Today, the world is looking for the possibility of improvement in productivity along with improvements in the surface finish on the components. The grinding wheel is perhaps the single most important element of the production grinding system. An improperly selected wheel or process can be a major source of persistent struggle and in-efficiency in the grinding process.
As we are aware the single most important purpose of the grinding wheel is to remove material easily, CUMI has developed a unique solution with ‘Micro Crystalline Grain – EX Series’ and a process monitoring & optimisation application known as “Grinding Cycle Monitoring System” which provides a ready means to measure quantitatively the grinding process through a ‘real time in process monitoring’.
Micro crystalline grain – Ex series
These are sharp/extruded grains of micro crystalline in nature with an aspect ratio of four times more than that of a regular grain
These are noodle shaped in nature increasing the natural
porosity in the wheel
Capable of handling higher feed rates (upto 3 times than a conventional grain)
Advantages & benefits over conventional grain:
Better cutting action: Due to the sharpness in its nature, this gives better ‘biting action’ on the component
Higher specific material removal rate (Q’): It can withstand higher feed rates of min 2.5 times
Higher depth of cut: Grinding muck generated from the higher stock can easily come out through the natural porosity in the wheel
More parts/dress: Due to micro crystalline in nature, the dressing due to the grain fracture can be deferred
Good surface roughness: Due to its inherent property of better ‘biting action’, it gives much better surface texture for a longer period
These grains can be used with the new generation CNC machines with higher rigidity, machines which has provision for skip dressing, machines with high pressure coolant flow.
Few Major applications: Gear grinding, roll grinding, angular grinding, internal grinding, centreless grinding, crank grinding, cylindrical grinding, creep feed grinding.
This can also be used in applications, which calls for replacement of milling to grinding.
Process monitoring & optimisation
Grinding cycle monitor is an instrument that monitors the power drawn by a grinding wheel with respect to the slide movement through LVDT (Linear Variable Differential Transformer) – It measures grinding power and slide infeed movement and captures these data on real-time basis.
This system is also used to capture various parameters like threshold power, maximum power drawn and axis position at maximum
power drawn which are key inputs for the design of the grinding wheel
and grinding process
Benefits with process monitoring:
To measure and analyse different grinding cycles
To optimise the grinding process and maximise the performance of the grinding wheel like need for dressing, effect of change in grinding / dressing feed rates, wheel / work speeds
To improve the Cp / CpK of Grinding Process
To analyse accurately the batch to batch performance of grinding wheel
To shorten the cycle time for product establishment and complaints resolution
To conclude – combination of micro crystalline grain – Ex series along with process monitoring can give a quantum leap in productivity of a grinding process.