

Designed and manufactured for the grinding of gears, injection components, transmission components and other machine parts.

SIMULTANEOUS INTERNAL & EXTERNAL

CHARACTERISTICS IED-400

Max. workpiece length mm 250

Work swing mm 300

Max. workpiece weight kg 70 / 170

X and Z Axis stroke internal grinding mm 220 / 400

X and Z Axis stroke external grinding mm 320 / 220

IED

GRINDING .15

Double column slide way grinding machines with fixed or mobile cross rail and tangential and/or universal wheelheads.These machines have been designed for the grinding of machine tool beds and guideways, and high precision heavy and large components.

The machine base, columns and sub-assemblies are made of stabilised perlitic cast iron. In order to obtain the maximum machine performance the SG machines can be equipped with automatic wheel balancing system, gap and crash, automatic wheel changers, etc.

SG

SURFACE

CHARACTERISTICS SG

Max. table length mm 14000

Max. table width mm 3000

Max. wheel dimensions mm 760 x 200

Max. height to be ground mm 2000

Max. wheelhead power kW 37

16. GRINDING

The ESTARTA series of centerless grinding machines have been developed for infeed and throughfeed applications, for parts from diameter 0.5 to 250 mm, involving high volume production and stringent quality requirements.

In keeping with the DANOBAT philosophy of modular design, these centerless grinders are totally customisable machines and can be equipped with fix or mobile workcenter, cantilever or twin grip headstock and single or double slide, as well as load/unload systems, post-process measuring equipments, etc.

CENTRELESS

E-305/318/327

CHARACTERISTICS E-305 E-318 E-327

Part diameter min-max 1.5 - 50 1.5 - 120 3 - 250

Max. infeed grinding length mm 160 254 500

Grinding wheel dimensions mm 400 x 160 x 203.2 610 x 254 x 304.8 650 x 500 x 304.8

Grinding wheel peripheral speed m/s 35 / 50 35 / 50 35 / 50 / 63

Regulating wheel dimensions mm 250 x 160 x 127 305 x 254 x 127 355 x 500 x 203.2

Main motor kW 11 / 15 22 / 30 55 / 75 / 90

Net weight kg 3000 7500 16000

GRINDING .17

Base built on a natural granite for optimum thermal and dynamic stability, the E-315 centerless grinding machine has been designed for ultra-precision infeed works. All six axes are driven by linear motors with positional control courtesy through glass scales.

The grinding wheel headstock is based on an electrosplindle concept, which means there is no mechanical transmission, and allows speed variations from 20 to 100 m/s for grinding with a conventional, diamond or CBN wheel.

CENTRELESS

E-315

CHARACTERISTICS E-315

Part diameter min-max 0.5 - 50

Max. infeed grinding length mm 200

Grinding wheel dimensions mm 610 x 200 x 304.8

Grinding wheel peripheral speed m/s 20 - 100

Regulating wheel dimensions mm 305 x 200 x 127

Main motor kW 20

Net weight kg 10000

18. GRINDING

DANOBAT VG high precision vertical grinding machine range has been designed for optimal stability and rigidity. Positioning accuracy on X, Z, C and B axes guarantees excellent machining results.Typical operations of this range include grinding, measuring, turning, deburring, milling and miscellaneous machining.The machine is equipped with high precision motorized grinding spindle, fully enclosed machine guarding, dresser unit (2 single

diamond points), DoGrind conversational grinding software, web based remote system and computerized operator and maintenance documentation.Options include measuring devices for pre, in and post-process measurements; multi-spindle turret; 15/30 tool capacity magazine with tool changing taking place outside of the machining area and performed by robot, external set-up station and pallet clamping system and disc type dressing system among others.

VERTICAL

CHARACTERISTICS VG-600 VG-800 VG-1000 VG-1500 VG-2000

Max. diameter to be ground mm 600 800 1000 1500 2000

Max. grinding height mm 500 500 / 700 500 / 1000 500 / 1000 / 1500 500 / 1000 / 1500

Turret positions nr. 1 to 4 1 to 4 1 to 4 1 to 4 1 to 4

Table load kg 1200 1200 2000 3000 3000

C axis speed rpm 150 150 150 150 100

VG

GRINDING .19

IEV

Natural granite bed for higher thermal and vibration stability.Direct driven technology in all linear and rotary axes for higher accuracy and longer component life.Swivelling “B”-axis with integrated torque motor.Interpolation software for non-round and eccentric parts.

Options: measuring systems, automatic tool changer, tool magazine and automatic wheel balancing system.Designed for awkward shapes and unround work pieces with high accuracy requirements.

GRINDING CENTRE

CHARACTERISTICS IEV

Max. diameter to be ground mm 800

Max. grinding height mm 800

Turret positions nr. 4

Table load kg 800

C Axis speed rpm 300

20. GRINDING

The DANTIP machines are for precision grinding, deburring and measuring fully assembled variations of jet engine turbine rotor blade tips.The DANTIP grinds the blade tips of the rotor while they are being rotated at high speed, thereby presenting the blades to the grinding wheel under the appropriate operating conditions.

This feature ensures the highest degree of accuracy that can be obtained with current technologies.It has been shown that diametric tolerances can be held to 0.025 mm. This achievement is regarded as very important, since the clearance between the rotor blade tips and the outer housing has a critical bearing on the engine’s performance.

