defect list grinding machinesdefective grinder machine

grinder inspection checklist (for angle, portable and bench grinders)

grinder inspection checklist (for angle, portable and bench grinders)

Grinders cause countless injuries and issues on construction and industrial sites; partly because they are inherently dangerous, and partly because the nature and familiarity of them make people more complacent with the dangers.

The primary purpose of these checklists is to ensure that workers/the worker is using and operating the grinder safely (whether that be an angle grinder, portable grinder or bench grinder) and that the grinder is in safe working order.

roll grinders - traversing grinding saddle - herkules - specialist for roll machining

roll grinders - traversing grinding saddle - herkules - specialist for roll machining

Herkules roll grinding machines are well-known throughout the world for their excellent performance in terms of precision, speed and efficiency. The user-friendly control, developed within HerkulesGroup specifically for roll grinders, achieves extremely precise machining results. The combination of an ultra-fast control and state-of-the-art measuring devices allows for correction grinding on the fly: adjustments are made in the course of the machining operation, and additional machine runs are no longer necessary.

All core components of the machines are manufactured to very high standards within the company group, which results in excellent quality, flexibility and a long service life. Decades of experience in constructing roll grinding machines as well as their modular design allow Herkules to build machines which are perfectly tailored to your application.

All roll grinders are optionally available with our patented MonolithTM machine bed in sandwich design. The advantages: outstanding damping properties, thermostability and significantly lower foundation costs.

Herkules offers a series of grinders with travelling tables that unite a number of technological benefits, such as the possibility to control the grinding process on the fly. High precision, mechanical rigidity and damping, as well as sophisticated measuring and control technology characterize the design of Herkules roll grinders. The strong ribbing guarantees the rigidity of the machines. The combination of hydrostatic and hydrodynamic guideways ensures highest precision and a long service life. Symmetrical load sharing results in absolute thermostability.

Distinct features of the upper and the lower carriage are thermostable and wear-resistant double V-guideways. They have a self-centering effect on the grinding head and absorb torsional forces during grinding particularly well. The grinding head is always ideally guided when machining big rolls (grinding head retracted) and smaller ones (grinding head extended). That results in consistently high grinding quality on the roll. Thanks to the combination of hydrodynamic and hydrostatic spindle lubrication, Herkules achieves a minimal bearing play for both very high and very low revolutions per minute and thus a precise positioning of the wheel under changing load conditions.

The combination of hydrodynamic and hydrostatic spindle lubrication means that the machine benefits from the advantages of both lubrication systems. The advantage of the hydrostatic part is that it prevents metallic friction, especially during the initial and final stage of the grinding spindle operation. The hydrodynamic lubrication produces an oil pressure of 750 bars, which would be impossible to reach with hydrostatic lubrication. This ensures that the grinding spindle is always positioned right in the centre of the rotation axis/bearing axis, regardless of load conditions.

The Z-axis has a backlash-free master/slave drive. For fine feeding, the C-axis is designed as a tilting axis. In the curve grinding mode in particular, the tilting axis refines the wheel feed in the direction of the X-axis by a factor of 40 to the fraction of a m. Typical mechanical disruptions such as the stick-slip-effect as well as any kind of reverse backlash are ruled out.

The tailstock is also made of high-quality cast iron. It ensures the precise positioning of the roll in Z direction. The tailstock can be equipped with a fully automatic dresser and a device for gauging measuring devices. Further equipment options are a motor-driven longitudinal motion, motor-hydraulic motion of the quill or a chock turning device.

For a stable and vibration-free roll support Herkules offers a wide selection of steady rests which can be customized to your specific roll range, particularly with regard to the steady pad design and lubrication system. The product range includes hydrostatic, hydrodynamic and combined hydrostatic-hydrodynamic steady rests as well as special solutions for grinding with or in chocks.

All grinding machines are also available with a patented MonolithTM machine bed. The machine bed is torsionally rigid and thermostable. Its sandwich construction consists of an iron-cast, ribbed upper section, fiber-reinforced high-performance concrete and a steel floor panel with special damping elements. As there is no metal connection between the upper and lower section, vibrations are effectively damped. The integration of the workpiece bed and grinding bed into a joint machine bed guarantees permanently precise alignment even after many years of operation.

