Okamoto Total Grinding Solutions
Published

Where Grinding Still Beats Hard Turning

For many critical applications, grinding remains the optimal machining process.

Share

Although advances in CNC turning centers and cutting tools have made substantial strides in favor of hard turning over grinding, grinding often turns out to be the better choice. That’s the position taken by Rob Titus, senior applications engineer—grinding products at Okuma America Corp. (Charlotte, North Carolina). Okuma is probably best known for its CNC lathes and machining centers. However, the company also offers a line of cylindrical OD and ID CNC grinders. With these interests in mind, the builder is always eager to find the best process for an application, whether it involves hard turning or grinding.

Mr. Titus points to the GA-26T OD grinder, shown recently at the 2012 International Manufacturing Technology Show (IMTS), as a representative example of grinding technology from Okuma. With automation provided by Gosiger Automation, the CNC grinder is designed for OD finishing of small- to medium-sized parts in high-volume production environments. To make the most of floor space, the grinder holds the workpiece stationary while the grinding wheel traverses back and forth. At the show, this grinder was equipped with in-process gaging, a wheel balancer and a 20-hp wheel spindle.

Mr. Titus frequently advises users on the merits of grinding versus hard turning. He says there are at least seven reasons to grind rather than hard turn:

1. Grinding excels at meeting surface finish, size and roundness requirements. A grinding process can achieve a 6 Ra surface finish, hold a size tolerance of less than 0.0002 inch and grind parts to within 30 millionths roundness.

2. Grinding provides a more cost-effective and stable process than turning for ceramic and carbide material. Hard turning carbides or ceramics requires diamond (PCD or CVD) inserts. Rapid wear and chipping of the inserts can result in size variation or scrapped parts. This adds downtime to change inserts and re-establish part size. In contrast, when grinding these materials with diamond-grit wheels, there is gradual wheel wear. The wheel can be dressed to expose new diamond grains without stopping production.

3. Grinding meets the “no lead” specification. This spec refers to the “spiral” visible on a turned shaft. It is created by a single-point cutting tool moving transversely as the part rotates on a lathe. This surface pattern can cause premature failure of seals on a shaft. By plunge grinding the shaft, the lead is eliminated.

4. Grinding is a common customer requirement. Automotive, aerospace and medical markets often specify a ground finish on critical parts.

5. Grinding wheels are not affected by interrupted cuts created by workpieces with features such as keyways or splines. Depending on the shape and size of these features, the interrupted cut can cause premature insert chipping in hard turning operations.

6. Grinding wheels cost less per part than other types of tooling. In some common cases, a grinding wheel can last 120,000 parts before it needs to be changed. If the cost of the wheel is $600, that’s a half a penny per part.

7. Grinding requires less downtime. How many times will an insert need changing on a CNC lathe throughout 120,000 parts?

Mr. Titus notes that most decisions about grinding or hard turning are not cut and dry. These decisions usually require expertise in both grinding and turning, he says, hence the value of consulting with Okuma, its distributor network or Partners in THINC consortium of technology providers. “We are certainly interested in raising the awareness that Okuma has a range of grinder models, but our primary concern is maximizing the user’s productivity and effectiveness,” he says.

Okamoto Total Grinding Solutions
Innovative Manufacturing for the Medical Industry
KraussMaffei
JTEKT
Hurco
World Machine Tool Survey
TIMTOS
Paperless Parts
DN Solutions
IMTS+
Koma Precision
QualiChem Metalworking Fluids

Related Content

Sponsored

Lean Approach to Automated Machine Tending Delivers Quicker Paths to Success

Almost any shop can automate at least some of its production, even in low-volume, high-mix applications. The key to getting started is finding the simplest solutions that fit your requirements. It helps to work with an automation partner that understands your needs.

Read More
Turning Machines

Inside the Premium Machine Shop Making Fasteners

AMPG can’t help but take risks — its management doesn’t know how to run machines. But these risks have enabled it to become a runaway success in its market.

Read More
Five-Axis

How to Successfully Adopt Five-Axis Machining

While there are many changes to adopt when moving to five-axis, they all compliment the overall goal of better parts through less operations.

Read More
Turn/Mill

5 Tips for Running a Profitable Aerospace Shop

Aerospace machining is a demanding and competitive sector of manufacturing, but this shop demonstrates five ways to find aerospace success.

Read More

Read Next

Automation

IMTS 2024: Trends & Takeaways From the Modern Machine Shop Editorial Team

The Modern Machine Shop editorial team highlights their takeaways from IMTS 2024 in a video recap.

Read More
View From My Shop

Inside Machineosaurus: Unique Job Shop with Dinosaur-Named CNC Machines, Four-Day Workweek & High-Precision Machining

Take a tour of Machineosaurus, a Massachusetts machine shop where every CNC machine is named after a dinosaur! 

Read More
Sponsored

Increasing Productivity with Digitalization and AI

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.

Read More
Okamoto Total Grinding Solutions