AEROSPACE APPLICATIONS

DANTIP

CHARACTERISTICSDANTIP

R1 R2 R3

Max. grinding diameter mm 400 700 1500

Max. grinding length mm 600 1000 1500

Max. component length mm 900 1425 2000

Workpiece speed min-1 20 - 6500 20 - 6000 10 - 4000

Wheelhead swivel degrees -10º / +115º -10º / +115º -10º / +200º

GRINDING .21

Machine designed and developed for precision grinding of different aircraft landing gear struts. Gap bed and traversing wheelhead configuration. Mobile workhead with maximum swivelling diameter up to 4 meters and different wheel-spindle configurations for OD, iD turning and threading operations.

Designed to machine the most advanced materials, such us HVOF, using the latest generation grinding wheels and dressing technologies.Recognized by the major landing gear OEMs and MROs through out the world as the best gap bed grinding machine for landing gear application in aerospace machine tool market.

AEROSPACE APPLICATIONS

CHARACTERISTICSDANUNI

2500/2500 3050/3400 4100/3400

Max. swing in gap mm 2500 3050 4100

Max. length between centres mm 2500 3400 3400

Max. width of gap mm 800 1400 1400

Max. swing over the table mm 840 1600 1600

Max. external diameter ground mm 610

DANUNI

22. GRINDING

DANOBAT-NEWALL has a vast experience in design, production and re-engineering of High Tech Machine Tools.DANOBAT-NEWALL offers remanufacturing services tailored to customer requirements that can go from a basic mechanical tune up, to the upgrading of the machines with the incorporation of new technical and safety features.Typical applications for the DANOBAT-NEWALL range of precision CNC controlled machines can be found in the

high volume automotive industry, specialized aerospace manufacturers and service providers throughout the world.Their expertise is in utilising the latest technology components and incorporating them into existing machine tools. The machine performance is therefore increased and overall output improved.The companies are forward thinking, incorporating both the customer’s process and machine design for the manufacture of re-engineered machines.

HIGH-TECH RE-ENGINEERING

BEFORE AFTER

GRINDING .23

INDUSTRIESMAIN

AEROSPACE

CAPITAL GOODS

24. GRINDING

AUTOMOTIVE

WIND POWER TOOLING RAILWAYS

GRINDING .25

26. GRINDING

REFERENCESSOME

AUTOMOTIVE & INDUSTRIAL VEHICLESBOSCHCATERPILLARDANADAIMLERDELPHIEATONFAW CHINA

FORDGETRAGGKNJOHN DEEREMAHLEMTURENAULT

SCANIASHANGHAI AUTOGEARSTEDRIVETRWVWZF

HEAVY DUTY APPLICATIONSAEROTECH PEISSENBERGALSTOM POWERATA GEARSCAFCINCINNATI EXTRUSIONEICKHOFF WIND POWERFISCHER & KRECKEGET GAMESA ENERGY TRANSMISSIONS

HARTCHROM AG STEINACHKLINGELNBERGLOHERMAN DIESELMARTINMOVENTAS OYMM MADERNRENK AG

SEW-EURODRIVESIEMENS AGSOLAR TURBINESST. LOUIS METALLIZINGUNION WERKZEUGMASCHINENVOITH TURBOWALDRICH COBURG

AEROSPACE & ENERGY GENERATIONAIRBUSAIR FRANCE INDUSTRIESALITALIAAMERICAN AIRLINESBOEINGDELTA AIR LINESGENERAL ELECTRIC

GE POWER SYSTEMSIBERIA AIRLINESITPLUFTHANSAMESSIER DOWTYPRATT & WHITNEYROLLS ROYCE

SAESLSIKORSKY HELICOPTERSSNECMA GROUPSR TECHNICSSTA ENGINESUNITED AIRLINES

GRINDING .27

Next to the customer from the beginning:· Local sales service team at your

disposal.· Production process analysis by local

product engineers.· Feasibility analysis.· Technical & economical study.

Customised solutions:· Customised machining solutions.· Improving machining process study.· Fixturing.· Tooling.· Software.· Acceptance trials machining

customer’s parts.

Together during the complete machine lifecycle:· Technical assistance by local service

engineers.· Teleservice.· Hotline.· Preventive maintenance.· Spare parts service.

Project management:· Machine set-up & commissioning.

· Personnel training.

· Production assistance.

In DANOBAT we offer a service to perform machining tests on our machines with your workpieces. In this way your company will be

able to see our facilities first hand, our experienced work force and

machine capabilities guaranteeing quality for your future investment.

OUR COMPANY, YOUR PARTNER

This

doc

umen

t is

not a

con

tract

. DAN

OBAT

rese

rves

the

right

of m

akin

g ch

ange

s to

all

mod

els

with

out p

rior n

otic

e. T

he il

lust

ratio

ns in

this

cat

alog

ue re

mai

n pr

oper

ty o

f DAN

OBAT

.©

DAN

OBAT

201

502

/201

5

DANOBAT Machine Tool Inc. USATel.: + 1 281 812 [email protected]

DANOBAT DO BRASILTel.: + 55 113 082 90 [email protected]

DANOBAT JAPANTel.: + 81 [email protected]

DANOBATGROUP INDIATel.: + 91 9819043038 + 91 9158884552 [email protected]

DANOBATGROUP CHINATel.: + 86 10 [email protected]

OVERBECK GmbHKonrad-Adenauer Str. 27D-35745 HERBORN GermanyTel.: + 49 (0) 2772 801 0Fax: + 49 (0) 2772 801 [email protected]

NEWALL UK LTD 1 Sturrock Way, Bretton, PeterboroughCambs, PE3 8YF EnglandTel.: + 44 (0) 1733 265566Fax: + 44 (0) 1733 [email protected]

DANOBAT Arriaga kalea, 21E-20870 ELGOIBAR (Gipuzkoa) SpainTel.: + 34 943 74 80 44Fax: + 34 943 74 31 [email protected]