An Unlikely Combination: How Wire EDM Opens Up New Possibilities in Grinding

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1 An Unlikely Combination: How Wire EDM Opens Up New Possibilities in Grinding Michael Klotz 2

2 founded Employees Fritz Studer AG ~ 770 Apprentices included in total 77 Sales CHF 210 Mio Michael Klotz 3

3 Chapters Technical Properties Economic Potentials Michael Klotz 4

4 Grinding is Dressing Michael Klotz 5

5 Approach Machine Equipment Grinding Process Material of Workpiece Grinding Tool Michael Klotz 6

6 Technological approach Grinding External cylindrical grinding Ceramics Tungsten carbide Hardened steel Superabrasives CBN Diamond Resin Ceramic Metal Metal Bonds Large potential Michael Klotz 7

7 Starting position Characteristics of the bond systems Cutting performance Dimensional stability Thermal stability Thermal conductivity Dressability Resin Metal Ceramic Metalceramic STUDER-WireDress Very good Good Unsatisfactory Source: Diametal Michael Klotz 8

8 Michael Klotz 9

9 Experience of basic research on the product applied research, swiss industry + ETH Zürich Agie Progress V4 Wire EDM machine ETH Zürich Prototyp 1 For internal wheels on S ETH Zürich Prototyp 2 For external wheels Ø500mm on S12 + S22 STUDER STUDER-WireDress Source: IWF ETHZ, Inspire Michael Klotz 10

10 Principles of EDM, WEDD process Electro Discharge Machining (EDM) / Wire Electro Discharge Dressing (WEDD) z x D91 Source: IWF, Martin Schöpf, Dissertation ETH Nr Michael Klotz 11

11 Principles of EDM, WEDD process non-contact method only bond becomes dissolved abrasive grain drops out abrasive grain stays sharp arbitrary geometries dressable (radii, chamfer, ) grain protrusion on wheel after WireDress -dressing Michael Klotz 12

12 Example: dressing system integrated in S22 grinding wheel WireDress wire cutter with collecting container workhead oil supply wire guide wire power supply WireDress unit tailstock Michael Klotz 13

13 Performance characteristics Michael Klotz 14

14 Dressing of metal bonds with diamond or CBN up to D126 / B126 D64 only with grinding oil B91 D46 D126 B91 GAP Michael Klotz 15

15 High grain protrusion producible Maximum cutting performance approx. 30μm ( ) grain protrusion blunt dressed Michael Klotz 16

16 Fine geometries possible on the workpiece R internal 0.05 mm ( ) R external 0.2 mm ( ) R Michael Klotz 17

17 No wear on the dressing tool Rotary dressing STUDER-WireDress No compensation necessary Continuously renewed tool Maximum precision Fewer influences, greater reliability Michael Klotz 18

18 Quick dressing Removal rate on the wheel approx. 80 mm 3 /min (depending on bond composition) STUDER-WireDress Wheel speed m/s possible during dressing (9,840 23,600 ft/min) Same conditions for profiling from solid and sharpening (0.39") 20 (0.79") WireDress Example: Dressing a Diametal D64 M263 C100 Ø400 D64 Dressing Time : 8.3min Michael Klotz 19

19 Simple handling Fully integrated in StuderWIN control system surface Usual procedure for machine set-up in StuderWIN Generation of path optimized programs in StuderDRESS Simple handling of dressing unit Michael Klotz 20

20 Michael Klotz 21

21 Chapters Technical Properties Economic Potentials Michael Klotz 22

22 Economic Potentials Abilities of Grinding Wheel Operation / Handling Dressing Tool Costs Energy Requirement Michael Klotz 23

23 Higher productivity WireDress Cutting performance Dimensional stability Thermal conductivity +30% grinding power Source: IWF ETHZ, Inspire Michael Klotz 24

24 Less wear at grinding wheel with metal bond Tungsten carbide, finishing, HSG peel grinding D mm Ceramic bond Metal bond + wear 80μm (0.003 ) after 100 pieces -75% wear wear 20μm ( ) after 100 pieces WireDress D mm after dressing after 100 strokes with Ø50μm infeed ( ) after 100 strokes with Ø50μm infeed plus 50 strokes with Ø100μm infeed Process data: Vc=120m/s (23,600ft/min) f z =200mm/min 7.8In/min f R =30mm/min A 1 = Ø0.05mm Michael Klotz 25

