Partnership to focus on grinding development

27th August 2014
Posted By : Staff Reporter
Partnership to focus on grinding development

Master Abrasives is now the exclusive UK and Eire agent for the Cool-Grind Technologies Grind-Loc modular range of high pressure, reconfigurable coolant supply lines and coherent-jet fluid nozzles.

John Webster, Managing Director, Cool-Grind Technologies, states: “We are looking forward to working closely with Master Abrasives on grinding application development projects. Master is one of the leading suppliers of grinding wheels, superabrasives and dressing tools to the market. Together we will really be offering the UK abrasive marketplace complete solutions and optimisation for applications.”

Master Abrasives’ Managing Director, Paul Batson, says: “Although the function of the grinding fluid is primarily to cool the component, it also has to cool the grinding wheel, which is very important with resin-bonded diamond wheels. It also has to allow the lubricants in the grinding fluid to perform correctly, especially important with single-layer superabrasive wheels. As well as flush the chips from the machine and workpiece area, and clean the wheel, often through the use of high power jets, especially when grinding ductile materials using water-based grinding fluid.

“Unfortunately the method of applying fluid into a grinding process is a highly neglected area. However, if done correctly it can have a significant influence on the surface finish, surface integrity and productivity achieved. Significant benefits can often be achieved with superabrasive grinding wheels, by improved grinding fluid application.”

Improvements include reduced dressing frequency, due to less loading with work material, and more effective use of the EP additives into the process; a harder grade of grinding wheel can be applied, improving form holding and reducing dressing frequency; thermal damage of the workpiece material is reduced, allowing higher removal rates and greater throughput; reduction in entrained air (foaming), misting and vapour problems.

Cool-Grind has developed a starter kit box-set with 49 nozzles, manifolds, a range of pipe fittings and installation tools included. The nozzles can be configured to suit any wheel profile, and fit most cylindrical, surface, internal, and creepfeed grinding machines. There is enough in the kit for customers to install the advanced coolant delivery technology on up to 20 machine tools.

“Cool-Grind nozzles are based on round and rectangular coherent jets, and produce a focused stream of coolant at higher pressure than stock nozzles – up to 100 psi. When applied at the optimum coolant flowrate and pressure, these nozzles have a number of advantages over plastic, bent tube, or fabricated nozzles,” Paul Batson explains.

Reconfigurable coherent-jet technology
Coherent-jet technology was pioneered at the University of Connecticut’s Centre for Grinding Research and Development (CGRD) in 1992. The project was funded by the USAF, with Pratt and Whitney as the industrial customer.

The definition of coherency was based on the dispersion of the jet at a distance of 300 mm from the nozzle tip. A very coherent jet is one that doubles in diameter or thickness over that distance. Coherency increases the jets ability to penetrate the air barrier around the grinding wheel using a concentrated impact energy, and avoids driving additional air into the structure of the wheel.

The reconfigurable nozzle system is an effective method of applying coolant into the grinding process. The basis of the method is the use of 250 mm long, individual stainless steel tubes, with either a round nozzle or flat nozzle permanently attached to the end that can fire a coherent jet of coolant.   

To fully exploit the adjustability of the reconfigurable nozzle system, they should include a smooth bend prior to the nozzle end. When coupled to Cool-Grind Technologies releasable compression fittings, the nozzle-tubes can be adjusted using two degrees of freedom; rotation in the compression fitting, and in and out of the ‘step-less’ compression fitting. The third adjustment is the bend angle, with different angles used to avoid interference with each other when closely coupled.

The nozzle-tubes are normally fitted to manifolds or female pipe fittings, using special compression fittings. For full flexibility for aiming, the manifold or pipe fittings should be plumbed at right-angles to the grinding zone, in-line with the position to be cooled. This allows just a single bend to be placed in the pipe, eliminating very close-coupled bends, and rotational torque from the jet that can unwind the fitting in the manifold.

Releasable compression fittings are supplied with no step inside, so the tube does not have to be accurately cut for the jet to be aimed at the target. They are fitted with an O-ring for a good seal, and a split ferrule to hold the tube to the fitting.
Reconfigurable nozzle kits also include a range of plumbing fittings, linear manifolds, locknuts, threaded nozzles, and possibly ‘donut’ manifolds, for versatile assembly of the nozzles. The contents of the kits are defined on a specific customer basis. A compartmented box and special tools are also supplied to make the installation easier.

A laser aiming system is available for the reconfigurable nozzle system. An adapter positions the laser onto the end of the nozzle and the compression fitting or nozzle clamp is tightened to target the grinding wheel. Paul Batson concludes: “Using established scientific principles with coherent-jet nozzle designs, plus extensive industry knowledge, Cool-Grind’s products help manufacturing companies to deliver better coolant flow and pressure to their grinding process. This results in faster grinding, better product quality, reduced wheel wear, and a minimal flowrate. To achieve these goals a close-to-ideal nozzle and manifold system is supplied to customers.”


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