processes 4500 4500
processes 4500 4500 Total Total removal removal height height 40 40 Wheel Wheel wear wear 4.0 4.0 Sharpening Sharpening ring wear ring wear 4000 4000 35 35 3.5 3.5 Efficiency Total removal height in µm Total removal height in µm 3500 3500 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 2657 2652 2625 2657 2652 2625 2481 2481 2320 2320 Wheel wear in µm Wheel wear in µm 30 25 20 15 10 30 25 20 15 10 29.5 29.5 13.5 13.5 10.5 10.5 8 8 8 8 Sharpening ring wear in mm Sharpening ring wear in mm 4 3.0 3.0 3.5 2.5 2.5 3 2.0 2.0 2.5 1.5 1.5 2 1.0 1.0 2.675 2.675 1.51 1.51 0.975 0.975 0.79 0.79 0.64 0.64 500 500 5 5 1.5 0.5 0.5 0 0 1 1 0 0 1 0.0 0.0 To tal stock To tal rem stock oval rem V 1-76daN oval V 1-76daN To tal stock To tal rem stock oval rem V 2-38daN oval V 2-38daN To tal stock To tal rem stock oval rem V 3-19daN oval V 3-19daN To tal stock To tal removal stock removal V4-9daN V4-9daN To tal stock To tal removal stock removal V5-5daN V5-5daN 76 daN76 38 daN38 19 daN19 9 daN 5 daN daN daN daN 9 daN 5 daN 0.5 Trial 1 76daN Trial 1 76daN Trial 2 38daN Trial 2 38daN Trial 3 19daN Trial 3 19daN Trial 4 9daN Trial 4 9daN Trial 5 5daN Trial 5 5daN figure 5: Total material removal height, disc wear & sharpening ring wear 0 Grain size reduction Rota tiona l spe ed reduction Force reduc tion 4 Efficiency Efficiency 22 22 Sharpening ring sets Sharpening ring sets 16000 Number of loads 3.5 14000 3 20 20 12000 2.5 18 18 10000 2 16 16 8000 1.5 6000 14 14 1 4000 0.5 12 12 2000 0 Grain size reduction Rota tiona l spe ed reduction Force reduc tion Grain size reduction Rota tiona l spe ed reduction Force reduc tion 10 0 10 Grain size reduction Rota tiona l spe ed reduction Force reduc tion Grain size reduction Rota tiona l spe ed reduction Force reduc tion Grain size reduction Rota tiona l spe ed reduction Force reduc tion 16000 Number of loads Number of loads figure 6: Efficiency across various parameter variations along with possible charge numbers and required sets of sharpening rings 14000 12000 10000 8000 6000 4000 2000 0 Regarding total material removal height there are minimal differences in grinding processes following pressure variation during sharpening; however, regarding tool wear there’s an observable difference greater than a factor of three (figure 5). Typically, wear volume of discs V S in mm³ is compared against Grain total size reduction volume Rota tiona l spe ed reduction V W in Force mm³ reduc tion ground from workpieces to evaluate process efficiency via what’s known as G-value. High G-values indicate long tool life: G = V W / V S (formula 1) Grain size reduction Rota tiona l spe ed reduction Force reduc tion Here disc wear occurs more during sharpening processes while considering that sharp rings must also be accounted for as “consumables.” Thus, an efficiency value E is introduced derived from comparing total removal volume V W against sum volumes of disc wear V S plus sharp ring wear V SR : E = V W / V S + V SR (formula 2) Besides pressure adjustments were also made to speeds as well as grain sizes during sharpening processes – reducing both pressure and speed positively impacts efficiency while only significant changes in grain size yield effects. Results indicated that lowering pressures along with speeds enhances process efficiency while changes in grain size only had significant effects under strong deviations – these adjustments directly influenced lifespan for sets of grinding wheels along with number needed for sharp rings. In summary for optimal efficiency in double-disc fine grinding it’s advisable not just to maintain standard processes but also implement targeted adjustments on process parameters like pressure or speed to extend tool life while improving overall process efficiency. Krebs & Riedel specializes in processing brittle hard materials such as glass & sapphire ceramics (SiC & SiN), mixed ceramics & hard metals along with steel & metal alloys processing too. Krebs & Riedel has also developed new fine grain specifications for large surface area grinding within nanometer range featuring high removal rates – the company offers tailored sharpening rings alongside global technological support aimed at optimizing customer tool efficiency & longevity. This adjustment directly influences possible charge numbers concerning a set of grinding wheels (assuming a coating thickness of 6 mm) as well as required number of sharp rings throughout disc lifespan. Reducing pressure alongside speeds leads to improved efficiency within both sharpening and grinding processes – the investigation revealed that pressure increased tool wear by more than a factor of three. Dr.-Ing. Marijke van der Meer Research & Development m.vandermeer@krebs-riedel.de further information: www.krebs-riedel.de 34 no. 2, May 2025
processes Top performance and cutting results Teaming up for ultimate performance: the longstanding cooperation between IMA Schelling Precision and Application and tool specialist TAC Performance creates the conditions for high-performance system solutions for cut-to-size operations on aluminum. The partners exhibited together at ALUMINIUM 2024 in Düsseldorf, demonstrating that they are strong team players who place top priority on innovation and efficiency in aluminum processing. “Our customers benefit from our in-depth know-how about machines, applications and technology”, says Markus Freuis, manager of the business unit precision at IMA Schelling. “Combining our expertise sets synergies in motion and lays the groundwork for comprehensive cut-to-size solutions in aluminum processing.” One stand-out product resulting from this partnership is the TAC saw blades that were specially developed for the plate saws from IMA Schelling precision. These high-performance tools have been precisely tailored to the machines’ requirements, guaranteeing top performance and cutting results. The application models designed by TAC, which can be used for processing aluminum as well as many other materials, are another key element in the partners’ collaboration, significantly boosting customer profitability and helping to increase production output. A further strength of IMA Schelling Precision and TAC’s joint portfolio is the comprehensive training and consulting they provide for their customers. TAC offers live training on production machines at the customer’s premises that are designed to give Teaming up for top results in aluminum cutting: TAC’s high-performance saw blades are tailored precisely to the requirements of IMA Schelling Precision’s plate saws, guaranteeing top performance and cutting results em ployees optimal instruction in handling the machines and tools. In addition, the company offers special technology training for users, production planners and tool managers. Automation solutions for aluminum processing As in other industries, digitalization and automation are making an increasing impact in the aluminum processing sector. IMA Schelling Precision and TAC Performance have responded by offering solutions that are in step with this trend. One example is the option to automatically activate the TAC application models directly on the saw or using the proprietary cutting pattern optimization (HPO) function in the parameter set management. Saw blade management also ensures that the tools are monitored in an accurate and transparent manner. In addition to its technical solutions, comprehensive services are a top priority at TAC. The company’s logistics solutions for saw blades ensure rapid, reliable tool deliveries. TAC also offers high-quality sharpening and repair services for saw blades to keep tools in an optimal condition at all times. further information: www.imaschelling.com no. 2, May 2025 35
