Category Archives: Centerless Grinding

We at O’hare Precision Metals, LLC. our Centerless grinding solutions provides the maximum surface finish, precision roundness, and tight diameter…

grinding steels

Grinding Steels

Applying the grinding technique to steels requires guidelines and proper implementation of tools and inserts to achieve quality results.

Steel has been thoroughly used by a lot of manufacturers and metalworkers nowadays.

grinding steelsThe almost perfect feature of steel makes it pass all rigid requirements when it comes to mechanical properties and excellent grade.

Steel is fused with different elements that have excellent characteristics on their own – alloyed together to form one solid metal that can withstand high performance applications.

Steels are the best materials for withstanding high temperature environments that require high tensile and yield strength and excellent resistance to corrosion and oxidation.

Steels are iron-based metals. By its improved strength, steels are common raw materials used for manufacturing parts for automotive engines, aircraft structure and turbines, and even for chemical plants and medical tools.

Machining Steels

Steel materials are challenging to be machined compared to other metals due to its kind of hardness feature. The higher the steel’s alloying content, the harder it is to machine. Mostly, this challenge falls to austenitic steel which contains a maximum percentage of chromium and nickel elements. But special metallurgical treatment has been made to enhance the machinability of steels.

In addition, hard steels need the rigid use of heavy machineries when machining. There is a need to obtain knowledge of the factors contributing to the machinability of steels to achieve complex precision engineered parts in high volumes. Mechanical properties, grades, alloyed elements, and strength are just four of the contributing factors that influence the machinability of steels.

Grinding Steels

Obtaining finer surface finish in grinding steels involves continuous abrasive metal removal. Thus, an implementation of healthy guideline to grinding steel is necessary especially when grinding hard, course part. For such operation, there are key variables to be followed such as: three-point positioning, consistent grain dressing, proper automation, and coolant application. Keeping a close watch to those key variables makes the operation running in a smooth flow, enabling to achieve that consistent part results in a single pass!

Since the operation is too continuous and rapid, tool grains on the grinding wheels might get worn out so redressing them is highly encouraged. To gain that precise surface finish and tight diameter tolerance, grinding procedure should be put properly into place.

Need machining procedure for your parts? Give us a call at (847) 640-6050 or Send us a Free Quote Now!

centerless Grinding

Innovations for Centerless Grinding Issues

Centerless grinding is best in achieving consistent part results at fast lead times but issues are inevitable – this calls for innovations to improve operation and productivity.

When it comes to mass production, centerless grinding receives all the recognition in achieving consistent part results at fast lead times.

centerless GrindingThe multifunctionality it performs allows the option to not just grind and cut the bar alone, but also polish and clean it to its accurate surface finish.

This cylindrical operation is highly applied in the mass variety of either round or complex components where quality parameters like tight tolerance, cylindricity, and roundness are crucial.

As of today, the cost of manufacturing is highly increasing which has pushed manufacturers to extract more production out of grinding machines to at least, lower the cost per piece. Let’s say a supplier of components for high performance application such as automotive engines, aircraft parts, turbines, and endurance racing will need to have boost-production but at reduced lead times. Outsourcing this required application is considered the best aid that put centerless grinding in place and specialization. Yet, it entails a large machine investment and skill not really common in the machinist workforce.

Thus, we can’t deny the fact that centerless grinding can be quite expensive and dirty; but there are best suggestions from experts to improve productivity and quality level while reducing the cost of centerless grinding process:

Floor Space Utilization

  • The land cost is always high which has hit the biggest percentage in the capital including the facilities and the equipment. This initiates the need to reduce floor space dedication to a single machine only and machine footprint. Upon this rising issue, some operators come up in designing small models of grinding machine. In addition, they add rigidity by adding weight to make it equal to the traditional models. This helps save more space for other operations.

Productive Dressing Time

  • Dressing is the major non-productive phase in the process. Thus, there really is the need to devise operations in order for the dressing time to be utilized productively. There is where the use of diamond abrasives comes in place. Diamond abrasives don’t get dull right away which are much effective in grinding parts. This leads to more production of parts with consistent finish even with less redressing.

Reduced Working Costs

  • This best explains why an automation implemented in the operation is important and effective. Running an automation helps the operator to do more than one task and run more than one machine. Skill is highly considered in this phase. Thus, it is important to hire a skilled person who knows how to look after the setting and do a regular inspection of the final pieces for the grinding machine. The implementation of CNC option also aids in the reduction of operator’s intervention to a large extent to reduce costs.

