REVOLUTIONARY BOND TECHNOLOGY RESHAPING THE WORLD OF PRECISION GRINDING

Transcription

1 REVOLUTIONARY BOND TECHNOLOGY RESHAPING THE WORLD OF PRECISION Cool cutting Precise profile High speed

2 REVOLUTIONARY BOND TECHNOLOGY FEATURES & BENEFITS COOL CUTTING: IMPROVE PART QUALITY A revolutionary new generation bond that will reshape the wld of precision grinding. Precise profile: REDUCE COST Significantly reduced burn Lower residual stress Increased cutting efficiency and cut rate Improved coolant flow, reducing heat build-up and wheel loading Improved chip clearance Ultra radius accuracy Extended wheel life Improved productivity Reduced dressing frequency and cost Improved cycle and process time HIGH SPEED: INCREASE THROUGHPUT & PRODUCTIVITY Wk at higher machine speed/pressure Leverage existing equipment Optimized machine efficiency Through Saint-Gobain Abrasives extensive research and development program in grinding wheel technology, comes Vitrium a new generation, patent-pending bond technology. Improved cost/perfmance ratio GRAIN availability Perfmance improvements with Vitrium span abrasive grains from proprietary Quantum ceramic alumina to conventional aluminium oxide, to optimise grinding processes. This revolutionary bond platfm features an exclusive chemistry that delivers an entirely new grain adhesion science, resulting in improved product versatility across a wide range of precision grinding applications. BEST NORTON QUANTUM & CERAMIC GRAINs Patented ceramic alumina provides the high perfmance f precision grinding. BETTER Conventional aluminium oxide grains High perfmance aluminium oxide blends adapted to the most common applications and materials.

3 A REVOLUTIONARY BOND THAT LOWERS YOUR PROCESS COST IN WAYS Scan this QR code to see the science in animation visit: COOL CUTTING An improved holding power utilising less bond-to-abrasive ratio exposes a larger grain surface area. This enables the wheel to cut freely, improving cut rate. The reduced bond-part interaction also minimizes heat build-up, reducing burn and power consumption and grinding fces on the part. Thinner bond posts enable better coolant flow and chip clearance f a cooler cut and improved part quality. Use Vitrium to improve part quality and ensure part integrity. STANDARD BOND Bond-part interaction VITRIUM BOND Bond-part interaction TEST : REDUCED BURN AND POWER CONSUMPTION The graph shows the increase in power consumption as Material Removal Rate (MRR) goes up. At an MRR index of 00, Vitrium requires 5% less power to remove the same amount of material. This means less heat is generated on the wk piece, resulting in less burn. At a power consumption index of, Vitrium removes 0% me material than the standard bond, at the same power consumption, reducing heat generated on the wk piece. KEY: Bond Traditional Nton Vitrium Power consumption (index) % MORE MATERIAL REMOVED 5% LESS POWER NEEDED MMR (index) PRECISE PROFILE Test : Profile holding after five cycles Vitrium provides superi grain holding properties than that of any other bond, significantly improving wheel fm and cner holding. This reduces dressing time, dresser wear and dresser replacement requirements. Vitrium considerably reduces unit process cost. Profiled wheel befe grinding After 5 grinding cycles Standard wheel Vitrium wheel After five continuous cycles (without dressing) the profile radius edge cner of wheels with standard bonds has a considerably higher wear than that of Vitrium F a given Material Removal Rate (MRR), Vitrium holds the wheel profile better than the existing ceramic VX bond and even the traditionally high profile holding VBE bond. KEY: Nton VX Nton VBE Nton Vitrium Profile breakdown radius (mm) VITRIUM HAS OF MM VX BOND HAS OF.MM VBE BOND HAS OF.5MM The. MRR (mm /mm/s) HIGH SPEED The Nton Vitrium bond provides the ultimate wheel strength. This allows lighter construction and high speed operation. Machines can wk at higher feed rates, speed and pressure, significantly increasing production with existing equipment. Vitrium maximizes equipment utility to improve your process and throughput. Standard STOP THE MACHINE MACHINE SPEED Vitrium CONTINUE Test : WHEEL STRENGTH Product strength and module of elasticity are linked to the amount of bond used in grinding wheels. strength increases as the module of elasticity goes up. Nton Vitrium always provides higher product strength than any other bond. At the same grade, a Nton Vitrium product is me resistant than any other comparable product. This allows higher pressure grinding at higher wking speeds. KEY: Bond Standard Nton Vitrium Product strength (relative index) % STRONGER Module of elasticity (relative index) Soft Hard grade

