machine tool
Features and effects of the automatic balancer "Zero Shin" for machine tools
1. By simply attaching the automatic balancer "Zero Shin" to various rotating parts, the three weights inside the balancing device instantly balance, eliminating runout and improving machining accuracy and surface roughness. Manual balancing is unnecessary, and grinding wheels and other parts can be mounted without balancing and then machined after dressing.
2. By using the automatic balancer "Zero Shin," deterioration over time is prevented, and the lifespan of each part is extended (the lifespan of consumables such as grinding wheels and cutting tools is extended by more than 50%). Furthermore, processing vibrations caused by uneven wear are suppressed, resulting in a positive effect of 20% to 30% energy savings.
3. Increased rotational vibration and machining noise all lead to uneven wear and deterioration over time. However, by installing the automatic balancer "Zero Shin," zero-core rotation is maintained, all unstable elements are suppressed, the positive benefits are enhanced, and ideal unmanned machining can be maintained.
4. Can be retrofitted to existing products.
Examples of differences between fixed balance and automatic balancer "Zero Shin" installation
(1) Comparison test of drilling processes using a standard tool and a tool equipped with the automatic balancer "Zero Shin" .
The results of a comparative drilling test using the short standard tool ① shown in photo A and the longer tool ② , which has a baby chuck attached to the automatic balancer "Zero Shin" .
The hole drilling in the thin workpiece shown in photo B was completed without any problems.
In the blind hole drilling of the thick workpiece shown in photo C , the short standard tool ① broke after drilling the first hole, making it impossible to continue. However, the longer tool ② , equipped with the automatic balancer "Zero Shin" and a baby chuck, was able to continue drilling eight holes, but the difference was confirmed, so the process was stopped.
Tools equipped with the automatic balancer "Zero Shin" suppress runout even under machining load, even at long lengths.
(2) Hole drilling using the automatic balancer "Zero Shin" tool on a vertical machining center from Company M.
SS400 material
60mm×30mm×3.2mm
Φ6 3-flute carbide drill
Outer diameter h6 finish
0~-0.009 tolerance
Machining with a Φ6 drill at a pitch of 6: A wall remains between the machined holes, with a thickness of 0 to 0.01 mm. (With standard tool machining, the wall between the machined holes disappears.)
The automatic balancer "Zero Shin" tool has been proven to suppress shaft runout!
(3) Comparison test of machined surfaces using an ultra-precision machining center <Difference in runout under the same machining conditions>
"Comparison of machined surfaces using standard tools and Zero-Shin tools"
Material: SKD11 HRC59-61 20mm square block
Processing machine: YMC430 manufactured by Company A
Cutting tool: Φ2-R0.2 Nisshin Tool Radius E
Machining conditions: Rotational speed S24000, Feed rate F1500
Standard tool machining, 700x magnification.
Automatic balancer "Zero Shin" tool processing 700x
(4) Photos of the fixed balance nut and the automatic balancer "Zero Shin" nut specifications.
Conventional fixed balance nuts are the type that require manually moving three weights to achieve balance.
The "Zero Shin" automatic balancer with a nut specification features a weight that is not fixed but is always in a state where it can swing.
The "Zero Shin" automatic balancer nut allows for immediate machining by simply attaching the grinding wheel to the grinding wheel flange and dressing the outer circumference of the mounted grinding wheel, eliminating the need for time-consuming and laborious balance adjustments.
This eliminates the need for skilled grinding professionals, making grinding possible even for amateurs.
Conventional fixed balance nut
Automatic balancer "Zero Shin" nut specification
Comparison photos of the ground surfaces using a fixed balancer and an automatic balancer.
Machining done using a used PSG52AN grinding machine (test sample: PA grinding wheel: SKD11 HRc60 material)
The top of the photo (blue frame) shows the standard flanged surface, and the bottom (red frame) shows the flanged surface with the automatic balancer "Zero Shin" installed.
You can see that the surface image (indicated by the red frame) is clearer. The automatic balancer "Zero Shin" installed results in less shaft runout.
(6) Condition of the grinding wheel before and after use with the ZS230 type automatic balancer "Zero Shin" nut specification.
While typical fixed-balance flanges cannot accommodate grinding wheels up to this extent, flanges equipped with the "Zero Shin" automatic balancer allow grinding wheels to be used close to the flange diameter.
One company has reduced its grinding wheel usage by approximately 50% by installing the automatic balancer "Zero Shin".
A: Image of a new whetstone attached.
B : Image after processing, before grinding wheel replacement.
Quartz glass is machined using a φ30 mounted diamond grinding wheel at 6000 rpm, 250 mm/min, and a thickness of 0.01 mm.
The standard tool created a step, but the automatic balancer "Zero Shin" does not show any step.
Standard Tool Machining There is a step at the ⇒ mark.
Tool Equipped with Automatic Balancer "Zero-Shin" No step at the ⇒ mark.
The photo shows a milling machine with a quick-change holder fitted with an automatic balancer "Zero Shin," and the other photo shows the surface of the processed leather.
※In the photo with the red frame, the version without the automatic balancer "Zero Shin" shows a disordered processing path, the bottom surface is uneven, and the cut is irregular and incomplete.
※ The photo with the blue frame shows that the automatic balancer "Zero Shin" is present, resulting in a uniform machining path and a clean, whitish machining surface.
Standard flange machining data
Test machining (standard flange machining) at Company A.
Noritake WPA60H Grinding Wheel
φ350, rotational speed 1800rpm
Processing material S45C raw material
Machined with a balance spectrometer value of 0.01um.
Automatic balancer "Zero Shin" flange processing data
Test machining (ZS flange machining) at Company A
Noritake WPA60H Grinding Wheel
φ350, rotational speed 1800rpm
Processing material S45C raw material
Machined with a balance spectrometer value of 1.03um.
The surface roughness is one order of magnitude better when equipped with the automatic balancer "Zero Shin".