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screw. They can also substitute the flat nozzles used in creep feed grinding for round nozzles used on narrow wheels for applications like radial groove grinding. The swivels also allow flat nozzles to be swiveled and oriented to aim at the sidewalls of the wheel. The nozzle system minimizes the downtime associated with finding and repairing a dedicated nozzle, makes it easy to aim the cool- ant, and delivers a more effective jet to where it’s aimed. Barnes said it also cut their scrap rate by decreasing burn thanks to the system’s higher pressure and side wall jets.


He’s Known as “Dr. Cool” for a Reason One reason Cool-Grind’s sys- tem delivers a more effective jet is Webster’s understanding of fluid dynamics. (It’s the subject of his PhD.) Cool-Grind’s nozzle apertures were customized for the Barnes CDCF grind- ers based on the conventional aluminum oxide abrasive used, wheel speed, and grinding power. The pressure available from the pump also allows the jet speed to match the wheel speed. And the form of the nozzle tips and stabilizer ends are designed and machined to produce a coherent coolant stream with modest fan-out before impacting the grinding wheel.


A similar installation at Goodrich delivered a 67%


reduction in flow rate, double the pressure at the manifold, better precision, elimination of burn, a 40% reduction in required grinding power for some applications, 25% more parts per dress of the vitrified wheel, double the life of the plated CBN wheel, quicker setup, first part perfect after setup, and the ability to use all the machines in a cell simultaneously without central coolant system starva-


tion. That’s a long line of major improvements to an existing grinding cell just by changing nozzles.


Null Grinding with a New “R-Axis” Gage The latest aerospace grind- ing news at United Grinding (Miamisburg, OH) is the addi- tion of an R axis with a movable gaging head to their Studer S11 cylindrical grinder. Vice President for Cylindrical Grinding Hans Ueltschi said they typically tackle applications like control valves, fuel system components, pistons, and actuators with extremely tight tolerances and recently had to figure out how to grind precise lands on the edges of a spool.


Studer added an R-axis to the S11 cylindrical grinder to enable a gage to automatically measure length and position along multiple points on a tight tolerance valve spool, speeding the process of getting to the right dimension.


The part had multiple edges with multiple lands and had to be tested on a flow bench to validate the correct edge posi- tions. If any land does not meet specifications the part must re- turn to the grinder for more work until the correct edge or “null” position is achieved.


While a conventional posi-


tion/length measuring gage would offer some feedback about part size and wheel wear, its fixed position would prevent it from getting real-time data along the whole length of the part if it involves multiple edges. Studer’s so- lution was to add an R axis with a gaging head that moves automatically along the table to be in front of the wheel at the right time to measure the length and position of each edge as it’s being ground. This delivers a more accurate edge grinding process in less time because it enables in-process control to compensate for any grinding wheel wear and temperature or process related impacts. Besides speeding the null grinding process, Studer’s innovation also makes it less dependent on operator skill.


83 — Aerospace & Defense Manufacturing 2016


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