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Investment at Gamet Bearings Increases Accuracy of Machine Tool Bearings
Following a sustained period of growth, 600 Group subsidiary Gamet Bearings has recently invested in a new grinding cell to increase capacity, improve bearing accuracy, reduce costs and improve both process consistency and customer satisfaction.
In the specialist world of ultra high precision tapered roller bearings, Colchester based Gamet Bearings is a world leader. With technology originally developed in France and transferred to the UK by 600 Group over 50 years ago, Gamet in the UK has developed to become the premier supplier of these bearings for machine tool and other specialist applications.
The recent growth of “teach” type lathes such as the Harrison Alpha and the Colchester Combi, the acquisition of the Gamet France business in 2001 and the rapid growth in the Chinese market have together led to a substantial increase in demand for these specialist bearings. This growth had put pressure on existing manufacturing processes, many of which dated back 50 years and relied on selective assembly techniques to achieve the desired precision.
In particular, the hollow ground steel rollers, of which there are typically 23 in each bearing, need to be produced to size and taper tolerances of +/- 1 micron. Existing methods could only achieve +/- 10 microns, and so a worldwide search was conducted to find a machine capable of grinding rollers to the required tolerance without the need for selective assembly. Trials were conducted over a period of two years to find a suitable CNC cylindrical grinder that could consistently achieve Gamet’s exacting demands.
Working closely with local Colchester firm Curtis Machine Tools (CMT) an automatic load/unload station was specified complete with vision system for roller orientation and incorporation SPC.
The new cell is located in Gamet’s air-conditioned precision grinding facility. Roller blanks are turned on a Colchester Tornado CNC lathe and are loaded into a bowl feeder. The CMT vision system checks the blanks for size and correctly orientates them for loading into the grinding machine. Inside the work area they are mounted on a precision three point slow taper mandrel for a first rough grinding operation followed by a second precision finishing operation which is tied in to the datum roller end face for accuracy. The outside diameter, taper and datum face are all machined in a single operation. The whole process, including load and unload, takes less than 40 seconds and is 100% confirmed by the in-process gauging capability in the grinding cell.
Gamet’s General Manager and Director, Gerry Shrimpton comments “This new installation has transformed the place and brings us right into the 21st century. This is a very important investment for both Gamet and the 600 Group. We spent over two years making sure that we had the right approach and equipment, but it was worth it.”
He continues “Our new cell is far more accurate than the old manual methods, it works unmanned for periods of 24 hours, occupies two thirds of the floor space and has released 5 people for redeployment within the Company. Throughput time has reduced from typically 2 weeks to just 24 hours and our predicted payback period is 30 months. But far more important to us are the benefits to our customers of more accurate and more consistent bearings with improved performance and quicker delivery.”
