New 3D Abrasives Technology
Innovative abrasive wheel technology combines micro-abrasive grains
with exceptionally porous wheel structures
The highlight of Meister Abrasives’ IMTS 2016 was the introduction of a new 3D Abrasive Technology that makes it possible to secure the tiniest grains of CBN (or diamond) within the most open bonding matrices ever created. The new 3D Technology drastically reduces forces within the grinding process to make it easier to finish grind deep bores while achieving consistently superior finishes and geometric properties. An innovative self-sharpening bonding matrix results in superior grit retention for longer wheel life and increased dressing intervals.
According to Dr. Peter Beyer, PhD, CEO, and Chief Technologist for Meister Abrasives, the new technology is the result of an intensive R&D effort that spanned 18 months. It involved the exploration of unique materials and manufacturing techniques to develop a new self-sharpening bonding matrix unlike any other that has been used to date.
With this innovative approach, abrasive grains are held securely within the posts of a honey-comb structured bonding matrix. This microstructure provides excellent grit retention, unmatched coolant and chip carrying capacity, and maximizes grit exposure from the wheel’s surface for sharper cutting.
This new technology will be particularly useful to manufacturers who have been stymied by hard materials that must be ground to micro-precision form, finish, and ever-tightening geometrical tolerances while providing low grinding forces that are essential to produce very smooth surface finishes and minimal deflection to the quill or walls of the component.
Dr. Beyer cited fuel injectors as an example of a bore grinding application that will benefit from this new technology. He said, “The requirements of these applications include tight dimensional tolerances and ultra-smooth finishes to be produced within very deep bores. An ideal wheel would be very sharp with fine grains held within a very open bonding matrix that allows freer flow of coolant for efficient heat and material evacuation.”
He said, “Until now, the porosity of a wheel (its openness) had to be reduced by the manufacturer as grain sizes were reduced for finish grinding applications.
The new 3D technology eliminates this restriction. Today we can incorporate grits ranging from 10-50 microns within matrices that have pores as large as 500 microns.”
3D wheel structures reduce forces within the grinding process, which previously could only be achieved by grinding less aggressively for longer cycles. With 3D technology there is no need to sacrifice removal rates when incorporating fine grits.
3D Technology is a part of Meister’s portfolio of innovative abrasive products, dressing tools, ancillary equipment, and technical support that allows it to dial up custom-tailored solutions for every customer’s specific grinding requirements.