25 High Wheel lifetime with Metal Bond + WireDress Wheel Setup once + balancing No external Dressing no Downtime for Wheel Change Wheel stays in Machine until end of tool life e.g. up to 15,000 parts (pending on process) Increase in OEE (Overall Equipment Effectiveness) Michael Klotz 26

26 Low costs for dressing tool 0.02 Rotary dressing STUDER-WireDress Dressing roll Purchase + Regrinding of roll -66% Dressing tool costs 1 wire coil ( 16h dressing) Tool costs example: Peel grinding with high requirement to profile accuracy, dressing tool costs for whole grinding wheel lifetime (5mm, 0.2 layer) Michael Klotz 27

27 Convenient rated break point at handling mistake Dressing roll -83% Tool costs Wire guide 2 cavities remaining Michael Klotz 28

28 Low energy costs Rotary dressing STUDER-WireDress 500W kW Sealing air 120 l/min 1kW (26 gal./min) in) -53% energy required operation -94% energy required standby standby after 5min no dressing Michael Klotz 29

29 Simple Economic Calculation Michael Klotz 30

30 Involved in Calculation Increases wheel lifetime Higher feed rate Less wear stable bond Abilities of Grinding Wheel Low Costs for damaged Wire Guide Operation / Handling No wheel change for dressing Increased OEE Long lasting wear parts Low dressing Wire costs Now wear at dressing Wire Dressing Tool Costs Energy Requirement Low energy use in operation Low standby energy use Michael Klotz 31

31 Previous Grinding Process Grinding with WireDress and Metal Bond Operation Hours per Shift 8h = 480min 8h = 480min Non productive auxilary time (wheel change, dressing) -5%, because no wheel change, longer dressing 15% interval 10% Real productive Machine operation per Day 408 min 432 min Grinding Time per part 6:00 min -30% Grinding Time 4:00 min Parts per Shift 68 pc. +58% output per shift 108 pc. Machine hour rate 100 $ 100 $ Machine Cost of Operation per Part (due to grinding time) 10 $ -3.33$ per part 6.66 $ Parts in 240 Workdays per Year, 1 Shift % output per year, 1 Shift Savings of Machine Operation Costs per Year 0$ $ Michael Klotz 32

32 Michael Klotz 33

33 Examples Michael Klotz 34

34 Sample Part (example for grinding performance + complex profile) 23,600 ft/min Michael Klotz 35

35 Process (example for grinding performance + complex profile) OP 1) Peel grinding OP 2) Plunging v c 120 m/s v fa 350 mm/min a e 0.5 mm 23,600 ft/min 13.8 In/min 0.02 In D91 Ø400 Ø15.75 In M267 C150 D25 Ø400 Ø15.75 In M263 C150 v c 120 m/s depht 0.7 mm v fr 1.6 mm/min 23,600 ft/min In 0.06 In/min Grinding time 3:35min Grinding time 0:35min resulting Surface R a 0.22μm 8.66 R a Total Grinding Time 4:05min Michael Klotz 36

36 Sample workpiece over 3.2mm section W t 1.18 μm Michael Klotz 37

37 Tungsten Carbide Thread Cutter Michael Klotz 38

38 Thread Cutter Profile of Thread Wheel HSG 120 m/s 23,600 ft/min Peel Grinding Roughing D126 + Finishing D9 From solid, ØTolerance within 1μm In (with Measurement control) Shaft Rough+Finish 5:00 min Total Grinding Time R z Shaft 0.5 μm 19.6 R z R z Thread 0.6 μm 23.6 R z Thread 4:00 min 9:00 min Michael Klotz 39

39 Tungsten Carbide Tool, Pre Form Michael Klotz 42

40 Workpiece Michael Klotz 43

41 Grinding Process Roughing Finishing D91 D10 HSG 120 m/s Peel Grinding Grinding time 4:24 min R z 0.47 μm In R ONt Corner Radius (repeatable) 0.54 μm 0.12 mm In Michael Klotz 44

42 Summary Michael Klotz 52

43 Product Dressing hardware Dressing technology Software StuderWin integrated Dressing module Electric cabinet Wire cutter Michael Klotz 53

44 WireDress as Enabeling Technology to overcome with Metall Bond In running processes Increase Dressing Intervall Decrease Grinding Time Until today, not producible Small Radii High constancy of profiles Michael Klotz 54

45 Michael Klotz 55

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