Successful application of cDD dresser technology where extreme profile accuracy of < 2µm was required from the dressing tool.
Background: This customer was profile grinding a large range of gear sizes and profiles in small batches for an aeronautical fuel pump manufacturer using electroplated CBN wheels on a machine with no dressing spindle. Each part profile required a separate plated (EP) wheel, and there was no way to make profile corrections on the machine, especially if the profile of the EP wheel was not accurate enough.
Goal: Achieve the flexibility to change between different part profiles and make corrections and adjustments on the machine without needing to change the grinding wheel.
Solution/Results: This was accomplished with the installation of a new Gleason P90G machine with an onboard rotary dressing spindle, high precision Meister cDD dressing tool, and Meister vitrified CBN grinding wheels. Due to the required part tolerances, the accurate generation and maintenance of the grinding wheel profile was critical to success. The dual-layer Meister cDD dresser, with its CVD-reinforced porous hybrid diamond matrix, was supplied with a profile tolerance accuracy of < 2-microns to ensure success. As a result of this project the customer now has a highly flexible solution for grinding a wide variety of profiles without the need for costly downtime to change wheels and maintain a large inventory of different EP wheels. Also, the cDD rotary dressing solution allowed the customer to achieve a new level of profile accuracy and repeatability that was not possible with the old process. Furthermore, without the dependence on delivery times for new EP wheels, they were able to offer much shorter delivery times to their customer for new part designs.