Grenzebach Maschinenbau GmbH

The machine were developed specially to meet the requirements of the Friction Stir Welding (FSW) process. The focus during the development of these machines was geared towards dynamic and precise process control as well as an intuitive control and operating concept. 4-axes gantry system – designed for high axis dynamics and precise line guidance. The integrated C-axis allows the welding head to rotate by +/-720° and enables much higher process dynamics for joining complex path trajectories with narrow radii.

Workpiece supply systems for enhanced productivity

In terms of cycle time, the rapid loading and unloading of workpieces is just as important as the dynamics and speed of the welding machine. Modular, expandable, automatic feeding systems for simultaneous welding and loading / unloading of work pieces outside of the machine. The loading and unloading of components can be done manually by the operator with the help of a manipulator or an indoor crane, or fully automated.

Friction Stir Welding

The Friction Stir Welding technology (FSW) by Grenzebach enables the joining of technically pure metals, alloys and mixed material compounds while providing a solid bond of exceptional quality. During the FSW process a rotating, wear-resistant welding tool generates frictional heat at the welding zone. The material becomes malleable and is stirred along the welding path by the welding tool without reaching the melting temperature of the joining materials. The stirred material is compacted by the tool shoulder and a solid, media and pressure-tight joint between the work pieces is formed. Compared to conventional fusion welding processes (e.g. arc welding), FSW does not require additional welding wire, inert gas or complex exhaust systems. Furthermore, FSW does not generate any discernible noise, emissions or optical radiation.

https://www.grenzebach.com/products-markets/friction-stir-welding-technology/4-axis-fsw-machines-of-the-dsm-series/

The robot-based FSW systems from Grenzebach are characterized by their flexibility, as well as the possibility to realize difficult 3D welding curves. R&D robot cells from Grenzebach are ideal for Research & Development projects. These cells can be combined with any additional equipment, such as welding tables, measuring equipment or media supply for the highest flexibility.

Friction Stir Welding

The Friction Stir Welding technology (FSW) by Grenzebach enables the joining of technically pure metals, alloys and mixed material compounds while providing a solid bond of exceptional quality. During the FSW process a rotating, wear-resistant welding tool generates frictional heat at the welding zone. The material becomes malleable and is stirred along the welding path by the welding tool without reaching the melting temperature of the joining materials. The stirred material is compacted by the tool shoulder and a solid, media and pressure-tight joint between the work pieces is formed. Compared to conventional fusion welding processes (e.g. arc welding), FSW does not require additional welding wire, inert gas or complex exhaust systems. Furthermore, FSW does not generate any discernible noise, emissions or optical radiation.

https://www.grenzebach.com/products-markets/friction-stir-welding-technology/rd-systems/

Due to the addition of a second gantry to the DSM two independently working welding heads are available for the welding operation. The immediate use? A reduction of the effective cycle time! But that's not all: Especially in the case of high production volumes, this leads to economic potentials, which are directly addressed with the D-DSM series. Therefore the efficiency boost of the overall invest can be reduced significantly with a reduction of system and equipment demands.

D-DSM2400 Double spindle equipment

• Independently operating welding heads for reduction of the effective cycle time
• Workpiece supply system from both sides for cycle time concurrent loading and unloading
• The usual low-level heat input due to the DynaSTIR technology

 Workpiece supply systems for enhanced productivity

In terms of cycle time, the rapid loading and unloading of workpieces is just as important as the dynamics and speed of the welding machine. Modular, expandable, automatic feeding systems for simultaneous welding and loading / unloading of work pieces outside of the machine. The loading and unloading of components can be done manually by the operator with the help of a manipulator or an indoor crane, or fully automated.

Friction Stir Welding

The Friction Stir Welding technology (FSW) by Grenzebach enables the joining of technically pure metals, alloys and mixed material compounds while providing a solid bond of exceptional quality. During the FSW process a rotating, wear-resistant welding tool generates frictional heat at the welding zone. The material becomes malleable and is stirred along the welding path by the welding tool without reaching the melting temperature of the joining materials. The stirred material is compacted by the tool shoulder and a solid, media and pressure-tight joint between the work pieces is formed. Compared to conventional fusion welding processes (e.g. arc welding), FSW does not require additional welding wire, inert gas or complex exhaust systems. Furthermore, FSW does not generate any discernible noise, emissions or optical radiation.

From cast iron to steel casting to aluminum cast and forged parts: Grenzebach manufactures high-quality industrial casting parts for technical equipment. The casting parts are used in special machinery within the automation industry, such as industrial robots or machine tools. The parts are given the finishing touches at the Grenzebach machining center. 

Milling, lathe turning, drilling: We own all processing steps for casting parts. In the Grenzebach machining center we have access to the latest technology with a CNC and multi-axle machine park because high-precision machining is a must for us. We process the workpiece with a flatness and surface precision of 8/1000 mm. It goes without saying that we also integrate innovative technologies like our Friction Stir Welding. For our customers we apply all painting methods for casting parts in-house. The automated Grenzebach paint-shop stands for high-quality results.

For many years now we have worked side by side with reputable customers within the automation industry who profit from our experience with casting methods, processing, production, surface treatments and quality control. Our supply chain lets us choose from different types of castings to satisfy the demand for casting parts that are ready for installation and processed in accordance with the European and international quality requirements. 

We also design and build molds and models tailored to the needs of our customers for both individual and optimized serial production of high-grade casting parts. We strive for short lead times and increased value.

https://www.grenzebach.com/products-markets/casting-parts/