Studer WireDress is cutting-edge EDM technology that save massive downtime and makes it possible to dress sintered metal bonds with the highest precision in the grinding machine at the full working speed.
Explains Michael Klotz, project manager for development at Fritz Studer AG: “It is a well-known fact that metal-bonded grinding wheels are much more durable and dimensionally stable when machining difficult-to-machine materials and ultimately enable higher productivity. The problem with this is that metal bonds can only be dressed to a very limited extent using conventional methods in the grinding machine. In addition to this, there is a high dressing tool wear associated with a low cutting ability. This is neither an operator-friendly, nor a high quality and process consistent dressing method”. And that's why the best bond – the metal bond - is rarely used. Studer has developed, along with technology partners, the machine-integrated WireDress dressing technology. Here, the dressing is done at full wheel speed. In contrast to conventional mechanical or external EDM dressing, WireDress dressing occurs by a modified wire erosion in the grinding machine, where the grinding oil serves as a dielectric.
The dressing process is contactless and wear-free. The grit itself is not dressed; the metallic bond around the grit is removed. Depending on how deep the grit is embedded in the bond, it either falls out or remains with original sharpness in the bond. The grinding wheel receives a high grain clearance for maximum cutting capability, lower grinding forces and low burning risk.
Using a bond with a high dimensional stability, almost any profile can be precision-contoured in the micron range. Long dressing intervals can be achieved. Yet another plus: the accurate processing of sophisticated or smallest geometries that were neither economical nor possible before, now become feasible. Compared to grinding with ceramic-bonded grinding tools, significant increases in productivity in the range of at least 30% is realistic, with resin bonds, even more is possible. With a sintered metal-bonded grinding wheel, users can even go beyond the limit, just re-dressing it in the machine again. With a conventional galvanic bonded grinding wheel, it is possible to go over the limit only once. "Maximise these limits without fear - that also makes greater profitability possible," adds Klotz.
