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Centerless grinding with superabrasives

Objective



Objectives and content Centerless grinding is a manufacturing process of particular importance for the automotive industry used primarily for mass production. The wide range of applications include motor, gearbox and pump shafts as well as needles, valves and bearing components. Up to now conventional corundum grinding tools have been used at maximum cutting speeds of 63 m/s. Recently, however, American and Japanese industries have started using superabrasive grinding wheels containing cubic boron nitride (CBN) or diamond at cutting speeds up to 90 m/s. It is known from various grinding processes between centres that the efficiency of superabrasive grinding materials increases with higher cutting speeds and is not exhausted at 90 m/s. The objective of the project is to develop a HIGH SPEED CENTERLESS GRINDING (HSCG) technology, which is able to reduce process time by more than 50 % compared to conventional centerless grinding operations. Innovative tool concepts and a cutting speed of 150 m/s are the key elements of this new technology. The complexity of the process conditions of centerless grinding combined with high speed technology leads to the necessity of an entirely new machine concept and the adaptation of process parameters. The demand for a high efficiency production and the need for environmental compatibility require the development of a technical and environmentally superior coolant system. This includes the coolant supply as well as the cooling lubricant itself. Production quality in terms of surface integrity of the workpiece demands a monitoring system enabling the on-line measurement of workpiece hardness and the detection of surface cracks. In addition an innovative controlling system for the reduction of the workpiece roundness error will be developed. The new system is based on dynamic stimulation of the workpiece. The project consists of a truly international combination of companies, including two SME's, from four European countries all with expert experience in their particular field. The manufacturer of the grinding machine, PETEWE, is a German company, the French contribution is the manufacturer of the grinding wheels, SAINT-GOBAIN. The Italian partners, MARPOSS and FUCHS LUBRIFICANTI, provide technical measurement devices and the coolant system, respectively. End-users within the automotive industry from three countries namely France, TRW COMPOSANTS MOTEURS, Italy, IVECO, and Spain, TORUNSA; will experience the direct benefits of the new technology. As a result. a wide distribution of the project's results will be secured. A German research institute, WZL, is responsible for the development of the HSCG technology. A successful development of a HSCG technology is expected to give a important contribution to competitiveness of European industry as a whole and to secure jobs in Europe.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Iveco Fiat SpA
Address
Lungo Stura Lazio 49
10156 Torino
Italy

Participants (7)

AACHEN UNIVERSITY OF TECHNOLOGY
Germany
Address
53 B,steinbachstraße 53 B
52056 Aachen
Fuchs Lubrificanti S.p.A.
Italy
Address
Via Riva
14021 Buttigliera D'asti
Marposs SpA
Italy
Address
Via Saliceto
40010 Bologna - Bentivoglio
SAINT-GOBAIN RECHERCHE S.A.
France
Address
Quai Lucien Lefranc 39
Aubervilliers
TRW Composants Moteurs Inc.
France
Address
Rue Des Forges
67130 Schirmeck
Torunsa S.A.
Spain
Address
San Juan Auzoa
20570 Bergara
Werkzeugmaschinenbau Präzisions Technik GmbH
Germany
Address
Carl Jacob Kolb Weg
97877 Wertheim