Year End Review

2016 Brought More and Better Custom Tailored Solutions

In 2016, Meister Abrasives USA released a number of significant new products that increase the range of custom tailored solutions available to help customers solve their most perplexing grinding problems. These new products inspired record numbers of customers – and even some of our competitors – to visit us at IMTS in Chicago:

New 3D Abrasives Technology 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.

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.

Big Wheels: Meister Abrasives USA has expanded its large diameter wheel making capabilities with processes, materials and equipment mirroring those used by Meister Abrasives in Switzerland. With this installation in place, Meister Abrasives will be able to manufacture its entire line of super abrasive wheels (with the exception of a few specialty products) from virtually identical  operations in the United States and Europe.

Swiss Quality Pellet Wheels Made in USA: Large diameter CBN and Diamond pellet wheels are one of the first big wheel product lines to be transitioned over to Meister’s US manufacturing operations. European manufacturers have employed Meister pellet wheels for decades to obtain more consistent close tolerance fine grinding and lapping performance with uniform wheel wear characteristics. Now this technology is close at hand for US manufacturers as well.

Micro-Precision Certified cDD Dressers: A new generation of cDD diamond dressers deliver certified, best-in-industry tool radius tolerances which are essential for today’s most demanding micro-precision grinding applications. Meister’s micro-precision certified cDD dressers are the result of a multi-year R&D project which culminated in a major investment in manufacturing, measurement, and verification systems. They can be certified accurate to within 2µm (+/-0.001 mm) if the application requires.

Pushing the boundaries of current abrasive product capabilities is business as usual at Meister. If your grinding applications need a cost/performance boost, contact one of our sales engineers.  They routinely help get our customers processes to the next level.

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INTRODUCED AT IMTS 

New 3D Abrasives Technology

Innovative abrasive wheel technology combines micro-abrasive grains
with exceptionally porous wheel structures

Meister Abrasives revolutionary 3D bonding matrix microstructures technology make it possible to secure the tiniest grains of CBN within the most open self-sharpening bonding matrices ever created.

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.

Standard vs. 3D:. Meister’s 3D Vit-CBN wheel’s microstructure (right) provides excellent grit retention, unmatched coolant and chip carrying capability and maximizes grit exposure for sharper cutting.

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.

Meister’s new 3D advanced manufacturing process opens up opportunities for grinding performance improvements in areas currently pushing the limits of today’s best available technology.

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.

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Best IMTS Yet!

booth2

By many measures, the 2016 International Machine Tool Show in Chicago this September was the best IMTS yet. It certainly was for Meister Abrasives USA, Inc.  

A record setting 2,400 companies exhibited their wares at the show, which was visited by 115,000 registered attendees. Traffic to the Meister exhibit was robust and many of our booth customers (20% more than 2014) registered with us for follow-up information or sales calls.

wheel-in-machineAn advanced Studer CNC grinding system paired with an application-specific Meister Abrasives wheel and dressing disk was a big draw at the booth.

3dAn even bigger draw was Meister’s innovative new 3D Abrasives Technology. We were gratified to be visited by several high-level executives including a CEO and two heads of R&D (from competitors) who wanted to know what 3D was all about.

There was also a considerable amount of interest in Meister’s large diameter wheels, micro-precision grinding capabilities, and advanced dressing technologies. We’ll be exhibiting again at IMTS in 2018. But you don’t have to wait. Our Sales Engineers would be delighted to talk with you about our abrasive technology solutions to your most pressing grinding problems.

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CASE STUDY: 3D Vit-CBN Bore Grinding

For Injector Bodies of Marine Engines

shipIn this application the customer was grinding the bores of large fuel injection bodies for cruise ship marine engines. They were using CBN wheels and dressing tools from another manufacturer. The customer’s goals were to increase tool life, reduce grinding forces, and reduce cycle time.  Meister’s solution was a super-porous 3D Vit-CBN wheel in combination with a porous hDD Hybrid dressing tool. The result was a much sharper and freer-cutting wheel, and allowed them to grind much faster, while also reducing heat and wheel wear significantly.

fuel injector nozzle bore

fuel injector nozzle bore

  • Feature: bore Ø38 x 240mm
  • Material: 18CrNiMo6, 62 HRc
  • Stock 0.35-0.4mm
  • Finish: Rz 3
  • Machine: Voumard 150 CNC
  • Coolant: oil
  • Surface speed of wheel: 20m/s

 

 

–> Wheel: IS 32x32x13 X=3, CB114-64-150-VD-3422723d-wheel

–> Dresser: DD 32x15x8 X=3 W=1.5 V=20°

RESULTS:

  1. Grinding time reduced from 25min to 15min
  2. Skip dress increased from 2 components to 30
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Meister’s 3D Technology Featured in Manufacturing Engineering Magazine

manufacturing-engineeringThe November 2016 issue of Manufacturing Engineering Magazine highlights Meister Abrasive’s 3D technology in a Round-up article about the new generation of ultra-porous grinding wheels.