In order to reduce wear to a minimum, the lubrication system of the grinder guideways combines a hydrodynamic and a hydrostatic part. The lubrication of the linear axes and at the grinding spindle bearing is hydrodynamic. Even if machines are used intensively, the running surface needs to be rescraped after 15 years of operation at the earliest. The particularly high pressures of the grinding spindle bearing produce a reliable lubricating film and a permanently wear-free operation. At speeds close to a halt, the hydrostatic lubrication makes sure that there is no contact between the running surfaces.

Geometry measuring devices are directly connected to the control without any additional interfaces. The measuring data is therefore transferred very quickly. For operating the sophisticated control functions, the operating system is equipped with real-time data processing (TwinCat). This combination allows for the correction of the grinding operation while the grinding wheel is still engaged correction on the fly.

High-quality measuring technology is the prerequisite for a precise control of the grinding process and key to achieving perfect grinding results. Herkules offers measuring and inspection systems which are developed and manufactured within the company group:

The C-frame measuring gauge measures the roll geometry at a frequency of one sec. Per second, 1,000 measured values are registered, processed and evaluated. The measuring probes are placed opposite the center of the grinding wheel so that an absolutely exact image of the current grinding status of the workpiece can be displayed.

The Eddy Current measurement reliably recognizes and locates cracks on the roll surface. Changes in the roll texture and subsequent hardening are detected during the measuring process as well. Since the Eddy Current measuring sensor is integrated in the roll measuring system, measurements are carried out during grinding and therefore without delay.

Manufacturing defects within the roll as well as fatigue from operation in the mill can be detected during a separately running ultrasonic inspection. The ultrasonic inspection detects possible cracks below the roll surface/in the barrel up to a depth of 250 mm. A typical application of ultrasonic technology is the inspection of compound cast rolls where the critical transition lies between the shell and the core of the roll.

The Roll Surface Inspection System registers and records the reflexion of a laser beam on the roll surface. Special image evaluation software detects and displays roll surface defects such as chatter marks and feed lines, commas or combinations of these and defines their location. The system also detects defects occuring only once.

Herkules has successfully developed a grinding technology that uses CBN wheels in cooperation with the Austrian grinding wheel producer Mach Rotec. The combination of Herkules grinders, HCC/KPM controls and measuring devices and Mach Rotec grinding wheels ensures reliable and repeatable grinding results.

By achieving greater stock removal in shorter grinding times, Herkules MACHtechnology saves substantial time. Optimizing stock removal significantly extends roll service life. Further advantages are absolutely homogeneous, flawless surfaces along the entire roll as well as high energy efficiency.

On request Herkules roll grinders are delivered with automation systems. The machines must be equipped with the latest version of our CNC control for that. All conceivable automation features can be combined from measuring and inspection systems to fully automated roll loading systems. Such tailored solutions make each Herkules grinder unique.

Salzgitter Flachstahl GmbH orders another roll grinding machine Coming out on top in direct comparison with a competitorAmerican companies rely on Herkules quality Herkules USASuccessful cooperation 20years of partnership between ArcelorMittal and Herkules

abrasive grinding defects. hazards related to abrasive grinding wheels - bright hub engineering

abrasive grinding defects. hazards related to abrasive grinding wheels - bright hub engineering

As we know from the study of the process of abrasive grinding that it is basically a process of metal removal through abrasive action. Needless to say, such a procedure would surely result in the production of sufficient quantities of heat. Hence it is very important to study the effect of heat during the grinding process in order to have an idea of the thermal effects involved. These effects can be studied from two perspectives - the effect on the grinding wheel and the effect on the work piece itself. Apart from heat there are other types of defects as well which could arise during the process of grinding. All these have been dealt with in the sections below

