Grinding Journal - Fall 2007 - (Page 29)

The Mägerle's nozzle system positions automatically and compensates for wheel dressing (Oh, and that traveling column wasn’t a bad idea either) flute form. (If the second roll is a much different diameter the wheel will likely not cut the same and will need to be dressed. Conversely, if the rolls are about the same diameter the wheel will create the same form.) After setup, Doug monitors the power level of the Coolant is important in any grinding operation and machine, the flute depth, and any signs of burning to Tiruna relied on Mägerle to deliver a complete system. determine when he needs to dress the wheel again. In this case it’s a 2,300 gallon vacuum based filtration When he has a stable process it’s time to close the doors system with two big chillers and a drier for the swarf. and let her run till completion. The Mägerle’s nozzle system positions automatically Unique testing capabilities and compensates for wheel dressing, so Doug only needs to select “low” or “high” pressure and he gets After grinding, Tiruna puts rolls on a test bed to good flow into the grind zone. (The only time he verify performance, duplicating the roll position and uses low is for an hydraulic loading unusually small roll characteristics that flexes under of the user’s high pressure setup. Do they coolant!) get contact across the roll? Do Naturally such the rolls make a large coolant marks? This system takes up in-house testing a fair amount of capability is floor space. But it’s unique to Tiruna important to note (there are only that because the two such systems Mägerle’s grinding in the world – the head rides on a other in Spain). traveling column The device can (instead of moving even test rolls the part on a manufactured by a traveling table), the competitor. machine itself needs relatively little floor Besides checking Tiruna boasts a unique ability to realistically test rolls both before and after refurbishing space given the size their own work, of the parts. Plus the machine always moves the same Tiruna can use this test bed to diagnose problems in mass, helping the operator optimize performance. In a the field. For example, if a user is experiencing traveling table design, machine dynamics change every contact problems, Tiruna can eliminate the roll as the source, perhaps pointing to a bearing on the user’s time the mass of the part changes. corrugating machine. Doing it right the first time When do you want it? For Doug, “doing his job” means doing it flawlessly, because that “makes everything easier throughout the rest of the process, right down to running the roll.” Given the size of the part, the need for a unique wheel shape, and Doug’s understandable perfectionism, setting up a first piece typically takes about six hours. The second roll in a set is usually faster to set-up because he’s already confirmed that the wheel grinds the proper Recoating takes ten working days, exclusive of transportation, making the 24 hour grind time seem short. When you add cleaning, inspection, handling, and a few other items not covered here, Tiruna can turn a job around in 8-10 weeks. But they are also willing to store the part while the customer considers their refurbishing recommendations. Grinding Journal 29

Table of Contents Feed for the Digital Edition of Grinding Journal - Fall 2007

Grinding Journal - Fall 2007 Contents From Virginia: Apparently no credit crunch for machine tools Why measure cutting tools Other perspectives on CNC tool measuring Productive grinding of superalloys SUPER service grinding BIG rolls Problem Solver

Grinding Journal - Fall 2007

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