Solving an aerospace manufacturer&#;s problems with customized solutions

For more information, please visit Leading Diamond Tools.

Weldon Solutions is accustomed to customizing. We&#;re in the business of making products work for our customers to help them keep costs down and save time in the process.

When an aerospace component manufacturer was looking to replace an aging grinding wheel dresser, they knew we were experts in the space and contacted us to help.

The grinding wheels in question are used in the customer&#;s manufacturing processes on many existing grinders. Their current system is more than 30 years old and not very efficient at rough and finish dressing their aluminum oxide grinding wheels. On top of those issues, these dressing machines are no longer being built by the original manufacturer.

The aerospace company&#;s engineering manager previously worked for another business which used several Weldon machines in its manufacturing processes and had a long history working with Weldon. Realizing the bind they were in, the manager contacted Weldon to find out if we could develop a workable solution.

Engineers get creative to solve customer problems

After considering the issues with the customer&#;s grinder, Weldon opted to use our own existing, standard Phoenix model for this project to customize and reduce the machine footprint.

While typically associated with a large-capacity ID grinder, our team designed a custom enclosure for side access on the Phoenix where the ID grinding spindles would normally sit. This makes it easier for an operator to load the arbor-mounted grinding wheel into the custom-built driving fixture.

Weldon teamed with MasterCAM to develop a software post-processor specific to this application. Thedual GII Solutions dressing spindles will rough and finish the grinding wheel profile in a more modern format to save a sizable amount of time over their existing process. It will also make better use of the diamond dressing rolls, using both sides of the dressing media to spread out the wear, saving in the consumables cost.

The biggest savings from the modified grinder is that the process of roughing and finishing materials, which would have taken 1 to 2 hours previously, now takes just 15 minutes.

&#;We were able to take a standard, existing structure and modify it to make it work for this customer&#;s needs and purposes,&#; said Ben Cornbower, Weldon&#;s manager of grinder sales. &#;It was a challenge to find out where everything fit and to make it user-friendly to load and unload.

&#;In the end, we created a machine with a smaller footprint and drove down costs while making sizable improvements in cycle time,&#; Cornbower continued. &#;It was exciting to take our standard machine and do something new and creative with it to satisfy a customer&#;s needs. &#;This custom approach and going the extra mile are what differentiate Weldon from our competitors and how we continue to build on long-term client relationships.&#;

If your company needs specialized, customized grinder solutions, contact Weldon today to discuss how we can help solve your machine problems.

Diamond cup wheels are diamond tools bonded with metal and diamond segments welded along a pressed metal wheel body, which appears in a cup shape. These cup wheels are suitable for breaking down heavy building materials like concrete, granite, and marble.

Diamond Cup Wheels are designed for various tasks such as:

• Cup wheels with multiple large diamond segments are used for heavy-duty jobs, including grinding of stone and concrete

• The smaller and lesser segment cup wheels are used to remove paints, glues, mastics, etc. 

Different variants require to be considered when using Diamond cup wheel, including the various diamond grits, the standard of the diamond segments. Therefore the diamond concentration to it most accurately fits different surface types. For instance, when grinding harder surfaces, contractors need to use a softer bond segment. Once they are grinding more delicate surfaces, they have to use a more rigid bond segment. It is often an incredibly important factor to know during surface preparation. Each cup wheel is specifically designed for grinding different building materials.

How to Select the Right Diamond Cup Wheel?

Choosing the proper diamond cup wheel can cause a severe headache even to the foremost experienced supplier or end-user. It's because a diamond cup wheel, like every other diamond manufacturing equipment, is suitable for various applications.

The company is the world’s best customized diamond disc for grinder manufacturers supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

However, no matter what you plan to use this must-have equipment for, following the ideas during this article can prevent tons of stress and stop wasting your money on a tool that won't offer you the result we desire.