We will first study the thermal effects of grinding and these can be covered under two headings namely effects of the wheel and that on the work piece respectively as shown below.Grinding wheel thermal effectsThe main effect of heat on the grinding wheel is the development of the cracks known as grinding cracks. These cracks appear in a direction that is at right angles to the grinding marks. Obviously if these cracks are present in too large a number, the grinding wheel would need to be replaced.Work piece thermal effectsThe work piece is more affected by the heat mainly because it retains a larger proportion of the heat generated during the grinding operation. The work piece can get damaged in various ways including some or all of the following.There could be certain reactions which take place at the high-temperatures attained during grinding. These reactions could result in minor changes such as discolouration of the surface due to oxide production, or there could be more serious chemical damage to the work piece.The material properties of the work piece might change due to the application of sudden heat during the process. The material could become brittle or it could get scratched due to ultra-sharp abrasive material.One of the solutions if the work piece is getting overheated is to change the grinding wheel with another wheel which is made up of relatively softer material.Other Problems and safety measuresApart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

The main effect of heat on the grinding wheel is the development of the cracks known as grinding cracks. These cracks appear in a direction that is at right angles to the grinding marks. Obviously if these cracks are present in too large a number, the grinding wheel would need to be replaced.Work piece thermal effectsThe work piece is more affected by the heat mainly because it retains a larger proportion of the heat generated during the grinding operation. The work piece can get damaged in various ways including some or all of the following.There could be certain reactions which take place at the high-temperatures attained during grinding. These reactions could result in minor changes such as discolouration of the surface due to oxide production, or there could be more serious chemical damage to the work piece.The material properties of the work piece might change due to the application of sudden heat during the process. The material could become brittle or it could get scratched due to ultra-sharp abrasive material.One of the solutions if the work piece is getting overheated is to change the grinding wheel with another wheel which is made up of relatively softer material.Other Problems and safety measuresApart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

Work piece thermal effectsThe work piece is more affected by the heat mainly because it retains a larger proportion of the heat generated during the grinding operation. The work piece can get damaged in various ways including some or all of the following.There could be certain reactions which take place at the high-temperatures attained during grinding. These reactions could result in minor changes such as discolouration of the surface due to oxide production, or there could be more serious chemical damage to the work piece.The material properties of the work piece might change due to the application of sudden heat during the process. The material could become brittle or it could get scratched due to ultra-sharp abrasive material.One of the solutions if the work piece is getting overheated is to change the grinding wheel with another wheel which is made up of relatively softer material.Other Problems and safety measuresApart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

The work piece is more affected by the heat mainly because it retains a larger proportion of the heat generated during the grinding operation. The work piece can get damaged in various ways including some or all of the following.

There could be certain reactions which take place at the high-temperatures attained during grinding. These reactions could result in minor changes such as discolouration of the surface due to oxide production, or there could be more serious chemical damage to the work piece.The material properties of the work piece might change due to the application of sudden heat during the process. The material could become brittle or it could get scratched due to ultra-sharp abrasive material.One of the solutions if the work piece is getting overheated is to change the grinding wheel with another wheel which is made up of relatively softer material.Other Problems and safety measuresApart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

The material properties of the work piece might change due to the application of sudden heat during the process. The material could become brittle or it could get scratched due to ultra-sharp abrasive material.

One of the solutions if the work piece is getting overheated is to change the grinding wheel with another wheel which is made up of relatively softer material.Other Problems and safety measuresApart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

Other Problems and safety measuresApart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

Apart from thermal heating there are several other problems which may arise during the process of grinding. For example the grinding wheel might be wearing too soon and this can be rectified through the use of harder wheel so that its relative hardness is much more compared to the work piece.If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

If the finishing of the work piece is not coming oun as desired, that means that there is certainly a matter with the structure of the wheel and it needs to be changed to either a coarse wheel or a finer wheel depending on which problem is arising.If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

If the grinding wheel is not properly balanced, that can also lead to problems such as chatter marks.Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

Normally an operator would check a wheel thoroughly before actually mounting it on the machine. The mounting should be perfect and proper guard should be there over the wheel to prevent injury to the operator.

top 5 centerless grinding problems & grinding troubleshooting | hindustan abrasives

top 5 centerless grinding problems & grinding troubleshooting | hindustan abrasives

Regular maintenance ofcenterless grindingmachine can help your business alot and reduces number of problems in grinding process. But when your superstar grinder suddenly becomes non-functional, youll start deep diagnosis to find out root cause or problem behind error.

