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ABRASIVES


Meister’s previous ID grinding bond (considered an industry benchmark) (left) and the new, more porous, 3D bond (right). 3D cuts cooler and with less force, improving accuracy and wheel life.


It’s also important to note that Meister hasn’t yet experi- mented with 3D using different grinding parameters, trying (for example) to increase feed rates to see if they can gain cycle time improvements at acceptable taper or surface fi nish costs. But it’s clear that 3D Abrasives Technology will push current


best practices in various applications in which hard materials must be ground with micro-precision accuracy and fi ne fi nishes.


Blasting Through Cranks at Nearly 20,000 sfm Sticking with vitrifi ed CBN wheels, Radiac (Oswego, IL)


offers new bonds and wheel bodies in their Genis line. Marty Prokipchak, business development manager, says the Genis features a “higher strength bond, with a specifi c porosity that carries coolant into the grinding zone, optimizing wetting. This yields higher thermal resistance and profi le retention, or form holding, to be able to get more grinds between dresses, extending the life of the wheel. A Genis wheel can also run up to 100 m/sec.”


A lighter wheel is easier to mount and less taxing on the machine’s spindle.


The Genis targets cylindrical grinding in the automotive in-


dustry, a key application being camshaft grinding and crankshaft grinding. One customer testing the wheel grinding 52 Rockwell camshafts on a Schaudt Zeus found that the Genis increased life over a standard vitrifi ed CBN product by 60%. In a test on a Junker machine grinding a 42CrMo4 crankshaft (54–58 Rock- well), the 700-mm diameter Genis running at 100 m/s (19,685 sfm) produced 5900 shafts versus 4200 (a 40% increase). Radiac has also introduced a variant with a carbon fi ber


core (Genis CF) to decrease weight up to 80%. A lighter wheel is easier to mount of course, and less taxing on the machine’s spindle. Perhaps more importantly, Prokipchak says the car- bon fi ber core also dampens any vibration, reducing harmon- ics and potential chatter, thereby improving wheel life and part


64 AdvancedManufacturing.org | November 2016


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