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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.
Meister’s New HPL Anti-Friction Technology Gets High Grades
Since Meister introduced its new HPL anti-friction bond technology the Company has been conducting field trials with numerous customers looking to improve their high precision grinding processes. The tests compare results produced by standard Vit-CBN grinding wheels versus the performance of wheels incorporating Meister’s new HPL anti-friction bond technology. The results of the field trials to date have been impressive.
HPL wheel technology relies on premium grade CBN crystals fixed with durable, porous, friction-inhibiting bonding matrix making it possible in many instances to adjust grinding processes to achieve faster grinding of difficult materials without sacrificing quality due to wheel loading and/or part burning.
The first 55 trials included 48 I.D. and 7 O.D. applications. They covered deep bore grinding, blind-end bore grinding, heavy stock form grinding, creep-feed grinding and high stock removal out-of-round grinding. In 85% of the trials, the new HPL technology worked very well, often providing cost-effective advantages over the grinding product the customer was currently using:
Longer Wheel Life – 36% of the participants in the trials were able to increase dressing intervals to achieve significantly longer wheel life.
Closer Tolerances – 38% were able to reduce grinding forces. This resulted in less wheel deflection so that the process resulted in better tolerances.
Part Burning Eliminated – Customers who were having a problem with burn marks on their workpieces, (16% of the field trial participants), were able to completely eliminate them by using HPL Wheels.
This innovative HPL wheel technology is only in the early stages of commercialization. Watch for upcoming reports demonstrating even more impressive results as we increase our knowledge of how this anti-friction technology can be applied to an ever-widening range of grinding applications.
The Meister Group was honored to receive highly coveted 2017 Preferred Supplier Awards from two of the world’s leading global technology companies. Shaeffler Technologies designated Meister and Schmeier as the preferred suppliers for grinding and dressing tools while the Bosch Group recognized Meister and Schmeier for their exceptional competence and performance with the Company’s Materials Group.
Significant Accomplishments in 2017
Most of our customers had a good year in 2017 and Meister Abrasives USA was out front providing them with the products they needed to achieve superior quality efficiently and economically. As a result, sales grew by more than 20% from 2016 levels and we had one of our best years ever.
While it might have been obvious that we were going all-out to meet our customers immediate needs, there was also a great deal going on – mostly behind the scenes – important achievements that will allow Meister to provide customers with even better products and services in the future.
Here are the highlights:
Up-Dated Toolbox Tools: Many of our subscribers find the Tools in the Toolbox section of this blog to be particularly useful. In 2017 we updated two of our most popular calculation tools – the Total Cost Calculation Tool and the Dressing Calculation Tool. They are available cost-free along with our popular tutorials on Dressing For Success and Top Ten Bore Grinding Problems and How to Solve Them Today. You will also find case histories detailing specific performance improvements customers have obtained by using carefully selected Meister Wheels in combination with best grinding practices. We will continue to expand these useful tools in 2018.
Dresser Product Line Expansion: Well-dressed wheels perform better, last longer and can significantly reduce per part manufacturing costs. So it is not surprising that sales of our dresser products were at an all-time high in 2017. Meister continued to advance its program of developing solution-specific dresser specifications and configurations including micro-precision dressers certified accurate to within 2µm (+/- 0.001 mm) if the application requires. We’ll have a lot more to say about our innovative dressers in future blog posts.
New Anti-Friction Wheel Technology: After an 18-month R&D effort Meister introduced its NEW HPL WHEEL TECHNOLOGY. It relies on premium grade CBN crystals fixed with a durable, porous, friction-inhibiting bonding matrix to allow substantially faster grinding of difficult materials without sacrificing quality due to wheel loading and/or part burning.
Big Wheels Made in America: 2017 was our first full year of producing large diameter (>Ø500mm) wheels using processes, materials and equipment mirroring those used by Meister Abrasives in Switzerland. Our customers’ enthusiasm for these American-made products has been gratifying.
Expanded Team Effort: Early in 2017, the highly regarded European internal grinding abrasives product manufacturer, Alfons Schmeier, was acquired by Abraxos Holding AG, Switzerland, Meister’s parent corporation. Since that time both companies have been working closely to share manufacturing and R&D resources where appropriate and extend the reach of their respective product lines around the globe. For example, a number of Schmeier products have been presented to Meister’s USA customers as solutions to specific grinding problems and are currently undergoing trials.
Semiconductor/Photovoltaic Support: Sales/Applications Engineer Salman Kassir is leading an effort to introduce new and innovative wafer-grinding process solutions pioneered by Meister in Europe into the United States, Canada and Mexico. A number of significant trials are underway.
Looking Ahead: All the initiatives reviewed here will continue to be on our agenda in 2018. We are looking forward to meeting as many of our existing and prospective customers as we can at IMTS 2018 this September.
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.