Case Studies

Application: Flute Grinding

Tool:
2 - flute, 1.875" length, 16 mm diameter, solid carbide Reamers

Machine:
Walter - Helitronic CNC (16 HP), in Oil

Performance:
Grind 0.211" flute depth @ 10 IPM on 1st pass and finish depth .001" @ 34 IPM

Results:
Total cycle time cut in half with 4-X more parts per stick dress & 15% Motor Load. Little wheel wear and no signs of burn. Competition burns part @ 6 IPM & 10%motor load.

Application: Flute Grinding

Tool:
4 - flute, solid carbide End Mill, 25.4 mm diameter, 6 mm depth, 40.6 flute length

Machine:
ANCA TX7+ (49 HP) in Oil extra nozzle & chiller @ 72 deg. F

Performance:
Grind 0.230" flute depth in ONE pass @ 4.5 IPM with 16.25 m/s wheel speed.

Results:
Cut cycle time from 20 mins to 2 mins. Competitive wheel used TWO passes @ 0.9 IPM

Application: Flute Grinding

Tool:
2-straight flute, solid carbide G-drill flute depth @ 7mm, length @ 63 mm

Machine:
Star PTG-2, (30 HP), in Oil, "up-grinding" with chiller @ 25 deg. C

Performance:
1st pass @ 0.180" depth @ 3 IPM, @ 3,400 SFPM. A finish pass @ 0.008" depth @ 12 IPM @ 6,000 SFPM

Results:
Competitive wheel used 4 - rough passes and one finish pass @ 0.003 depth to produce the same quality tool. The 10 minute fluting time was reduced to 3.43 minutes.

Application: Flute Grinding

Tool:
2 - straight flute solid carbide drill 16 mm diameter, 63.5 mm flute length

Machine:
Schneeberger (10 HP) in Oil no chiller, no steady rest

Performance:
Rough pass 0.210" deep @ 2 IPM Finish pass 0.010" deep @ 4 IPM Both passes @ 2,550 SFPM

Results:
Competitive wheel needed 3 passes: 1st @ 0.125" deep @ 1 IPM 2nd @ 0.085" deep @ 1 IPM 3rd @ 0.010" deep @ 3 IPM Total fluting time 11.6 mins. Vs 2.5 mins.

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