6 DGI Supply | Greenlee Engineered Super Abrasives Improve Productivity Exponentially

RECENT APPLICATION SUCCESS STORIES

Manufacturing innovations often make incremental improvements to productivity. However, certain technologies, like super abrasives, really have the potential for exponential productivity improvements.

The challenge is identifying the right solution for a particular situation. This is why super abrasives are sometimes considered an art in their development and application.

Greenlee Diamond Tool – A DoAll Company— has been helping customers optimize their manufacturing productivity for over 70 years through the use of super abrasives over conventional abrasives or other manufacturing methods.

Greenlee holds staunchly to the belief that there is an optimal super abrasive solution and that Greenlee has the ability to develop that solution for the most demanding and difficult grinding applications.

Electroplated Thread ChasersA customer was machining uniquely profiled internal threads that were being used as part of a linear slide. This customer required the internal thread to be burr free as well as have an excellent surface finish. The customer was meeting these requirements through the use of conventional abrasives and tools however it was taking a tremendous amount of time. Greenlee developed a family of super abrasive plated thread cleaning tools that had excellent tool life and the customer was able to achieve mirror like surface finishes while reducing the cycle time significantly.

Diamond Plated Reciprocating SawA customer needed help tooling up their uniquely designed wafering machine. Their machine utilized multiple linear saw blades simultaneously that reciprocate to slice wafers. Greenlee developed a linear diamond blade that is plated on .006" backing material and utilizes fine grit diamond to produce an excellent finish with minimal edge chipping.

Is there a process that is dependent on conventional abrasives that is taking significantly longer than you need it to?

Greenlee Engineered Super Abrasives Improve Productivity Exponentially

7TECH PROGRESS | March 2016 | Issue 2 |800.923.6255 | www.dgisupply.com

Greenlee has been a manufacturer of diamond plated band saw blades for many years. These blades can range from 7' up to over 25' feet in length, are generally on a stainless steel backing that is either 0.020" or 0.040" thick and come as welded loops.

ROUND TOOL GRINDING CASE STUDY:Greenlee’s 1A1, 1V1 and 11V9 hybrid bond system wheels are utilized at premier round tool manufacturing companies throughout North America. Review the most recent case study comparing the newest Greenlee hybrid bond system on Star and Walters machines to our competitors’ products and see how 150% improvement was achieved.

Equipment and Tool Details

Machine Type STAR CNC Tool Grinder WALTERS CNC Tool Grinder

Horsepower 24 30

Coolant Transor Oil Transor Oil

Tool Size 1 inch solid carbide 1 inch solid carbide

Length of Cut 1 ½ inch 1 ½ inch

Number of Flutes 4 flute 4 flute

Helix angle 27 degree 37 degree

Depth of Grind 0.190 inch 0.220 inch

Number of passes 1 1

STAR Results

Parameter Greenlee Competitor

White stick frequency Every 5th part Every part

Feed rate 2 ½ ipm 1 ipm

Form reduction Only 0.007" after 25 parts

Motor load Started at 20% and ended at 50%.

Started at 25% and climbed to 30% but then required white stick

Comments Ran 25pcs and never had to retrue the wheel

150% productivity improvement%

WALTERS POWER Results

Parameter Greenlee Competitor

White stick frequency Not necessary Every 10 parts

Feed rate 4 ipm 2 ½ ipm

Form reduction Only 0.010" after 25 parts

Motor load Started at 16%, settled in at 25% after 10 parts

Started at 16% and climbed to 35% then had to be white sticked

Comments Ran 110 pcs and never had to retrue the wheel

60% productivity improvement%