Energy Efficient Motors

  • The increasing cost of power is happening right now, thus more energy efficient motors must be explored.

Efficient Formulation

  • The production of fuel-efficient vehicles is important to run the operation, however, this is also greatly affected by the increasing rate of fuel prices – which is a burden to the manufacturers. This opens up the need to explore and try different materials and techniques to reduce vehicle weight. And if possible, machines with the capability to grind such components need to be devised. An installation of Variable Frequency Drive to the grinding wheels helps in achieving constant surface speed. This also aids in the reduction of the dressing frequency as the wheel diameter is reduced, resulting in an optimum use of the grinding wheels.

Contact us or get our Free Quote and see how we can deliver the right machining solution for you!

Accessories and Equipment in Centerless Grinding - Ohare Blog 03

Accessories and Equipment in Centerless Grinding

Sophistication must not only come in a machine but also productivity and multifunctionality – for an optimum centerless grinding operation.

The success in any machining operation doesn’t lie only on skills or facilities, though they are one of the most critical segments in the process, it is also important to take the machine accessories and tools into great consideration.

Accessories and The Machine

Accessories and Equipment in Centerless Grinding - Ohare Blog 03Sophistication must not only come in a machine but also productivity and multifunctionality. But how are all these achieved?

Of course, skill, preventative maintenance, equipment, and tools are always part of the process but the proper implementation of machine equipment may also have its part.

To make the operation successful and much more effective in centerless grinding, there should be an involvement of machine tools and accessories (such as outboard supports, ejectors, supporting rollers) in place. The use of these accessories and operator assisted devices makes the work more efficient, improve grinding application, and achieve the better tolerance required in every bar.

In all kinds of centerless grinding operation, may it be thrufeed or in-feed, the presence of such tools is taken into high importance by operators for optimum part removal with controlled bar straightness.

Proper setting and attachment

Thrufeed grinding

For thrufeed grinding, the work size compensation is one significant factor to consider in attaining tight tolerances. Simple supporting is not enough to have an effective centerless grinding operation. There can workpieces that weigh 200 kg or even more, so support tables (with self-contained drives) are needed to help rollers enhance turning rate or the high rotational speed of the regulating wheel.

Rollers

• Imparts peripheral speed which is equal to that of regulating wheel’s rate
• Enhances speed proximity

Push button/ Gage Directed Actuation

• Basically for work size control
• Also, works for compensating wheel wear
• Withdraws the wheel slide when balancing thermal effects on the work size is necessary

In-feed grinding

If you are looking for less practice times but with exacting diameter tolerance in every infeed grinding operation, machine accessories and attachments should not be ignored. These tools make the set-up and operation more efficient and make it even more possible to gain fast machining production.

Grinding small part diameters and even out-of-round parts is highly complex requires attachments to hold the workpiece in proper place.

Harmonic Drives

• They ensure good repeatability for the fine compensation and grinding cycle
• Allow incremental movement of slides

Precision Ground Ball Screw

• This makes it possible for achieving great tolerance and roundness up to even .0002” in 56” length

Twin-Grip Mounting

The combination of those necessary attachments enable both wheels (regulating wheel and grinding wheel) to use the “Twin-Grip” mounting, which is essentially used in eliminating and resisting wheel-separating wheel pressures even under heavy loads. Aside from proper placement and controlled gap, this mounting is critical and important in providing maximum rigidity between spindles that affects the consistency of part geometry.

If you want to learn more about a high precision centerless grinding operation, these services, and best products, call or contact us now at (847) 640-6050.

Discover How Centerless Grinding Operates - Ohare Blog 04

Discover How Centerless Grinding Operates

To operate a centerless grinding process takes skill and further understanding of its rules to be able to attain flawless results out from the raw materials.

Discover How Centerless Grinding Operates - Ohare Blog 04Centerless grinding is a kind of metalworking operation that highly requires full understanding of its basic fundamentals to achieve quality and consistent results. This kind of grinding process is very crucial resulting to most operations to fail in achieving the desired quality due to the lack of understanding of its basic principles.

Basically, centerless grinding is a kind of OD grinding process which is far different from other cylindrical processes in which the workpiece is not mechanically forced with pressure. The workpiece must be placed above the centerline of the wheels to let the grinding process create a rounding action on the workpiece.

