As grinding and surface finishing operations can account for 20-25% of the cost of all machining operations, the centre’s vision is to extend and enhance its capability, both in terms of equipment and resource, to a level required by the existing partnership.
Recently, a Studer S41 CNC universal cylindrical grinding machine was installed there.
AMRC technical fellow, Dr David Curtis explains: “Previously grinding has mainly been regarded as a means of machining for final dimensional accuracy and of achieving the workpiece’s required surface finish. Although, thanks to recently developed techniques which greatly increase material removal rates, this perception is rapidly changing.
“The AMRC with Boeing’s grinding and surface finishing team have the capabilities and expertise to improve performance and quality across the range of grinding operations, with a particular focus on aerospace components. Process areas include cylindrical grinding, surface and profile grinding, multi-task grinding, hybrid grinding, gear grinding and mass finishing. Our current grinding related research areas include cost modelling, environmental impact, hardware/applications development, process optimisation, process control as well as training and support functions. In addition our studies involve coolant, wheel technology and wheel dressing.
A visit to Studer HQ and subsequent S41 demonstration sealed the deal. He says: “In addition to boasting a higher level of stability and precision than the alternatives we looked at, the Studer S41’s multiple wheel-head capacity and overall flexibility, allowed it to cover the vast majority of our demanding needs.
The AMRC ordered a modification with increased centre height of 325 mm, allowing a swing of 650 mm, plus the inclusion of high-speed grinding, thread grinding, out-of-round grinding, as well as a special high-pressure coolant system that is suitable for use with emulsion and neat oil.
He explains: “The target was to specify a machine tool platform with research flexibility as well the ability to engage with a range of industrial applications.
“Our Studer S41 is now actively engaged in a number of important projects including research into the grindability of materials and the study of automated process control for aerospace applications. Also, rather than users relying on the data supplied by the manufacturers of grinding wheels, we are currently looking to develop a standard wheel test to allow all grinding wheels to be benchmarked against each other. So far, although some other wheels have delivered good results, we have been particularly impressed with the high stock removal rates delivered by 3M’s Cubitron grinding wheels.
“As United Grinding has become a Tier 1 Partner with the AMRC, our Studer S41 is also occasionally used as a demonstration resource for prospective Studer customers.”
The advanced machine boasts a wide range of advanced technical features, such as high-precision axis drives with linear motors, extremely fast direct drive of the B-axis and a large selection of wheelhead variants, it also features Studer’s StuderGuide guide-way system.
Standard centre height is 225 or 275 mm and distance between centres is 1,000 or 1,600 mm. The S41 can also be configured as a single-purpose machine for large batch production use.
