Cutting Cycle Times in Technical Ceramics Grinding with Vitrified Bond Wheel
What does it take to deliver cutting-edge solutions for some of the world’s most advanced applications? Success starts with strong foundational values. At Continental Diamond Tool, we value being a Global, Responsive, Innovative Team [GRIT].
One recent collaboration with a global manufacturer of technical ceramics exemplifies CDT’s GRIT in delivering timely, innovative, quality, custom solutions to our customers. This story highlights how our application engineers and Vitrified Bond department collaborated to provide a superior superabrasive solution that dropped cycle times by an astounding 86% for advanced ceramics operations that supply the world.
The Challenge: Improving the Grinding Process
This initiative started when this valued customer in the ceramics sector reached out to CDT to address a grinding operation that was inefficient and inconsistent. The challenge stemmed from a new material they were using for parts that needed to be produced in high quantities. Their existing process required an hour to correctly grind the preformed ceramic part; and they were experiencing significant challenges including excessive heat and chipping. The result was a frustrating combination of high cycle times and inconsistent quality.
Grinding technical ceramics is a very complex process due to the unique properties of the material. Ceramics are incredibly hard and brittle, making them prone to cracking and chipping under improper grinding conditions. Unlike metals, ceramics lack ductility, meaning there is little room for error when removing stock material. Achieving precision requires tools that maintain sharpness while withstanding the intense friction and heat generated during grinding. Furthermore, ceramics often feature intricate shapes and tight tolerances, adding another layer of difficulty to the process.
One of the most significant challenges is minimizing wear on grinding tools while maintaining efficiency. The wrong grinding wheel will wear down quickly or fail to deliver the necessary precision when working with ceramics. This is where Vitrified Diamond Bond grinding wheels are a superior solution, offering a balance of durability and performance that meets the rigorous demands of ceramic grinding. Our product managers and application engineers understand these challenges and work closely with customers to design, develop, and deliver quality custom tools for specific applications.
The Solution: Innovation through Product Development and Process Parameters
Our Application Engineer, Andrew Olvera, consulted with the customer to analyze their existing setup and recommend strategic changes. He travelled to their facility to see the process and speak with the operator firsthand. Reflecting on the project, Andrew said, "I really enjoyed working with the customer on this challenge. We first began seeing positive results after making tweaks to the machine's programming. When we introduced the customized wheel, the jump in efficiency really ramped up. The cycle times dropped even more than we expected without the chipping that the customer usually saw in their process."
By reprogramming the machine's grinding operations, custom engineering an optimized wheel, and fine-tuning parameters, the CDT team achieved a groundbreaking improvement. Here are the key adjustments that were made, and the results:
Enhanced Machine Parameters:
Increased spindle speed to 10,000 RPM.
Doubled table speed from 100 to 200 inches per minute.
Adjusted infeed to .0035-.004 inches with no measurable wheel wear.
Achieved .005” infeed with minor wear observed.
Reduced Cycle-Time:
The customer’s previous process took an hour; our optimized process completed the task in just 8 minutes—an astounding reduction in cycle time by over 86%.
Improved Quality:
We addressed the quality issues in the preformed parts and optimized for a consistent 0.170” stock removal. This enhancement balanced efficiency and consistency with minimized wheel wear.
The Response: A Testament to Teamwork
This project also highlights CDT's commitment to responsiveness in meeting our customer’s unique requirements. Recognizing the critical challenges posed by the customer’s quality issues and process inefficiencies, our Vitrified Bond Product Line Manager, Walt Baumbach, spearheaded efforts to provide a custom grinding wheel. Walt Baumbach noted, “Our team rallied together to design, develop, and deliver a solution in an impressive 15 days. This quick turnaround shows the abilities and flexibility of our team.”
Walt Baumbach, CDT’s Vitrified Bond Product Line Manager, reviewing custom grinding wheel designs. His team helped cut cycle times by 86% for advanced ceramics.
The Outcome: Setting a New Standard
The results speak for themselves: CDT partnered with this prominent global technical ceramics manufacturer to provide a superior superabrasive solution to their unique grinding challenges. The innovation improved process efficiency and enhanced the durability and reliability of the Vitrified Bond grinding wheel used for this task. The wheel’s ability to handle challenging stock removal with minimal wear underscores the superior performance of our custom engineered products for the manufacture of technical ceramics for a global market.
While the 15-day rapid turnaround was an exceptional circumstance, enabled by a focused allocation of resources, we consistently strive to meet customer needs with efficient lead times tailored to the scope and complexity of each project. The quick delivery for this customer minimized their downtime and accelerated productivity improvements that will have a lasting impact.
Living Our Values: GRIT in Action
In many ways, this example embodies CDT’s GRIT. By combining a global mindset and responding to customer needs with innovative products and services, our team delivered a superior superabrasive solution that exceeded expectations. It is opportunities like this that define our commitment to excellence and drive us to continue pushing the boundaries of what is possible in grinding technology.
At CDT, we are more than a tool provider; we are a tenacious partner in progress. As we continue to serve industries around the world, our focus remains on delivering cutting-edge solutions that empower our customers to achieve their goals. We look forward to sharing more success stories as we advance the future of manufacturing together.
For more information about our Vitrified Bond product line or to discuss your unique grinding challenges with ceramics or other materials, reach out to our team today.