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used grinding machines & industrial metal grinders | cnc & more

used grinding machines & industrial metal grinders | cnc & more

Grinding machines have been known since ancient times. The original manual machines for shaping, sharpening or smoothing are used today as conventional or CNC grinding machines in various industries. Generally, grinding wheels and grinding belts reach higher accuracies than machining with geometrically undefined cutting edges. For this reason, tool grinding machines, circular grinders, surface grinders, bench grinders, etc., are essential for many stages of production for the industry and crafts. At Surplex you will find a great variety of grinding machines and its corresponding accessories such as used grinding wheels, wheel spindles and many more. High quality for the best price!

In the metalworking industry, dimensions need to be precise down to a thousandth of a millimetre. Even a surface that feels smooth to the touch may be far too rough for the intended application. Milling machines and lathes, for instance, can produce outstanding dimensional accuracy, but the final touch can only be applied using an appropriate grinding machine.

This particularly applies to surfaces subject to narrow tolerances: piston tracks in combustion engine cylinders, for example. They need to precisely and securely guide the piston rings within a wide temperature and speed range without jamming, which can only be ensured through use of a metal grinder.

Grinding machines work without tools: all they need is the corresponding abrasive medium, such as types of paper and textiles with an abrasive surface. Grinding stones are also used and consist of a pressed and fired abrasive medium mostly quartz sand. The finer the abrasive medium, the less surface that will be removed per grinding cycle.

And if solid abrasive media are insufficient to achieve the desired dimensions, fluid abrasive agents are another alternative. Wet polishing machines and lapping machines facilitate this type of abrasion.

Polishing and lapping processes are used for achieving the best dimensional accuracy and a consistently smooth surface, which is ideal for galvanising applications, for example. A product can only be galvanised or chrome-plated if it has been polished to a very high sheen.

Round grinding media carriers are used in eccentric and plate grinders. They consist of a circular surface and the media are either moved radially or eccentrically. Radial grinding machines are designed very simply and are affordable.

Grinders with a belt-type abrasive medium carrier are called belt grinding machines. These types of grinder involve a grinding belt being tensioned between a drive roller and one or two tensioning rollers. They are used to remove outer layers from materials consistently and smoothly. Belt grinding machines remove a pre-defined quantity of material per work cycle, which makes it easy to maintain dimensional accuracy by spreading the abrasion process across different work cycles with varying grinding heights. Belt grinding machines are also designed to be simple and are thus easy to maintain.

A metal grinder always consists of cooling lubrication and powerful extraction. The particles removed from the workpiece need to be transported away as quickly as possible since fine metallic dust can quickly lead to heavy wear and tear. This particularly applies to iron-containing dusts, which increase in volume as they corrode and lead to further damage.

Surface grinders are used when an extremely flat surface is needed. They work using a grinding disc that is consistently guided across a workpiece. These machines are key to the tool-building and mould construction industries and can be relied on to achieve the required dimensional accuracy.

Guideway grinding machines, as the name suggests, are used to grind guideways and are deployed wherever very large cutting machines are being manufactured. Mechanical guideways need to be very precise and the guideway grinders on offer today can achieve tolerances of 1/1000 of a millimetre across seven metres of length.

Internal (cylindrical) grinding machines are used to create consistent and accurate internal radii. They work using roll-shaped grinding bodies. The internal grinding machines available today feature computerised numerical control (CNC) and can thus achieve the strictest of tolerances.

Jig grinders feature CN controls and a very small grinding body. They are used to grind away at specific points on a workpiece as required by the respective production process. As such, jig grinders feature a very similar design to CNC mills.

Cylindrical grinders serve to grind profiles, pipes and round steels in a cylindrical manner. Tensioning cylindrical grinding machines use centre tips similar to the tail stocks of lathes. Centreless grinding machines, by contrast, can be used to indefinitely process profiles without any clamping process being required.