These are a number of the factors you want to put into consideration when selecting diamond cup wheels. These include:

Selecting the Appropriate Diamond Cup Wheel Category

The diamond cup wheel comes in variants of different specifications. According to the application type, the cup wheel category is selected. For example, heavy loads like concrete and grinding stone would require a diamond wheel cup with a huge diamond segment. On the opposite hand, smaller diamond segments fit perfectly for lighter works, including glues, paints, epoxy, and other surface coatings. Therefore, it's imperative first to work out the character of the task ahead.

Understand Surface Hardness

Depending on the hardness of the surface, the diamond cup wheel generally exists in two phases. 

• Phase 1 consists of coarse grinding. In this phase, diamonds possess a high propensity to become blunt. It occurs because a diamond cup wheel quickly blunts out when operating on hard surfaces. Thus, a soft diamond bond with high diamond highness is suitable for this phase.

• Phase 2 involves fine grinding or polishing. It requires the utilization of a tough bond thanks to its superior precision. However, as a diamond doesn't disintegrate quickly, a soft diamond will do the work briefly. Grit between 80 to 120 is right at this phase, while the concentration must be set high.

Identify the Proper Abrasive Components

The diamond cup wheel has two significant parts- the cut of abrasive grains and the bond between abrasive grains. The mixture of the grain, bond, and therefore the spacing between the wheel form the structure. You want to consider the share also. The precise abrasive that a cutting wheel uses mostly depends on its interaction with the work material.

A perfect abrasive self maintains itself through automatically sharpening. The abrasive fracture works by establishing new cutting points when dulling set in. However, there's a particular feature for every abrasive type in terms of strength, hardness, resistance to impact, and fracture toughness.

Abrasives are available in three primary forms. It includes alumina, zirconia alumina, and carbide.

Check The Grit Size

Every diamond cup disc comes with a variety that showcases its characteristics. It represents the dimensions of the precise abrasive grains that the wheel carries. To work out the grit size, you've got to count the number of openings per linear inch. You'll find this within the final screen size. Coarse grains have numbers like 10, 16, and 24. Coarse grain indicates that the dimensions of the fabric the tool removed are large. Grit wheels range between 70, 100, and 180 and useful in making fine grit wheels. They're also ideal for fine finishes, tiny contact areas, and valuable materials with high brittleness.

Know the Various Diamond Cup Wheel Shapes

Although all Diamond Cup Grinder may appear as if they're straight once you view the image, they are available during a wide selection of shapes. Some have a hollow center that permits them to suit into machines spindle flange assembly. Others include cylinders and dish wheels that even have different shapes. Some mounted wheels also are available in cone or plug shapes. They're suitable for off-hand and grinding jobs that need high precision.

Choose the Proper Bond

You need the right bond for your wheel to run efficiently. Bonds are materials that bind abrasive grains to stop them from falling apart and run effectively. Bonds, like abrasive grains, also wears away with frequent use. The first bonds that are in use in diamond cup discs are vitrified and organic bonds. Each has its unique strengths and weaknesses. As an example, vitrified bonds are both challenging and brittle. Also, they provide resistance to acid, oil, water, and temperature.

Organic bonds exist in several forms, like resinoid and rubber. Organic bonds are ideal to be used in fabrication industries for diamonds and also for sharpening saws.

Customization

It is a choice you want to make. The web offers a good range of diamond cup wheels. While many of them live to their billings, unfortunately, most are well packaged junks, which will not provide the desired result. Instead, it's advisable to travel for a customized diamond cup wheel. Besides that, they give the most exact value for money; you'll freely customize the specifications consistent with your needs. Also, with a customized cup wheel, you'll successfully eliminate guess works.

Uses of Diamond Cup Wheels

These are tools useful for grinding the dry concrete surface and smoothen other materials, including diamond. Best Diamond Cup Wheel offer more aggressive removal than conventional abrasives.

While you'll easily and quickly purchase ready-made 7" diamond cup wheel and other diamond cutting tools in e-commerce stores, none can offer you the freedom of getting the precise specification you would like for a selected application. Thus, going for customized diamond cup wheels may be smarter for diamond tools distributors, suppliers, and end-users alike.

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