Hardend D2 Material grinding wheel selection - Page 2
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  1. #21
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    Hey thanks for suggetion i will try

  2. #22
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    Hey every one thanks for sujetion
    I will try diamond type for tryel bases
    And then i will go for cbn for production
    Thanks for your valuabel feed back

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    Quote Originally Posted by 1953chevB View Post
    with precision ground gears , typically for aircraft application, these attributes have to be held
    lead (parallel )
    Involute (and can be tricky).0002-.0003 inch tolerance form of the gear
    total and tooth to tooth error(index).0002 inch tooth to tooth
    modified tip offs

    so important to maintain the wheel form
    this was the application.

    on journals cylindricity sometimes as low as .0002 tolerance, and concentric W/I .0003 tolerance
    So why not use CBN? Sounds like you guys were shooting yourselves in the foot right from the get-go.

  4. #24
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    Quote Originally Posted by Gutsy02786 View Post
    Hey every one thanks for sujetion
    I will try diamond type for tryel bases
    And then i will go for cbn for production
    Thanks for your valuabel feed back
    I would just go straight to the CBN for high production. No reason to even try diamond unless you just have it sitting there and don't want to wait for the CBN wheel.

  5. #25
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    I don’t get the VMC for grinding either??? Never the less, D2 has been ground with aluminum oxide since before 99% of those remaining were born… AO first, AO + some chrome oxide next bump up. If those don’t work then you move to SG(sol-gel) or one of the endless Norzon’s & clones out there. Last step would be diamond IMO.

    What type of grinding? Surface, cylindrical, internal will all have different starting wheel recipes with aluminum oxide and machine type/process.

    I’ll just post a generic wheel & parameters recipe for D-2 @ 56-65Rc hardness, SURFACE GRIND(recip-table).
    I’d start with an A46I(roughing) or A60I(finishing) wheel(soft I know).
    WHEEL SPEED – 5500-6500SFPM.
    TABLE SPEED – 50-100FPM.
    DOWNFEED – rough .002” & finish .0005"(max).
    CROSSFEED – rough (wheel width/5) & finish (wheel width/10).

    For cylindrical grinding A46K/L & internal grinding I’d be using A80L.

    If this is really production then calling a wheel maker would be worth the OPs time.

    Good luck,
    Matt

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  7. #26
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    Quote Originally Posted by eKretz View Post
    So why not use CBN? Sounds like you guys were shooting yourselves in the foot right from the get-go.
    cbn plated machined well but could not hold form
    let explain a few other details, if CBN plated wheels work great when it's moderate tolerance, in my world it's .0005 max.
    form wheels are expensive, high cost
    long lead times, sometimes 2-3 months

    The pro's if no issue with tolerance and lead time and cost
    no dressing required
    grinds very fast
    productivity is high.

    Just never worked for my application, like I said parts would go out of tolerance.

    In my industries there are different specialized machines for different applications, pump gear or most external gears with clearance , worm grinding wheels are used,
    same concept as hobbing, except grinding, this is where a silicon grinding wheel excelled, it would grind pump gears like popcorn,
    also used for od & id grinding

    form grinding is used in applications like internal gears, or external gears with not enough clearance, and every part is different
    some require pencil grinding, some 1.00 diameter max wheels, an some with 3.00 dia wheels.
    if the tolerance is open enough CBN form wheels are the way to go, if not then the best next is silicon carbide, in my industry
    don't use aluminum oxide except in rare cases,

    so technology changes yesterdays is and does become obsolete and grinding wheels are for ever also changing.

  8. #27
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    I use a 39CA500 Grit wheel for thread forms. My theoretical sharp at the point calls out for .0015" I am successfully able to get that to about .0022" which is about all I can do. The material I is H13 tool steel and it will wear but actually cuts very nice and I need do need to redress a fair amount to restore my thread form.

    This is interesting because the rule of thumb some grinders have mentioned is to have about 3 grains worth of material in your radius point. The grain size of a 500 is ~.0007 so 3x.0007 = .0021" which became my teachable ah-ha! moment (although some of the ceramics bonds I use I have been able to keep a single grain in the point).

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