Bench grinders are standard grinding tools that are found in every workshop. A bench grinder can be used to sharpen, grind, plane, or deburr a workpiece by hand. They consist of a motor to which one or two grinding discs are attached. They are produced in single- and double-sided variants.

A Roll grinding machines serve to precisely grind press rollers to the desired dimensions. They can be used to grind new, used and freshly turned rollers to achieve the required tolerance. Precision rollers can only be created using a roll grinding machine.

The wide variety of grinders for sale does not make it easy to choose the right device, but there are some general tips that any prospective buyer of a second-hand grinding machine should know. The first consideration is what applications the (used) device should perform a simple bench grinder is incomparable to a complex jig grinder.

A good starting point is to look at the general condition and cleanliness of the machine. Even with comprehensive rinsing and extraction units, grinding machines require a great deal of cleaning daily, thorough cleaning is essential for any frequently used grinder. If the first thing you notice about a second-hand grinding machine is that it is soiled, you should definitely take a very close look at the machine from all aspects.

Unless you buy a metal grinding machine from a trader in used machinery who has taken care of the maintenance and repair tasks, it will be necessary to completely dismantle and clean the equipment. If those intending to repair/maintain a used metal-grinding machine are lacking in qualifications to do so, a specialist service provider should be commissioned.

The weakest points in all used grinding machines are the bearings: the high speed experienced by the grinding spindles, the continual one-sided impact, and grinding heads that frequently lose their shape have a major effect on the bearings. It is therefore important that the bearings are inspected and, if there is the slightest amount of rattling, replaced. Once equipped with new bearings, a used metal grinder can continue operating for thousands of hours to come.

Those looking to buy a used grinding machine will find everything they need at Surplex. We regularly have second-hand grinders for sale. You can purchase machines via our portal where you will regularly find online auctions featuring a wide range of grinding machine types for a variety of needs and at attractive prices. The metal grinders for sale are generally in a good to very good condition.

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2019 how to avoid the 6 types of centerless grinding defects

2019 how to avoid the 6 types of centerless grinding defects

The centerless grinding machine is a kind of grinding machine that does not need to use the axial grinding of the workpiece. It is composed of three mechanisms: the grinding wheel, the guide wheel, and the bracket. There are centerless grinding defects as follows:

There are centerless grinding wheels with different materials, such as diamond and CBN centerless grinding wheels, or silicon carbide centerless grinding wheels. In the process of actual processing, there are different centerless grinding defects. Need to continuously summarize the experience in the practice process and find the right solutions.

chamfer grinder itm international tool machines

chamfer grinder itm international tool machines

All spindles are equipped with the HSK quick-change Coupling System. The main machine feature advantages of the HSK system are perfect radial and axial repeatability and quick and easy wheel changes. The System consists of a hollow HSK shank that holds the wheel flange, and the HSK receiver that is mounted to the spindle. Both shank and receiver are machined to a short but very accurate 1:10 ratio taper and a mating face. To achieve perfect repeatability when reengaging the coupling, the shank is pulled exactly against the mating face of the receiver with a draw bar. Mounting a wheel flange with traditional CAT or SK Systems in a defined axial position has proven to be very difficult because only the mounting force determines how far the flange slips onto the taper of the spindle. Wheels mounted on a HSK flange can be removed from the machine in seconds using a standard ALLEN wrench. For dressing outside the machine, the wheels remain on the flange and they are mounted to a matching HSK receiver on a standalone dressing unit. After reinstalling the wheels into the machine and entering the new wheel diameter into the control the production can continue without additional touch up procedures.

The consistent production of precision chamfers and countersinks require efficient, high-performance grinding machines. The ITM UODG is the solution for quick set-up of all your chamfering jobs. The ITM UODG is a universal OD grinding machine for chamfering straight and helical right-hand and left-hand taps, taps with front and main chamfer with or without relief, taps with OD relief, taps with chamfered back angle, and taps with extra-long chamfers (using multiple plunge option). The workhead is mounted on a heavy precision slide which is moved by a variable speed hydraulic cylinder for loading and unloading tools. It can be equipped with a center or a square driver, or with an ultra-precision collet for the grinding of the tool between the centers.

