Mattison Surface Grinder Rebuild
To the left is a picture of the front of a 30" x 72" Mattison Die Block grinder as it is being unloaded for remanufacture and Fagor CNC retrofit.
To the right is another picture of the back of the 30" x 72" Mattison Die Block grinder.
To the left the Mattison bed is being ground on our 60" x 60" x 20' Gray way grinder. Tolerance is .0001 per foot.
To the right the bottom of the table is being ground.
To the left the ground bed is being leveled before hand scraping the bottom of the table to mate with the base. We cannot perfectly match the table angles to the base during way grinding. Final match has to be by hand scraping.
To the right the base has been Prussian blued and red die spotting ink is applied to the table bottom. The red gives us a better contrast with the blue. The table is slid back and forth on the base which transfers the blue to the high spots on the bottom of the table. These high spots are then scraped away and the process is repeated until there is an even pattern of blue on the table bottom. This indicates proper bearing quality. Lack of sufficient bearing quality forces oil into non-contact areas and increases wear in contact areas causing pre-mature wear.
To the left is the finished bed.
To the right the dovetail ways of the column are being ground. Tolerance is .0001 per foot.
Here the vertical slide is set up on the way grinder. The Y-axis dovetail ways are being ground straight and perpendicular to the vertical dovetail ways.
To the right is another picture of our set up for grinding the Y-axis dovetail ways. The ways are ground primarily to establish perpendicularity to the Z-axis ways. They will have to be hand scraped to mate with the dovetail ways of the spindle housing.
To the left the dovetail ways of the spindle housing are being ground straight within .0001 per foot. They also must be parallel with the centerline of the spindle.
To the right the spindle bearing is being hand scraped to mate with the spindle itself.
To the left the ground spindle housing is being inserted into the Y-axis of the vertical slide. The spindle housing is the master and the ways and gib in the vertical slide must be hand scraped to mate.
To the right can be seen the vertical slide after bluing above and ready for hand scraping to match the spindle housing dovetail ways. This procedure must be repeated many times to achieve proper bearing quality. As can be seen by the size of the castings and difficulty in handling them this is a long process. This is also where a disreputable rebuilder could cheat their customer by NOT repeating the process enough to get proper bearing spots.
To the left the second vertical dovetail ways of the vertical slide are being scraped to mate with the master column. Red and blue die ink can barely be seen on the opposite vertical way which has already been scraped in.
To the right can be seen the completed bluing on the female vertical dovetail ways. Centers are relieved per industry standard practice. This prevents the way surface from becoming curved as the machine becomes worn.
To the left the height of the dovetail flats from each other is being measured with a dial indicator on a height gage. They must be equal at the top and bottom of the vertical slide. Differences are corrected as the bottom side of the vertical slide is scraped to mate with the column.
On the right the original crown tying the two columns together has been replaced by a 1" thick plate. The original vertical feed screw & nut on the left and splined shaft on the right have been replaced by two 1-1/2" ball screws & nuts. The machined boxes on top of the plate allows for securing the ends of the ball screws and mounting the servo motors. 
On the left can be seen one of the ball screws and ball nuts. To the right of center in the picture is the shaft of a hydraulic counter balance cylinder which reduces the amount of work the servo motors have to do and also prevents the head from dropping should the brakes on the servo motors fail.
To the right is the hardware machined to mount the ball nuts as pictured above. All new Trabon lubrication blocks, tubing & fittings have been installed.
To the left is pictured the top of the remanufactured machine with hydraulic counterbalance cylinder. One servo motor acts as the master while the second one is a slave.
To the right is pictured the finished 30" x 72" Mattison/Fagor CNC grinder. The longitudinal axis remains hydraulic due to the weight of the table, the magnetic chuck and the mold bases to be ground. The machine holds .0005 on twelve blocks evenly space on the chuck's surface.
To the left is a view of the back of the machine.
To the right is a close up of the Fagor control panel.
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