Case Study 32 of of Industrial Engineering ONLINE Course
A New Technology from Studer (a member of the United Grinding Group) for Dressing Metal Bond Wheels To Extend Its Use
Metal bonded grinding wheels have very good dimensional stability, thermal stability, and thermal conductivity. But there was a disadvantage due to the difficulty of maintaining their shape throughout a production run. Dressing the wheel when it becomes loaded with workpiece material is also time consuming. It typically required “sticking” it with aluminum oxide inside the machine , or dressing it offline with a silicon-carbide wheel. Both consumed time. And, if a radius or any point along the profile broke down, it was really hard to reform it. Together, these factors severely limited the adoption of the wheels despite positive benefits which are substantial.
Studer’s WireDress technology uses a thin, electrically charged wire to both shape and dress a metal bonded wheel—on the machine and at speed. It can maintain a complex form, including thread forms, with high accuracy. It is very consistent on the forms dressed, and it gives extremely accurate form. It is a wire erosion process and the wire doesn’t actually make contact with the wheel and leaves the abrasive grains untouched. It erodes the metal bond around the diamonds, creating a really open and free cutting wheel. With finer grit wheels, more aggressive cutting action is observed up to about 30 percent higher.
When Studer first introduced WireDress four years ago, it required space on the machine table. The company has now introduced a second-generation Wire-Dress system that fits entirely behind the workhead, so it doesn’t take up any table space on the machine.
The dressing technology requires a considerable investment, but for the right application with the right volume, there is return on investment. Suitable applications include carbide, carbide coatings, ceramics, or high-volume work where the combined material removal rate and durability of metal bond wheels add a lot of value.
2023 12 May
Studer Report: Another area that reached a record high was WireDress technology, which enables the precise dressing of metal-bonded grinding wheels, boosting productivity to higher levels.
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