During chamfer grinding, the tool is supported between centers on a sturdy tailstock mounted in a fixed position on the machine base. This set-up allows for quick and easy changeovers to different tools because the tip of the tool always determines the location. The machine is either equipped with an automatic cassette loading system or a Fanuc robot work cell that uses standard cassettes or pallets for extended production runs. With multiple simultaneous controlled CNC axes, setup time is short, making the machine economical for both large and small production runs. Since the distance from the face of the wheel flange to the point of the tail stock center is known, the operator only needs to enter basic parameters such as tool length, OD, chamfer angle, chamfer length, and the relief angle. A Renishaw probe can be installed to locate the flutes in automatic grinding process.

The machine is installed with the latest FANUC CNC with a 1-in-1 million defect rate and a 15 Panel-i CNC include software to store 100,000 part programs. The software is the worlds first dedicated Windows based software with 2D and 3D simulations and grinding of various short or long chamfer, back taper for normal and high helix chamfers.

medical & surgical equipment grinding applications | glebar - centerless grinding machine manufacturers

medical & surgical equipment grinding applications | glebar - centerless grinding machine manufacturers

Glebar is synonymous with medical and has been at the forefront of medical centerless grinding machine technology for over 50 years. From medical guidewires to arthroscopic shavers, dental components, surgical tubing, catheter bodies, bone drills and more, Glebar has the experience and expertise to optimize any grinding process for the medical industry.

Our versatile precision grinding machines are workhorses which require a smaller footprint than similar machines yet excel in demanding high production environments where the name of the game is high volume at low cost.Glebar engineers can tailor a medical precision grinding turnkey solution, complete with a series of pre- and post-grind inspection steps, ensuring the product going into the Glebar machine meets the requirements of the final ground product with guaranteed accuracy.

Exposing the material to high heat can affect the chemistry and mechanical properties of the material requiring manual secondary finishing operations. Setup and production are slow, requiring extensive mechanical adjustments. Frequent wheel dressing causes faster wearing, resulting in higher tooling costs.

Low production output, as only one wire can be ground at a time. Changeover between wire diameters is time-consuming, delaying production. Grinding can leave burrs requiring secondary processes to deburr, lengthening production time.

Heat sensitive applications may limit the use of the laser for cutting. Laser cutting leaves recast and heat-affected zones, affecting the tube's quality and increasing scrap rates. Beam deflection when cutting through a tube can affect accuracy and cause damage. Laser cutting is not capable of creating clean and sharp edges. Therefore, time-consuming secondary processes to deburr tubes and remove any debris are required. Delivering a process that cuts tubes to length, maintains a high level of quality and accuracy, leaves no recast or slag, and improves production times.

Narrow work wheels prevent generating tapers over 4" requiring multiple setups to generate the shape. Highly skilled technicians are required to ensure proper setup. Upper and lower slides are strapped, preventing the regulating wheel and work rest blade from being adjusted independently. Wheel dressing is applied manually, which leads to inconsistent wheel conditions. Blade sizing is conducted manually leading to variability in setup longevity.

Deliver a process that can grind up to 8" tapers on guidewires in one pass while maintaining quality and repeatability. Decrease downtime related to setup and complicated changeovers. The process must meet CE Certification standards for operator safety.

Cycle time reduction while maintaining overall machine uptime resulting in increased throughput. Added versatility to the control system allowing process improvement through actionable reporting. Reducing maintenance such as wheel dressing to increase up time. NiTi is a difficult material to shape due to its high nickel content, moreover, a smooth surface finish is critical to prevent part failure.

Converted OD grinders with custom tooling and soft grinding wheels all of which wear at a high rate. Setup and changeover time is significant and requires extensive mechanical adjustments. Parts, in most cases, must be taped for handling requiring additional steps in the production process. Primary cut leaves a large ID burr which must be removed in a secondary process step such as grit blasting or electro-polishing. Complex needle points, i.e. Menghini points, require separate primary bevel cut and secondary sharpening, leading to long cycle times.

Parts are cut using abrasive cutting saws, conventional abrasive grinding, wire EDM or laser cutting; slow processes resulting in long cycle times. Potential to expose material to high heat leading to heat affected zones, recast, and slag. Requires secondary process to deburr parts and remove any surface debris which reduces productivity.

