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Grinding auto parts using double disc

Source:Ringier Release Date:2011-05-30 979
Metalworking
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Cinetic Landis Grinding Corp. double disc grinder Flexibility is a very strong requirement for customers in the automotive industry today. Double disc grinding in automotive parts manufacturing is perhaps one of the main selling features for a manufacturer of grinding systems.

The UAE automobiles industry is taking the lead among Gulf countries in average sales growth as it recorded a double-digit growth rate in the first quarter compared to the same period last year. The industry witnessed a 12 percent growth in sales, while Saudi Arabia's rate was flat and Qatar at 1.4 percent, Ford Middle East Director of Sales Hussein Murad told reporters at a news conference where the U.S. automaker announced its first quarter sales results for the region.

Double disc grinding cells are designed to change over from part to part in as little as three minutes. Considering that production double-disc grinders have been historically dedicated machines, it is quite an about-face.

Accuracies obtained are, to a large extent, application-dependent. Typically, however, double-disc grinding can hold size tolerances to as close as 0.0001-inch and flatness to within 50micro-inches, while achieving surface finishes as fine as 5rms with conventional abrasive discs. (Polishing discs typically produce surfaces of 1 to 2rms.) The ability to achieve tight tolerances often eliminates the need for lapping or polishing work, fine grind work and secondary inspections. It also reduces part handling, scrap and rework.

How it works

Double disc grinding is the removal of material from a part with parallel surfaces. The metal removal takes place on both sides of the part simultaneously, with the grinding occurring on the faces of the grinding wheels. Most commonly, the disc wheels are attached by inserted nuts to diametrically opposed horizontal spindles, each contained in a heavy-duty precision grinding head assembly.

Some typical applications include the grinding of connecting rods, engine valves, valve seats and lifters, brake pads, brake rotors, clutch plates, piston rings, universal joints, and bearings. Materials vary from cast iron to stainless steel, from forgings to powdered metal, from basic carbon steel to high-tech alloys. Disc grinding has become a highly flexible process capable of many operations, from the snagging of rough castings to extremely precise lapping, holding tolerances in the millionths. The majority of disc grinders utilise wheels from 12- to 42-inches in diameter, between 1- and 4-inches thick. Typical grinding wheel grit sizes fall between 16 and 240, depending on the operation.

Disc grinding operations can be described by two defining characteristics. The first is the primary method of stock removal: a shear grind, a progressive grind, or a plunge grind. The second is the method of part introduction: through feed, rotary feed, reciprocating feed, or oscillating feed.

Easy operation

The level of technology to be found in the latest generation of double-disc grinders is consistent with other types of state-of-the-art machine tools. For example, the latest controls include a more user-friendly operator interface, a colour monitor, and a movable pendant that can be positioned in front of the machine for setup and in back of the machine, when necessary, for convenience during machine operation.

Such improvements address the concerns of the automotive industry, in particular, where machine operators frequently find themselves running a lathe one day, and a grinder the next. Plant managers in that industry rarely have the luxury of sending their operators to a two-week training school before making the transition from one machine to another.

Cost-, time-saving

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