Implement proven, state-of-the-art grinding techniques.

The goal of the IGI is twofold:

1) perform state-of-the-art research in grinding;

2) take ready-to-use research and apply it to real-world production.

Applied research and advanced development are carried-out to address a real, tangible need of your company, as perceived by working engineers. Research often fails to make the transfer from the lab to the operational environment. The IGI takes these underexploited technologies and works with companies to implement them into real production.

The focus is on short-term research that results in improved operations in terms of quality and productivity. IGI offers a full spectrum of services: developing research from technology concept, to testing, and finally to implementation. There is a special emphasis on technological developments that are ripe for quick transfer to industrial applications – typically within a few months.

With an international group of technology consultants and senior researchers, we can solve any grinding-related question you may have. We work with large industries, machine builders and world-leading organizations in production research to maintain the latest perspective on state-of-the-art technology.

Completed &
current projects:

The theory of Aggressiveness

IGI founder Dr. Jeffrey Badger developed the practical concept of Grinding Aggressiveness and first published it at a 2008 CIRP conference in Dublin. The IGI has developed this concept further, applying it to all abrasive interactions. An in-depth, first-principles description was published in the International Journal of Machine Tools and Manufacture. A simplified, practical version was presented at a 2021 CIRP conference in Ljubljana and published in Procedia CIRP.

Non-round grinding

Non-round cylindrical grinding is a unique process used to create complex workpiece geometries. However, it suffers from surges in material removal rate and, consequently, excessive wheel wear and risk of thermal damage. In an EU-funded project, the IGI modelled this geometry for a Slovenian punch producer and developed parameters to minimize cycle time. The findings were published in CIRP, the International Academy for Production Engineering.

Double-disc grinding

The IGI is involved in a collaboration with SKF, a Swedish bearing manufacturer, and numerous industrial partners affiliated with the Chalmers Centre for Metal Cutting Research (MCR) to model free-rotation, double-disc grinding of bearing components with the goal of avoiding: 1) workpiece stoppage, which occurs at low free-rotation workpiece RPMs; and 2) thermal damage, which occurs at high free-rotation workpiece RPMs. The project is ongoing.

Camshaft grinding

The IGI developed a novel "constant temperature” process in camshaft grinding for Scania, a large Swedish truck manufacturer. The end-result was a 20% shorter cycle time with less risk of thermal damage (via Barkhausen-noise Rollscan measurements). The findings were published in CIRP, the International Academy for Production Engineering, and resulted in a patent.

Coolant performance

The IGI is involved in a collaboration with Sandvik Coromant, a Swedish tool manufacturer, and Quaker Houghton, a Dutch-American grinding-fluids producer, to study the effects of different coolant chemistries when grinding tungsten-carbide with diamond wheels. Testing is scheduled for spring 2022.

Grinding of cermets

The IGI was involved in a collaboration with VOLLMER WERKE Maschinenfabrik, a German grinding-machine builder, to study diamond grinding of cermets, a particularly difficult-to-grind material. The findings were presented at the 2016 International Symposium on Advances in Abrasive Technology (ISAAT) in Stockholm and published in the Materials Science Forum.

Multi-grit superabrasive wheel

The IGI is involved in a collaboration with Tyrolit, an Austrian grinding-wheel manufacturer; Element Six, a British superabrasives producer; Scania, a Swedish truck manufacturer; and Chalmers, a Swedish university, to produce a novel, high-performance, multi-grit cBN crankshaft grinding wheel.

Flute-grinding lift-off

The IGI investigated the phenomenon of end-of-cut power surge in flute-grinding, a phenomenon that causes thermal damage and long cycle times. A model was developed that tells the end-user how to minimize this surge and shorten cycle times. The findings were published in the International Journal of Abrasive Technology.

Diamond-wheel truing

The IGI modelled truing geometry for Rush Machinery, an American diamond-wheel truing-machine builder. The end-result was an online program to help users choose the optimal truing wheel and truing parameters to reduce cycle times and truing-wheel consumption. The findings were published in CIRP, the International Academy for Production Engineering. The project is ongoing.

Crankshaft grinding

The IGI modelled the complex geometry and thermal aspects of crankshaft grinding for Scania, a large Swedish truck manufacturer. The goal was to choose "feed increments” that minimized wheel wear and workpiece temperature (verified via Barkhausen-Noise Rollscan measurements). The end-result was a 25% reduction in cycle time and lower risk of thermal damage. The findings were published in the Journal of Materials Processing Technology and resulted in a patent.