4 PRECISION APPLICATIONS INTERNAL DIAMETER Bearing (cylindrical) Internal track, be Gears Be Hydraulic components Fluid diffusion Pipe connections Large contact area Low grinding fce per grain and bond post Difficult access f coolant Risk of part defmation when cut quality is not high enough Wk piece in ID grinding Decreased risk of part defmation (ovality) on thin rings Excellent coolant diffusion throughout the wheel f cooler cutting and reduced burn on the wk piece Free cutting capabilities, and improved cut rate Faster cycle with limited grinding fce on part Longer wheel life LARGE TAPERED Ring 00x00x9 Specification: NQ70G0VSP Competit wheel: Specification: xx80h6vxx Steel 60 HRc Part diameter: 4mm, width 80mm Cycle: Over thickness:.5mm speed: 50m/s Feed rate increased by: +0% -0% Total cost per part -5% With a softer wheel grade, a higher G ratio is achieved, reducing stress on the wk piece. SURFACE Wk piece Aerospace (creep-feed regular surface grinding) Blades, NGV Gear All modules, including bevel Bearing (linear) Track, base, top General engineering Flat surfaces with profiles Toolroom MRO Average size contact area Medium grinding fce per grain and bond post Wide variety of applications: hizontal spindle (wheels) and vertical spindle (cylinders, segments, cups, disc) FIXED SURFACE grinding Improved fm holding Reduced dressing Longer wheel life Higher wking speed, f improved productivity Faster and deeper cutting capabilities Cool grinding (significantly reduced burn risk) OUTER DIAMETER Bearing (cylindrical) Centerless, external track Automotive components Cam/crank/gear box shafts General engineering Bars/tubes (centerless) Small contact area High fce per grain and bond post In general, no problem with coolant access Wk piece in OD grinding Improved profile holding High wheel speed capability f increased throughput Increased free cutting without wheel speed reduction Shter cycle time with limited risk of burn, improving part quality Lower stress on wk piece, especially on long components (bars, tubes) CENTRELESS PLUNGE, SHAFT Cincinnati Viking 406x75x0. Specification: 5NQP80NVS Specification: 5NQP80NVQN Mild steel 5Hrc Rough cycle : Infeed: 0mm/min Removal: 0.mm Rough cycle : Infeed: mm/min Removal: 0.5mm Finish cycle: Infeed: 5mm/min Removal: 0.5mm Infeed increased by: Total cost per part +50% -5% -5% At the same wheel grade and bond volume, the Vitrium bond allows faster process time, with limited risk of burn on the wk piece. Gear grinding - wm Kapp KX00P 0x5x5 6m/s Specification: NQ80HVS Specification: NQ80HVQN Steel 58-6Hrc Diameter: 0mm, width 5mm 86 tooth, module.5 Number of passes per cycle: Parts between dress: reduced from to increased from 5 to 45-6% Gear grinding - profile Gleason-Pfauter P00G 400x45x7 m/s Nton TG Specification: TGP60G0VSP Nton TG Specification: TGP60G0VXP Steel 60Hrc Diameter: 00mm, width 450mm 50 tooth, module 4 Dress compensation per part: -40% -% Improved fm holding properties of Vitrium showed a vital reduction in dressing frequency and shter cycle time. surface grinding - segments Blanchard 0x50x50 Shape: Shape Specification: NQ0FVS Specification: NQ0GVQN 00 Steel plate With the same parameters, and at one grade softer, Vitrium grinds with no surface damage. At one grade softer, Vitrium maintains the same MRR than the wheel with a standard bond, reducing the risk of burn and maintaining consistent perfmance.

5 RESHAPING THE WORLD OF PRECISION Exclusive bond chemistry allows higher wheel speed, improved profile holding and reduced wk piece burn. The ultimate high perfmance grinding TECHNOLOGY VITRIUM Cutting edge, high perfmance ceramic grain technology. Multiplies cutting efficiency f maximum perfmance and unrivalled precision. High precision, high perfmance diamond dressing tools. EnvironmENTAL BENEFITS NO CHEMICAL PORE INDUCERS Pe inducers used in the manufacture of many high posity products are harmful to the environment. Vitrium wheels require no artificial pe inducers (chemicals) to achieve a high level of permeability, unlike other pous vitrified wheel technologies. By choosing Vitrium technology f your grinding operation, you help to preserve the environment. In addition, Vitrium eliminates costly revalidation of processes associated with using certain chemicals. Reduced CARBON FOOT PRINT Increase productivity with existing machine capacity. Wk with higher feed rates, speed and pressure, significantly increasing production leveraging existing equipment. In addition, Nton Vitrium is manufactured using a low firing temperature, reducing energy consumption and lowering carbon footprint. SAINT-GOBAIN ABRASIVES SEA MAIL: CS_SEA@saint-gobain.com Nton is a registered trademark and Vitrium is a trademark of Saint-Gobain Abrasives. Fm #405