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.
Research is tailored to your company’s specific needs –
with a focus on capability building and solutions to get your operations running more efficiently and cost effectively.
Some candidate
subjects are:

Grinding parameters

The parameters of "Q-prime” (specific material removal rate), Aggressiveness Number, Grinding Overlap Ratio (in cylindrical-traverse grinding), Dressing Overlap Ratio (in stationary dressing), Speed Ratio (in rotary-diamond dressing), RPM Ratio (in cylindrical grinding), among others, are well-established and are of enormous benefit to those who know how to use them. Unfortunately, many of these have not made it to the inputs and outputs on the CNC controls where, with straightforward explanations, they would be of huge benefit to the end-user. The IGI can help you implement these parameters onto your machine.

Chatter and waviness problems

When the wheel RPM divided by the workpiece RPM is close to an integer (5.00, 6.00, 7.00, etc.), there is a high risk for chatter and workpiece waviness. This is also true in rotary dressing, where the dresser RPM divided by the wheel RPM is an integer. This situation has plagued grinding operators who don’t know this basic relationship. A simple warning can alert the operator when this situation is present. Other options are to apply a correction – a small increase or decrease in wheel speed or workpiece speed – to avoid the integer value or to vary the wheel and workpiece velocities sinusoidally. These are all concepts that are well-proven in research and ripe for use in production. The IGI can help you implement them.

Grinding with constant removal rate

In most grinding machines, operators input depth of cut, feedrates, plunge speeds, etc. The concept of inputting the material removal rate  and allowing the machine to choose a corresponding feedrate  is better. This can be of enormous benefit in reducing cycle times, avoiding excessive wheel wear, and achieving more consistent grinding. The IGI can work with you in implementing this useful concept into your machine.

Power monitoring and energy efficiency

Several commercial devices have been developed to monitor grinding-wheel spindle power during the cycle, which is enormously useful in avoiding burn, troubleshooting grinding problems, optimizing the cycle, and assessing energy efficiency. The IGI can help you to implement a power-monitoring device into a machine and leverage the potential for more efficient grinding.

Grinding temperature control

The "Jaeger's moving-heat source model" has been used to predict grinding temperatures successfully for over 40 years. However, it has yet to make it to the shop-floor. If the spindle power is monitored, the IGI can help you estimate grinding temperature, which is the only method to avoid grinding burn. This is particularly true in shallow-cut, uniform-geometry grinding operations such as cylindrical grinding and peel grinding.

Diamond wheel sticking

Many modern machines now have "auto sticking” when using diamond wheels, particularly when grinding tungsten carbide and cermets. However, little is known about how "hard” to stick these wheels, resulting in either poor cleaning effect of grinding loading or in excessive wheel wear. A simple calculation and output can tell the user how hard to stick the wheel. In addition, if power monitoring is available on the machine, this can be used to determine when sticking is needed and if the sticking aggressiveness is adequate. The IGI can help you implement this into your controls, resulting in higher productivity, less risk of burn and less wheel wear.

Non-round cylindrical grinding

Many non-round complex forms are now produced on cylindrical grinders by controlled wheelhead retraction. However, many of these operations suffer from temperature surges and longer-than-necessary cycle times. Optimal cycles have been developed for these operations (punching tools, cam lobes) and are now ready to be implemented onto machines, which will result in shorter cycle times and less risk of grinding burn. The IGI can help you implement such a state-of-the-art program into your machine.

Optimal wheel lift-off in creep-feed grinding

In multi-pass creep-feed grinding operations (e.g. flute-grinding of HSS and tungsten-carbide endmills, drills and taps) there is a "power surge” at the end of the stroke, causing workpiece burn and rapid wheel wear. Some end-users cope with this by slowing down the feedrate – often prematurely and incorrectly – resulting in larger cycle times and limited effectiveness. A simple, yet effective solution can be implemented to a machine to eliminate this surge and maintain short cycle times and no risk of burn. The IGI can assist you with the implementation.

Centerless grinding

On the shop floor, where different part geometries are ground with the same machine, set-up adjustments are usually based on trial and error. This leads to significant production downtime. The quality of in-feed centerless grinding can be greatly improved and set-up times shortened with straightforward simulation. Additionally, for improving the accuracy of a thru-feed process, it is also necessary to ensure simultaneous line contact of the moving part with the grinding wheel, the blade, and the regulating wheel along the length of the grinding gap. This can be achieved by appropriate truing of the regulating wheel. The IGI can help you with obtaining both higher process flexibility and productivity by offering you the needed tools for process planning.

At IGI, we help you take your grinding to the
highest level – quickly and seamlessly.

Contact us
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