Tags3D aerospace anniversary automotive bore grind bore grinding calculation tools calculator CBN cDD consultant customer service diamond diamond dresser dresser Dressing fine grinding finish hDD hDD Dresser history HPB HPL HVOF hybrid IMTS IMTS-2012 IMTS-2016 IMTS 2010 milestones pellet wheels people Problem Solving process optimization prototype R&D semiconductor stationary dressers technology trouble-shooting Troubleshooter variables vit diamond vitrified CBN vitrified diamond
The Meister Toolbox Blog is on-line!
The Meister Toolbox is our blog, containing case studies, how-to/tutorials, company news, success stories, technology updates, and even calculation tools to help make your job easier. The Meister Toolbox will be updated frequently, and if you sign up for our mailing list, we will let you know when information that may be useful to you has been posted here. It’s our way of keeping you connected to the future of superabrasives technology today. We hope you’ll find it informative and look forward to your feedback.
New wheel technology achieves higher throughputs and better micro-precision accuracy while nearly doubling the parts per wheel.
This case study summarizes the successful application of HPL (High Performance Lubrication) Vitrified CBN wheels in a demanding application for Electronic Power Steering.
In this application, the customer was grinding the ball tracks in an EPS Steering Nut with a vitrified CBN wheel from another manufacturer. The application was demanding because of heavy stock removal, aggressive feeds, difficult coolant application, and asymmetrical loading of the grinding wheel. The trick was to find a wheel that was tough enough to stand up to the rigors of the application, while at the same time producing a smoother finish, a burn/crack-free surface, and reduced cost/part.
HPL combines a high concentration of premium grade CBN crystals with a durable, porous, and intrinsically lubricated bonding matrix, which allows faster, cooler, and more efficient grinding with less wheel wear. The technology was tailor-made for this application, and with HPL the customer was able to speed up the process and drastically reduce abrasive cost/part, while also improving the surface finish and eliminating the onset of cracks and burns. Below is a summary of the process and the results.
This case study is just one example of the benefits of this new technology. HPL can also produce impressive results in applications such as deep-bore fuel injection nozzles, lash adjusters and tappets, creep-feed grinding of tool steels & superalloys, and out-of-round grinding for punches. Stay tuned for additional case studies coming soon.
Intrinsic lubrication delivers faster grinding without burning...
According to Dr. Peter Beyer, Meister Abrasives’ CEO and Chief Technologist, the new HPL super abrasive wheels are a significant extension of the Company’s proprietary HPB (High Performance Bonding Technology). It departs from conventional approaches to manufacturing wheels with lubricating properties that rely on fillers that can clog the wheel’s pores and are less likely to distribute lubricating properties evenly.
Meister’s NEW HPL Wheels rely on premium grade CBN crystals fixed within a durable, porous, intrinsically lubricated bonding matrix to allow substantially faster grinding of difficult materials without sacrificing quality due to wheel loading and/or part burning.
Applications for the new HPL abrasives technology include:
- Deep bore grinding with limited coolant access, such as fuel injection nozzle components.
- Blind-end bore grinding such as lash adjusters and tappets.
- Heavy-stock form-grinding applications such as electronic power steering (EPS) ball-nut tracks.
- Creep-feed grinding of tool steels and superalloys.
- High stock removal out-of-round grinding for punches.
- Any application where the concentration of oil and lubricant are less than ideal or the flow of coolant is impeded, as is the case with deep bores.
Dr. Beyer indicated that R&D for this technology has been going on for about 18 months. He said, “Early adapters in Europe and the United States have tested dozens of application-specific HPL recipes with excellent results. Although the extent of performance improvements varies from application to application, I can say that our customers rarely switch to a new technology for existing production grinding applications if they are not realizing a 25% or better improvement in productivity.”
If you have an application that could benefit from our new HPL wheels, talk to a Meister Applications Engineer
“Top Ten Bore Grinding Problems…and how to solve them today” now available as a white paper.
Bore grinding is probably one of the most difficult grinding applications to master. That’s why we created a series of blogs to address the most frequently encountered problems and how they can be resolved. These problems/solutions evolved from a collaborative effort by Meister’s Applications Team.
