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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.
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.
How a better Dressing Process can improve your Grinding Performance
One of the most effective ways to improve the quality and productivity of your grinding process is to methodically assess and fine tune the method for dressing your grinding wheels. When Meister engineers are called out to help solve a customer’s grinding problem, the majority of changes they make involve dressing. We often show our customers how to make their vit bonded CBN or diamond grinding wheel sharper for more aggressive cutting or duller for a smoother surface finish, simply by adjusting the dressing parameters. Manufacturers who take advantage of these tips can:
- improve productivity by reducing cycle time and making fewer wheel changes
- save money with better wheel life
- and improve part quality with better finishes and tighter tolerances.
This article provides an overview of the dressing process and why knowledge of it is essential to achieving optimal performance and productivity in your grinding operations. It also describes the latest emerging dresser technologies and provides a calculation tool to assist in setting up a new grinding operation or troubleshooting an existing one.
Dressing 101: Contrary to popular belief, the dressing of vitrified-bonded superabrasive grinding wheels is not a black art, but a well-known scientific process, much like the grinding process itself. Dressing is also a powerful tool that engineers can use for fine-tuning their grinding process and troubleshooting grinding problems. However, before you can use this tool effectively, you need a basic understanding of the various constituents of wheel dressing.
Dressing is a combination of two processes, truing and sharpening. Truing is the procedure used to ensure that the wheel, once it has been installed on the spindle, is optimally round. it may also refer to the methods used to create shapes on grinding wheel surfaces. Sharpening involves removing bonding material from in-between the abrasive grains to expose them so they are ready to cut. For vitrified-bonded wheels these two processes occur simultaneously.
Dressing Tool Selection: Numerous tools may be used to dress grinding wheels. They include simple handheld abrasive sticks; conventional abrasive rotary wheels used on driven or brake- controlled dressing spindles; single and multipoint stationery diamond tools; and a wide variety of rotary diamond tool configurations (cups, discs, and form rollers). Rotary tools are preferred for dressing superabrasive wheels, in particular vitrified-bonded CBN and diamond wheels. See the table below for recommended dressing tools by grinding wheel type.
Dressing Variables: Once the dressing tool has been selected there are six variables that are most frequently adjusted to yield an optimal dressing and grinding process, opening a whole new world of process improvement possibilities:
- Wheel and dresser surface speeds: Linear speed at the periphery of the wheel or dresser.
- Direction at point of contact: Uni-directional (wheel/dresser turning with each other), or Counter-directional (wheel/dresser turning against each other).
- Speed ratio: The ratio of dresser surface speed divided by wheel surface speed.
- Infeed amount: The depth of cut taken per pass by the dresser on the grinding wheel.
- Traverse speed: The linear speed that the dresser travels across the wheel surface.
- Overlap ratio: The number of wheel revolutions for the dresser to traverse a distance equal to its contact width.
Dressing Calculation Tool: Once you have mastered the basics, you are ready to make some calculations. The Meister Dress Calculation Tool is specifically designed to assist the user in setting up the optimal parameters for rotary dressing of vitrified CBN and Diamond grinding wheels. It can also be used to troubleshoot problems and understand the effects of changing different variables in the dressing process. To download your own copy of the Tool, click this link to open a preview of the file and then the “download” button to save the file to your computer.
Emerging Dresser Technology: As the old saying goes; “Use the right tool for the job.” Developing promising new dresser technologies is one of the most active areas of R&D being pursued at Meister Abrasives, with the introduction of diamond dressers that excel at both truing and sharpening superabrasive wheels simultaneously. Referred to as hDD (Hybrid Diamond Dresser) and cDD (CVD-tipped Diamond Dresser), these tools rely on a unique porous hybrid-bond diamond matrix. This matrix combines the porosity of a vitrified bond with the wear resistance of a metal bond. The cumulative advantages of this technology include:
- Superior Truing (accurate and consistent profile generation on the grinding wheel)
- Superior Sharpening (does not dull the grinding wheel)
- Low dressing forces
- Grinding wheel cuts better and achieves better part quality
- Lower dress in-feed or higher skip dress possible
- Dressing tool stays sharp – No conditioning required
Learn More: If you would like to improve your dressing process and need help, don’t hesitate to contact Meister and talk with one of our experienced sales engineers.
We’ve recently improved our very popular Dress Calculation Tool with an updated look, improved functionality, and guidance to help you get the best possible performance from your grinding operation.
This tool is specifically designed to assist the user in setting up the optimal parameters for rotary dressing of vitrified CBN and Diamond grinding wheels. It can also be used to troubleshoot problems and understand the effects of changing different variables in the dressing process.
Download your own copy of the new Dress Calculation Tool today by clinking this link to open a preview of the file and then the “download” button to save the file to your computer.
Vitrified CBN justified to replace Aluminum Oxide
25% total cost/part savings plus other benefits
This case study illustrates how Meister’s Total Cost Calculation Tool was used to justify the conversion of an aluminum oxide grinding process over to vitrified CBN. The application was an OD/face grind on a pump rotor shaft for truck engines.
Although the CBN wheel carried a >40% increase in abrasive cost/part, the savings in cycle time, productivity, and downtime for wheel changes far outweighed the additional abrasive costs to provide a total cost/part savings of over 25% and also provided a significant potential increase in capacity, not to mention improved part consistency and tightened control over surface finish, roundness and flatness. below are the details of the application and results. To download your own copy of the Total Cost Calculation Tool, please follow THIS LINK.
To view the entire worksheet: