INSERTS NORTON WINTER PRECISION TECHNOLOGY TOOL GRINDING / 81 DIAMOND GRINDING WHEELS FOR PROFILE GRINDING OF INSERTS The profiling of inserts is a multi-faceted process. Various contours are generated, from simple flutes to complex profiles on the periphery of the inserts. Therefore, the applied profile wheels (e.g. 1E1, 1F1 or 1V1) are made from metal or resin bonds. With multi-process profiles (e.g. grooves for positive locking of the inserts in rotary holders) in the past, crushable metal or vitrified bonded systems were often used. Currently, there is a clear trend to insert profiles into optimised metal or hybrid bonds using EDM. This enables the use of significantly more form-stable bonds, which ultimately achieve better tool life and also higher performance. WORKPIECE TC - Profile Insert - Finish Profile R < 0.1 mm GRINDING WHEEL 14E1-125-5-10-30 20 D46 BZ387 C125 COOLANT Oil GRINDING PARAMETERS INFEED ae = 0.2 mm CUTTING SPEED vc = 28 m/s CUTTING SPEED vf = 80 mm/min DRESSING CYCLE >100 pieces BENEFITS • > 10 % increrased dressing interval APPLICATION EXAMPLE PROFILE WHEEL SAINT GOBAIN Abrasives Standard = Ihr Vorteil Time[s] Leistung -10,0 0,0 10,0 20,0 30,0 40,0 50,0 60,0 70,0 80,0 1,10 1,00 1,20 1,30 1,40 1,50 1,60 1,70 1,80 1,90 2,00 2,10 2,20 2,30 2,40 2,50 WORKPIECE Tungsten carbide insert with pre-sintered threaded profile GRINDING WHEEL MC1A1-150-4.5-5 D64 DMC C75 COOLANT Emulsion GRINDING PARAMETERS PROFILE DEPTH 0.95 mm RESIDUAL ALLOWANCE 0.6 mm INFEED ae = 0.6 mm CUTTING SPEED vc = 23 m/s FEED RATE vf = 150 mm/min SPECIFIC MATERIAL REMOVAL RATE Q‘w = 1.5 mm³/mm · s BENEFITS • 80 % cost savings APPLICATION EXAMPLE PROFILE WHEEL DMC CONDITIONS OF USE The crushing device should be part of the original machine; at least it should be strongly mounted onto the machine By doing so, the advantages of profiling, without annoying tool changing, can be utilised. Pre-forming of the layer to the required profile is also possible. Crushing can be carried out either with a powered grinding wheel, which drives the profiling roller, or with a powered profiling roller driving the grinding wheel. (If attention is not paid to this point, the wear of the profile roller will increase). Profile crushing should always be performed using flood coolant, as the grinding wheel and the crushing roll must be lubricated. Additionally, during crushing, the abrasive layer must be cleaned with a Norton Winter stone No. 2 or No. 5. This reduces profile distortion that may occur due to adherent wheel particles.
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