In this article: “Maybe it’s time to try some ‘Swiss Cheese,” the author, Ed Sinkora says:

Meister's 3D Abrasives Technology combines grits as small as 10 um in a matrix with pores as big as 500 um, enabling a tiny wheel on a quill (left) to grind the internal bore of this fuel injector nozzle without deflection, for a 7x improvement in cylindricality and taper.

Meister’s 3D Abrasives Technology combines grits as small as 10 µm in a matrix with pores as big as 500 µm, enabling a tiny wheel on a quill to grind the internal bore of this fuel injector nozzle without deflection, for a 7x improvement in cylindricity and taper.

“These days the most important theme in super abrasive grinding wheel development isn’t the abrasive, it is the bond. The diamond or CBN grains do the cutting, but the bond plays a decisive role in exposing the grains to the workpiece and enabling coolant to remove heat. Without exposed grains the wheel won’t cut. And without porosity in the bond, coolant won’t be able to flush away material with the heat that would otherwise damage the workpiece, not to mention the wheel. So while no one seems to be touting new super abrasives, all the high-tech players are experimenting with new, open bonds.”

Sinkora goes on to cite Meister’s 3D technology as “the clearest example of a recent improvement in bond technology.”

Follow this link to view the complete article.

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Join the Crowd!

and visit Meister Abrasives      Swiss quality made in USA 3

IMTSBAdvanced Technology Highlighted at IMTS 2016
IMTS 2016 is underway, and there is still time to plan a stop at Meister Abrasive’s Booth # N-7351, McCormick Place, Chicago (September 12-17). You’ll get a first-hand look at two important abrasives technology advancements:

  • Dresser Photo croppedNew cDD diamond dresser technology
    capable of being certified accurate to
    within 2µm (+/- 0.001 mm).
  • Meister Abrasives will introduce products incorporating its innovative 3D abrasives technology early in 2016New 3D Abrasives Technology which allows Meister
    Abrasives to customize the porosity of its abrasive products to provide previously unachievable performance characteristics.

In addition, visitors will be able to:

  • Check out a new Studer S11 CNC grinder equipped with a Meister Abrasives diamond wheel and cDD dressing disk…a configuration ideal for aerospace HVOF component grinding.
  • Inspect a large CBN pellet wheel for fine grinding, made by Meister Abrasives, USA.
  • Say hello to Meister Abrasives Switzerland’s Chief Executive Officer and Chief Technologist, Dr. Peter Beyer and confer with Meister Abrasives USA’s Applications Engineers about solutions to your most pressing grinding challenges.
group photo B(Left to right): Dr. Peter Beyer/CEO and Chief Technologist Meister Abrasives AG; Bruce Northrup/Vice President and General Manager Meister Abrasives, USA; Tom Cappadona/Sales Applications Engineer Midwest Territory; Roy Auerbach/Sales Applications Engineer Southeast Territory; Patrick Roberts/ Sales Applications Engineer Northeast Territory.
  • And sample some of our Swiss chocolate!Meister ChocolateWe look forward to seeing you at the show!
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Seven Important Reasons… (#7)

To visit with Meister Abrasives USA at IMTS 2016

Continued…Reason 7

layout

See us at Booth # N-7351 at IMTS 2016, McCormick Place, Chicago (September 12-17). You’ll be in for a treat for a number of important reasons:

  • Reason #1: New cDD diamond dresser technology capable of being certified accurate for form tolerances of 2µm (+/- 0.001 mm).
  • Reason #2: New 3D Abrasives Technology which allows  Meister Abrasives to teaser piccustomize the porosity of its abrasive products to create performance characteristics that were previously unachievable
  • Reason #3: Sample some of our Swiss Chocolate.
  • Reason #4: A red cabinet displaying solutions that push the limits of today’s best available technology.
  • Reason #5:  Explore our wide range of industry-and-application-specific grinding solutions for bearings, automotive, fuel injection, semiconductors, tools & cutters, and medical products.
  • Reason #6:  Learn about how we make our Swiss quality products right here in the USA. We make wheel sizes from less than 1 mm up to 1200 mm in North Kingstown, RI, so you don’t have to wait for your products to cross the ocean.
  • Reason #7: Tailored SOLUTIONS

Tailored Solutions Banner Talk to our sales engineers about Meister Tailored Solutions that are a perfect fit for grinding applications based on your specific cost and quality objectives.

LOOKING FORWARD TO SEEING YOU AT THE SHOW!!!!

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