WHY REVAMP OR RETROFIT YOUR ROLL GRINDER?

Over years of continuous operation, roll grinding machines experience wear, accuracy drift, and outdated control systems. A full new machine investment is often not justified — especially when the structural foundation and major castings remain sound. Prime Machine Tools offers a cost-effective alternative: professional revamping, retrofitting, and modernization that brings your machine back to — or beyond — its original specification.

 SECTION 1 — MECHANICAL REVAMPING

After long-term machine use, critical mechanical components suffer wear, loss of flatness, and degraded accuracy. Our mechanical recondition service systematically restores every key assembly — giving your machine a new lease of life with improved rigidity, reduced breakdown frequency, and restored geometric accuracy.

1.1 Bed Slideway Scraping

Slideway scraping is the most critical operation for restoring machine accuracy. Our skilled craftsmen perform precision hand-scraping on all major slideways, delivering flatness and straightness that cannot be achieved by grinding alone.

• Improves machine accuracy — reduces bed error and achieves high-level flatness on guideways
• Creates micro-oil pockets that ensure continuous lubrication, reducing friction and wear for longterm stability
• Fitting of anti-friction material (Turcite-B or equivalent) on mating surfaces for smooth, low-stick-slip movement
• Achieves straightness and parallelism to within micron-level tolerances
• Verified using precision straight edges, autocollimators, and test bars

1.2 Machine Mechanical Reconditioning

All major mechanical sub-assemblies are disassembled, inspected, repaired, and reassembled to original or improved specification:

•  New spindle shaft and bushes — precision ground for minimal runout and vibration-free operation
•  New ball screw installation with pre-tensioned nuts for zero backlash and high positioning accuracy
•  New centralized auto-lubrication system for guideways and spindle
•  New coolant system installation with upgraded filtration and pump
•  Headstock reconditioning — bearings, seals, drive components, and chuck assembly
•  Tailstock reconditioning — quill, center, adjusting mechanism, and clamping
•  Steady rest reconditioning — contact shoes, hydraulic/pneumatic circuits, and alignment
•  Restoration of all mechanical assemblies to original or better-than-original condition

1.3 Machine Geometry Check & Alignment

• Before and after all mechanical work, a comprehensive geometry survey is performed using calibrated precision instruments:
•  Machine level check using precision spirit levels and laser alignment tools
•  Flatness and straightness measurement of beds and slideways
•  Spindle runout measurement — radial and axial
•  Headstock–Tailstock alignment check (parallelism and coaxiality)
•  Table travel parallelism to spindle axis
•  Post-reconditioning: final geometry verification with full inspection report supplied to customer

Key Benefits

A geometry-verified machine produces consistently accurate rolls — reducing scrap, rework, and operator adjustments

SECTION 2 — CNC RETROFIT & ELECTRICAL UPGRADATION

Retrofit, refurbishment, and CNC upgrade re-engineer the machine's control and drive systems. The result is a machine with modern high-precision CNC control, improved process automation, and dramatically reduced electrical maintenance costs.

2.1 CNC Controller System

•  Replacement of obsolete NC/PLC with latest generation Siemens / Fanuc CNC controller
•  Full servo motor replacement — X-axis (infeed), Z-axis (traverse), C-axis (rotation), and U-axis(crown/camber)
•  New servo drives with modern bus communication (PROFIBUS / EtherNet)
•  Humanized HMI operator panel with intuitive touchscreen interface
•  Automatic crown/camber grinding — camber values assigned by program, U-axis CNC controlled
•  New main electrical panel: design, fabrication, and installation to current safety standards
•  Full rewiring — power cables, signal cables, and earthing to current norms
•  CNC programming — machine logic, interlocks, alarms, and diagnostics
•  Remote diagnostics capability — machine data accessible over network

2.2 Advance Process System

Automatic Wheel Balancer

•  In-built spindle automatic wheel balancing system (Balance Systems, Italy or equivalent)
•  Static and dynamic unbalance correction during grinding — no manual intervention required
•  Increases surface finish quality and extends spindle bearing and grinding wheel life

AE Sensor — Touch Detection & Gap Control

•  Acoustic Emission (AE) sensor mounted in wheel head spindle for touch detection
•  Gap control system — detects air-grinding and brings wheel to work contact instantly, reducing cycle time
• Crash protection — monitors for abnormal contact force and triggers emergency retract
•  Wheel dressing monitoring — detects dressing completion and prevents over-dressing

Auto Wheel Dressing System

•  Automated dressing cycle — triggered by AE sensor or programmed interval
•  Envelope monitoring with master acquisition and comparison for consistent wheel profile
•  Reduces dressing tool and grinding wheel consumption and maintains consistent surface finish

Linear Encoder — High-Precision Axis Feedback

•  High-end absolute linear encoders for X-axis (infeed) and U-axis (crown) — micron-level repeatability
•  Direct position feedback bypasses mechanical backlash — achieves Ra ≤ 0.1 µm and cylindricity ≤ 1 µm

2.3 Roll Measurement & Inspection Systems

In-Process Roll Measuring System

• Absolute gauge for in-process diameter measurement during grinding
•  Closed-loop size control — machine automatically stops at target diameter
•  Eliminates manual measurement and reduces skilled operator dependency
•  Data logging of roll dimensions for quality traceability

Roll Crack Detection System (LISMAR / Equivalent)

•  COMBI Tester using Eddy Current Technology + Ultrasonic Technology simultaneously
•  Detects surface defects: cracks, bruises, spalling
•  Detects sub-surface defects: cracks, debonding, inclusions
•  Prevents defective rolls from returning to the mill — avoids catastrophic strip breakage

Value to your business

In-process measurement and crack detection reduce scrap rolls and prevent costly mill incidents.

SECTION-3 - MACHINE ACCESSORIES SUPPLY

Prime Machine Tools supplies a full range of precision accessories and peripheral systems to support efficient, accurate, and reliable roll grinding operation — whether as part of a revamping project or as standalone supply

SECTION-4 - OUR REVAMPING PROCESS

We follow a structured, customer-transparent process to ensure every revamping project is delivered on time, within scope, and to the agreed specification

SECTION-5 OUR EXPERIENCE & CREDENTIALS

5.1 About Prime Machine Tools

Established in 1992, Prime Machine Tools has over 30 years of specialized experience in precision grinding machine manufacturing, supply, and service. We are a leading manufacturer and exporter of CNC Roll Grinding Machines, with installations across three continents.

•  Over 30 years of roll grinding machine expertise
•  In-house design, manufacturing, and service capability — all under one roof
•  Deep knowledge of mechanical, electrical, and CNC systems on all major roll grinder makes and models
•  Experienced service engineers with field experience across India and export markets

5.2 Global Supply FootPrint

Prime Machine Tools has supplied and commissioned CNC Roll Grinding Machines in:

• India
• UAE
• Egypt
• Kuwait
• Kenya
• Algeria
• Nepal
• Bangladesh
• Uganda
• Zambia
• Mozambique
• Portugal

5.3 Our Customers

•  SAIL (Steel Authority of India Limited)
•  Tata Steel (Tinplate Unit)
•  Jindal Steel
•  Visa Steel
•  Kandil Steel (Egypt)
•  Misr Steel (Egypt)
•  MMI Steel
•  Hulas Steel (Nepal)
•  Vishal Aluminium
•  Alumill Tech Gulf LLC (UAE)
•  T.K. Group
•  RMC, Global, Vedik Steel — and many more

SECTION 6 — WHY CHOOSE PRIME MACHINE TOOLS?