Other traditional OD machining processes like center-type or chucker-type grinding require center holes, drivers, or workhead fixtures – centerless processes don’t. Instead, a workblade that is located between the grinding wheel and regulating wheel supports the workpiece on its outer diameter. The grinding wheel has much higher velocity than the regulating wheel. The presence of these three components like the workblade, the grinding wheel, and the regulating wheel makes the grinding process attain a perfect centerless grinding operation.

Major Parts that do the Grinding Process

  • Grinding Wheel

    The grinding wheel is the part of the machine that does the grinding process and has higher speed than the other wheel. It applies a downward force to the workpiece and is placed on affixed axis.

  • Regulating Wheel

    This wheel is the movable wheel and has slower speed than the grinding wheel which applies a lateral pressure to the workpiece.

  • Workblade blade used for abrasive cutting.

Why Centerless?

The idea of “centerless” may confuse manufacturers. But from the word itself, “centerless”, the centerless grinder has no centers, appearing to have no control on the workpiece. That’s what makes the operation indeed crucial and difficult. If proper fundamentals are acquired in the process and if it’s set up properly, centerless grinding will achieve surface finish, roundness, and dimensional tolerances in the metalworking operation. What makes this grinding operation stand out for other processes is that it comes up with a flawless roundness of workpiece blanks – if the process is done through properly sticking to its fundamentals and with a proper handling of the grinding wheel, the regulating wheel, and the workblade.

There are numerous companies that offer a lot of services when it comes to manufacturing parts for different production of automobiles, aircrafts, hardware, and constriction of raw materials. Among these companies, only one is considered to be the company which worth your trust.

The great actions to prepare firsthand in the grinding process and all other machining operations are highly one of our tasks here in O’Hare Precision Metals, LLC.

Our company can be well-trusted for that. From the quality of materials and choice of machines used in various operations, you can sure expect the finest of the results at O’Hare Precision Metals.

We offer here various excellent services you seek for upon manufacturing your parts for your business and also products which are superior in quality and high standards. For more information, call or contact us now at (847) 640-6050!

What Is Centerless Grinding - Ohare Blog 01

What Is Centerless Grinding?

When it comes to manufacturing parts, centerless grinding is one of the best operations to use to come up with flawless products.

What Is Centerless Grinding - Ohare Blog 01

There are a lot of necessary and important operations upon manufacturing parts like in the production of automobiles, making hard wares, and any necessary equipment to aid human living.

This production involves division of labor among workers, the utilization of mechanical power and machinery.

Another essential thing needed in these operations is the use of advanced precision technology to possibly achieve your desired goal upon manufacturing your parts.

The Centerless Grinding Operation

Centerless grinding is a type of operation that is considered to be highly important in manufacturing and in assembling component parts. Steels, for example, play a large percentage of automobile components and in other wares. That is where centerless grinding plays its significant role.

This operation mainly helps in both removing and inserting parts of the workpiece by an abrasive cutting process. To explain the operation, two grinding wheels are used and placed opposite to each other above the work holding platform. One wheel remains stationary that applies a downward force while the other wheel is movable that applies lateral pressure to the workpiece.

The stationary wheel is responsible for the grinding process and the moving wheel is the one that takes firm hold of the material. The wheels apply relatively same speed as they get in contact with the workpiece to complete the grinding process. This involves the use of a purpose-built grinding machine that already has built-in grinding wheels and a platform. The operation itself undergoes a very crucial process to be able to produce a better material.

Obviously, a lot of brands offering different grinding services surround you now. When you are into manufacturing parts which have to undergo processes like material construction, cutting, or grinding, it is best expected for you to look for the finest in standards and quality.

Here at O’Hare Precision Metals, the best quality that you aimed for is within your reach!

We promise you here to bring out the raw materials and transform them into flawless products. You can be sure to lay trust on our services and on our reputation. Having been a top supplier and manufacturer of steel products, O’Hare Precision Metals, LLC is now rapidly growing its name in the industry.  We have here a tight goal of bringing up the best quality service and products to our dear customers.

O’Hare Precision Metals, with its technological advancement and highly skilled people, can transform any raw material to a perfect product for the maximum satisfaction of customers. Services that have already been offered here are the centerless grinding, bar chamfering, bar grinding, parts machining, and more.

If you want to enjoy these services and best products, call or contact us now at (847) 640-6050.