Design a process that can provide a burr free cut without recast, slag, or heat damage while maintaining a high quality part and reducing cycle time. Reduce the number of steps in the production process.

The arthroscopic shaver teeth are commonly produced by conventional abrasive grinding, wire EDM, or laser cutting; slow processes resulting in long cycle times. EDM and laser cutting burn away the metal at high temperatures leaving changes to the metal surface including a heat affected zone, recast, and slag. Laser cutting requires significant post processing to produce an acceptable sharp edge and surface finish. Conventional grinding requires a secondary process of deburring without damaging the cutting edge. It also involves frequent wheel dressing to maintain the correct form.

Tubes are cut one at a time using a standard abrasive cutting saw which leaves burrs. Requires secondary process of wire brushing and tumbling to deburr tubes and remove any debris. Older machines have poor accuracy and outdated safety features. Debris from abrasive cuts cause frequent maintenance issues.

Design a process that can cut multiple tubes burr free simultaneously without damage from debris. Reduce the number of steps in the production process. Provide a machine that wont deteriorate over time.

Numerous manufacturers around the world find themselves with legacy equipment incapable of meeting the changing environmental and safety standards recommended by regulatory standards.The customer in this case was operating an outdated grinding system lacking mist control with minimal safety features.

Maintain CE safety and environmental standards without hampering the functionality of the machine. Thrufeed grind 0.003- 0.006 of material from steel tubes with a tolerance of +/- 0.0002 and achieving a superior surface finish. Lastly, the customer required the ability to connect the machine to the intranet for data gathering, monitoring and remote diagnostics.

The operator would manually feed the stainless steel orthopedic pins into the centerless grinder then manually clean and gauge each pin. Manual input and adjustment were required during the process to ensure quality.

Increase process throughput and quality production by integrating automation. Produce a part every 13 seconds in an automated lights out system. Reduce the opportunity for damaging critical features in material handling.

Challenge: To size implantable spinal cord stimulation devices that deliver precise doses of electricity to targeted nerve sites for patients suffering from chronic back problems. The device is long and flexible, which made it difficult to handle. It is also constructed of dissimilar materials of varying diameters, from metal conductive rings to fine electrical micro-wires to molded polymer and plastic supports, which made grinding a fine surface finish with stringent diameter control and without damage to the parts very challenging.

Asthma inhalers are comprised of a medicine canister fitting inside a plastic sleeve. When the patient pushes the canister, the stem, a small metal pin, releases an actuator inside the sleeve allowing the medication to be released and inhaled by the patient. The stem must mate properly with the actuator to ensure the medication is dispersed properly. Any defect could cause the device to fail.

Asthma inhaler pins are ground one at a time using multiple production lines and automation integrations. This setup requires a large footprint to meet high demand. Labor and numerous automation integration costs are expensive.

Challenge: To thrufeed grind ceramic pellets, which are used to manufacture radiopharmaceuticals (radiotracers) used in CT scans. The pellet count had to be tracked through the machine and the customer needed to measure a set frequency of parts that would be programmable. In addition to accounting for all the components, the machine had to separate the set number of parts processed for data collection.

Challenge: A Medical device customer needed to rapidly changeover between a family of Nitinol guidewires having various lengths and geometries. Since the geometry of the components varied in length, the customer needed to change tooling over frequently, a process that can take up to 4 hours. Also, rapidly removing over 30% of the the material as it thrufeeds into the machine accelerated tool wear on the existing system and as tooling degrades, dimensional integrity suffers.

Challenge: Infeed grinding 0.010 on two diameters over a 7 long metal drill blank in one operation while maintaining 0.0002 diameter accuracy, .00006 roundness and maintaining part straightness and concentricity.

Found at the highest end of the GT610 series spectrum, the GT610 CNC High Precision Automated Infeed/Thrufeed Centerless GrindingMachine excels at grinding a wide range of materials and is the complete "lightsout" solution for applications where a high degree of automation, data gathering and gauging feedback is required. In addition to our 10" work wheel design, Glebar is now offering an ABEC 7 twin-grip work wheel spindle design (with 12" work wheel option) on the GT-610 CNC for increased rigidity, faster component processing speed and larger diameter parts.

