>90% reduction in dresser cost/part!
In this case study, a high-volume manufacturer of cam rollers was seeking an improvement in their grinding process. Meister engineers identified an opportunity for significant cost reduction by replacing their existing stationary natural diamond dressing tools with hybrid-bond cDD tools.
The new tools utilize an engineered CVD insert that is surrounded by a diamond-encrusted porous hybrid-bond matrix.
In addition to the engineered bonding matrix, the Meister tool was designed with 5mm of useable diamond that maintained the same contact area and dressing conditions for its entire lifetime. Here is a comparison of the tools and the results achieved in the process.
RESULTS ACHIEVED:
- lifetime of tool increased from 1-day to 80-days
- dresser cost per part reduced by more than 90%
- surface finish improved from a range of (0.2-0.35µm) to < 0.26µm
- capacity increased with less time needed for dresser changes
- no maintenance or rotating of the tool required. Tool stayed sharp for entire lifetime.
- more stable process