The blogs proved so popular that we’ve compiled them into one comprehensive white paper complete with magnified graphics to add clarity. You can still find the individual blog chapters in the Meister Toolbox. However, if you prefer a version with everything in one place for fast, convenient access, download the white paper here.
If, after reading the white paper, you need to go deeper, contact a Meister Applications Engineer and we’ll do our best to help. We may be able to offer just the right solution.
Delivers Faster Grinding Without Burning
Meister Abrasives’ New HPL (High Performance Lubrication) Grinding Wheels rely on premium grade CBN crystals fixed within a durable, porous, intrinsically lubricated bonding matrix for faster grinding of difficult materials without sacrificing quality due to wheel loading and/or part burning.
HPL wheels contain a lubricant that is intrinsic to the bonding matrix chemistry and is released uniformly as the wheel breaks down. Wheels manufactured with this technology minimize friction from bond//workpiece interactions, minimize heat generation, and deter the onset of metal loading into the bond structure.
HPL technology also makes it possible to implement wheel characteristics that are not economically feasible with standard vitrified bondings. The superior grit retention and lubricating properties of the bond make it possible to utilize high concentrations of premium grade CBN crystals that in a standard bonding matrix would generate too much pressure and heat. This allows Meister to manufacture wheels with superior cutting performance and wear resistance to others on the market.
The unique properties of these intrinsically lubricated wheels address a wide range of problems including: burning of parts, wheel loading, excessive wheel wear due to heat related issues, and quality issues due to temperature sensitive materials. They are ideal for CBN grinding applications requiring maximum wheel sharpness and lubricity.
If you have an application that could benefit from our new HPL (High Performance Lubrication) Grinding Wheels, contact a Meister Applications Specialist, HERE.
The part was a hardened thin-walled steel sleeve. The customer was dissatisfied with the results he was obtaining from a bore grinding process using a vitrified-bonded CBN wheel. Grinding pressure was too high, which resulted in deformation of the part and poor roundness results. The only viable solution at the time was to slow down the process to an unacceptable cycle time of 45-seconds. The production requirement was to be under 35 seconds.
In addition to the slow cycle time and part deflection, the customer also complained that after the dressing cycle, they were seeing a size drop along with increased taper that only corrected itself after grinding 2-3 parts.
After reviewing the wheel and dresser designs, Meister engineers decided to have a closer look at the dressing process. It was determined the dress process was unnecessarily dulling the CBN wheel, causing it to build too much pressure during the grind cycle. This resulted in quill deflection which, in turn, caused the taper and size control issues after dress as well as the part deflection and roundness problems. Using the Meister Dress Calculation Tool, the following chart shows the changes that were made to improve the dressing process and the grinding results.
A screen shot of the full calculation tool can be seen by clicking the thumbnail image to the left.
Results/Conclusions: Moving from a counter-directional to a uni-directional dress (both wheel and dresser rotating in the same direction), combined with a faster dress traverse rate resulted in a more open and aggressive cutting wheel, so the customer was able to increase feed rates and get the cycle time down from 45 seconds to 35 seconds, while keeping the roundness in spec. Furthermore, taper and size control dramatically improved, so there were no more dimensional issues after dressing. As a bonus, since the wheel was cutting more efficiently, the customer found he could increase skip dress from 10 to 13 parts, allowing a much improved wheel life.
Would you like your own copy of the Meister Dress Calculation Tool? Download it HERE.
US-Manufactured Pellet Wheels make their debut in 2017
In 2016 we showcased Meister’s investment into its US production of large diameter CBN and diamond grinding wheels, including pellet wheels up to Ø1200mm. We are proud to report that production of pellet wheels for customer orders started in early 2017, and here is one example of vitrified diamond pellet wheels on a new Supfina Spiro double-side fine grinding machine.
Mobile friendly and updated with the latest Abrasive Innovations
In addition to a modern, mobile-friendly layout, the site contains the latest information on products, applications, and abrasive technology innovations.
Check it out at www.meister-abrasives.com.