The GT-610 Automated Infeed/Thrufeed Centerless GrindingMachine can be custom fitted with automation. This system is the ideal option for when infeed applications do not require a CNC dresser and for the vast majority of thrufeed applications. The GT-610 excels at hard metals and composites, producing carbide blanks, spools, bushings, and engine components such as automotive fasteners and valve lifters. It can also effectively size down metal bars.

The GT-610 EZ is the newest addition to the GT Series Centerless Grinder suite. A lean version of the GT-610, the GT-610 EZ brings slide motion control to the operator at an affordable price point. Operating on a much smaller footprint than the competition, this system excels at thrufeed grinding hard materials such as steel, carbide, pcd inserts and technical ceramics. Slide positioning allows for precise diameter control on close-tolerance components. The machine is also capable of gauge feedback for even more precise diameter control.

TheCAM.2 combinesthe latest in multi-axis servo motor control, submicron positioning, and an intuitive HMI touchscreen interface to offer unmatched performancein grindingmedical guidewires, dental parts, and small complexed precision parts for various industries.

The GT-9AC is designed to grind medical guidewires with multiple tapers, paddles, and even parabolic shapes, with the ability to update the linear position of the wire every 0.00025" (0.006 mm) at grinding speeds superior to traditional centerlessgrinding.

The computer controlled TF-9DHD Infeed/Thrufeed Micro Grinder grinds both hard and soft materials, specializing in parts from 1 in diameter down to .002". The TF-9DHD is utilized to grind catheter, guidewires, pins, bushings, PTFE, plastics, ceramics and other engineered materials.

The TF-9BHD Infeed/Thrufeed Micro Grinder grinds both hard and soft materials, specializing in parts from 2.5 in diameter down to .002". The TF-9BHD is utilized to grind catheter, guidewires, pins, bushings, PTFE, plastics, ceramics and other engineered materials.

The DD-7 is one of the most compactdouble disc grinding machines on the market. Designed for grinding small diameter components, it accurately controls their length and perpendicularity. The machine is capable of grinding many high-performance parts for a wide range of industries from medical and aerospace to automotive. The DD-7 can be configured in three fixturing modes, depending on the application, the shape of the part, and the degree of automation required.

The P4K Gauging System is the fastest and most accurate profile metrology system available for long parts or multiple short parts and is the gold standard quality control device for the measurement of guidewires. As a setup reduction device (for the GT-610 CNC), the P4K scans and provides feedback of the entire component geometry for all parts in a cycle to automatically correct the grinding wheel dress shape (correcting the wheel dress shape from any measurement device is patent-pending).This is done in a matter of seconds, drastically reducing setup time and improving quality control. For other compatible Glebar machines, (GT-610, GT-610 SD, CAM.2 and GT-9AC) the P4K serves as a closed-loop quality control device that feeds back diameter to the control system for automatic size compensation.From titanium fasteners to medical guidewires, the P4K system has you covered.

The CS1-A Precision Abrasive Cutoff machine from Tridex Technology features superb accuracy and multiple bar cutting for applications requiring tight tolerances in medical, aerospace, fasteners, and automotive industries. The Precision Abrasive cut leaves almost no burr on the bar or tubing.

The CS1-EA Hybrid Burr Free Electrochemical and Precision Abrasive Cutoff Machine from Tridex Technology combines the best of the CS1-A Precision Abrasive and CS1-E Electrochemical Cutoff machines into one robust and compact design.

The SG-2060 Burr Free Electrochemical CNC Surface Grinder from Tridex Technology provides burr free and low force cutting leaving no heat affected zones while cutting. It has numerous applications across many materials and industries including medical device, automotive, and aerospace.

When added to the Tridex Model SG-1645 or SG-2060 electrochemical grinders, the PGS-100 is a fully programmable pointing and material handling system to manufacture a wide variety of medical device points on tubing or solid wire using electrochemical grinding technology (ECG).

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