CPT International 02/2021

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GRINDING Superabrasives for the foundry industry Cool grinding for more parts per wheel How can foundries increase their productivity and product quality aswell as the safety of their employees? Asuitable tool isthe new Foundry Xelectroplated single-layer grinding wheel from Norton Winter, the premium brand from Saint-Gobain Abrasives. by Andreas Eckhard, Norderstedt Photos: SAINT-GOBAIN ABRASIVES Compared with existing electroplated tools on the market, Foundry Xsteps things up agear in terms of performance, durability and safety during cast product machining thanks to aspecial new electroplated bond technology which allows foundries to cut costs per approved part considerably. Futhermore, Foundry Xalso offers a reason for foundries to switch from standard electroplated tools and particularly from conventionally bonded abrasives to diamond and CBN grinding tools. Increasing productivity –reducing dust exposure Modernization is akey trend inthe foundry segment. New CNC- and robot-assisted systems, which appeal to foundries of all sizes, come with the promise of extra production output and arapid ROI. At the same time, demand for higher-quality cast and ductile iron is growing. “In light of this, foundries are focusing partly on making their production systems more environmentally friendly and improving their efficiency in the process. With Foundry Xattheir disposal, these two objectives are not mutually exclusive. For example, switching from conventio- 30
nally bonded wheels to Foundry Xdiamond and CBN abrasives not only increases productivity and quality but also cuts down on dust by as much as 90 %”, says Andreas Eckhardt, product manager at Norton Winter. Service life, quality and consistency An electroplated grinding wheel consists of asteel body with asingle layer of diamond or CBN. The grains are embedded in aspecial nickel bond. This gives users agrinding wheel with astable diameter and profile. That means that there is no need to make diameter adjustments in the machine software during series production. The main body can be re-used many times, provided that it is not damaged. The wheel can then be used until there is no protruding grain left. The new line of Norton Winter Foundry Xelectroplated single-layer grinding wheels, featuring an extremely hard and yet ductile nickel bond coupled with high-quality special diamond and CBN grains, have been developed to prevent heat and load problems from being factors limiting productivity and quality in grinding and cutting work. For that purpose, Norton Winter has equipped Foundry Xwith high-quality special diamond and CBN grains arranged inhigh concentrations bonded to the high-grade steel main body by the nickel electroplating. This enables the grain toprotrude more than on wheels with multiple layers. The special new electroplating technology also ensures excellent grain retention, which leads to anoticeable reduction in wear in applications on CNC-controlled machining equipment as well as in robot guided applications and manual processes. Automated cell grinding is one example. Foundry Xtruly shines in this department, with along service life, reduced wheel changes and minimized downtime, with consistent wheel dimensions and minimal wear. Its precise geometry reduces vibrations, while the unchanging wheel dimensions allow for faster and easier programming. As Eckhardt explains, “Foundry X combines unique grain quality and maximum grain concentration in the wear zone and offers better homogeneity in comparison with other coated wheels. Grain quality is selected depending on component material. The grain size can also be adjusted to suit the application. Foundry Xcan maintain the expected tolerances depending on the grain size and offers excellent diameter and profile stability as well as profile tolerances of 0.05 mm to 0.15 mm.” Thanks to the design benefits and the ability to make minute adjustments to the tool in line with the specific application, manufacturers can cut and grind at lower temperatures and improve their material removal rates. Foundry Xsuperabrasives last for longer thanks to their wear resistance. According to Andreas Eckhardt, “they offer the longest service life per wheel on the market compared with directly coated standard wheels. That means more grinding between wheel changes and also Foundry Xoffers impressive performance, durability and safety during cast product machining thanks to a special new electroplated bond technology. The grinding wheels are available in a range of sizes and profile shapes to meet specific requirements for grinding various cast materials. reduced downtime. Consequently, depending on the application, using a Foundry Xwheel can allow you to machine up to 50 %more parts”. This is underlined by aNorton Winter case study entitled “Rough machining grey cast iron: Foundry Xvsstandard electroplated wheel with agrain size of D851”. With parameters of a hardness of 67 HRC, material removal of 3mm, wheel speed of 50 m/s and feed rate of3mm/s, the Foundry Xtool manufactured 40 %more workpieces per wheel. In cutting processes for machining a brake calliper from tempered grey cast iron (67 HRC) in aMaus robotic cell, Foundry Xachieved aservice life 30 % longer than aconventional superabrasive available on the market. Furthermore, it did so with better chip clearance, astraight cut and fewer rejects. Safety for employees The switch from conventional grinding wheels to diamond and CBN wheels in foundries offers significant potential for improvements in safety and environmental aspects. The steel bodies of the diamond and CBN grinding wheels prevent the risk of the wheels breaking during use. Much less dust is produced than with conventional abrasives and the odour that is typically emitted during grinding in foundries is almost entirely eliminated. All Foundry Xwheels are manufactured to suit user requirements. They are available in arange of sizes and profile shapes to meet specific requirements for grinding various cast materials. Arange of special shapes can also be created. www.nortonabrasives.com/de-de Andreas Eckhardt, Product Manager Direct Plated Products, Superabrasives EMEA, Saint-Gobain Diamantwerkzeuge GmbH, Norderstedt, Germany CASTING PLANT &TECHNOLOGY 2/2<strong>02</strong>1 31
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