Brochure - Grindwell Norton

REVOLUTIONARY BOND TECHNOLOGYRESHAPINGTHE WORLD OFPRECISION GRINDINGCool cuttingPrecise profileHigh speed

REVOLUTIONARY BOND TECHNOLOGYA revolutionarynew generationbond that willreshape theworld of precisiongrinding.Through Saint-Gobain Abrasive’s extensiveresearch and development program in grinding3wheel technology, comes Vitrium a newgeneration, patent-pending bond technology.This revolutionary bond platform features anexclusive chemistry that delivers an entirely newgrain adhesion science, resulting in improvedproduct versatility across a wide range of precisiongrinding applications.

FEATURES & BENEFITSCOOL CUTTING: IMPROVE PART QUALITYPRECISE profile: REDUCE COST• Ultra radius accuracy• Extended wheel life• Improved productivity• Significantly reduced burn• Lower residual stress• Increased cutting efficiency and cut rate• Improved coolant flow, reducingheat build-UP and wheel loading• Improved chip clearance• Reduced dressing frequency and cost• Improved cycle and process timeHIGH SPEED: INCREASE THROUGHPUT & PRODUCTIVITY• Work at higher machine speed/pressure• Leverage existing equipment• Optimized machine efficiencyImproved cost/PERFORmance RATIOGRAIN availabilityPerformance improvements with Vitrium 3 span abrasive grainsfrom proprietary Quantum ceramic alumina to conventionalaluminium oxide, to optimise grinding processes.BESTBETTERNORTON QUANTUM & CERAMIC GRAINsPatented ceramic alumina provides the highperformance for precision grinding.CONvENTIONAl alUMINIUMoxide grainsHigh performance aluminium oxide blendsadapted to the most common applicationsand materials.

A REVOLUTIONARY BOND THAT LOWERS YOUR PROCESS COST IN 3 WAYS1COOL CUTTINGAn improved holding power utilising lessbond-to-abrasive ratio exposes a largergrain surface area. This enables thewheel to cut freely, improving cut rate.The reduced bond-part interaction alsominimizes heat build-up, reducing burnand power consumption and grindingforces on the part. Thinner bond postsenable better coolant flow and chipclearance for a cooler cut and improvedpart quality.STANDARD BONDBond-PART interactionVITRIUM 3 BONDBond-PART interactionUse Vitrium 3 to improve part qualityand ensure part integrity.2PRECISE PROFILEVitrium 3 provides superior grain holdingproperties than that of any other bond,significantly improving wheel form andcorner holding. This reduces dressingtime, dresser wear and dresserreplacement requirements.PROFILED wheelBEFORE grindingAFTER 5 grinding CYCLESVitrium 3 considerably reduces unitprocess cost.Standard wheelVitrium 3 wheel3HIGH SPEEDThe Norton Vitrium 3 bond provides theultimate wheel strength. This allowslighter construction and high speedoperation. Machines can work athigher feed rates, speed and pressure,significantly increasing production withexisting equipment.Vitrium 3 maximizes equipment utility toimprove your process and throughput.Standard WheelSTOP THE MACHINE403050206010 70080MACHINE SPEEDVitrium 3CONTINUE GRINDING

Power consumption (index)3.5315%LESS POWERNEEDEDTEST 1:REDUCED 2.5 BURN AND POWER CONSUMPTION20%MORE MATERIALThe graph 2shows the increase in power consumption REMOVED as MaterialRemoval Rate (MRR) goes up.At an MRR 1.5index of 200, Vitrium 3 requires 15% less power toremove the same amount of material. This means less heat isgenerated 1on the work piece, resulting in less burn.0 50 100 150 200At a power consumption index of 3, Vitrium 3 250 300 350removes 20% morematerial than the standard bond, at theMMRsame(index)power consumption,reducing heat generated on the work piece.KEY: BondTraditionalPower consumption (index)3.532.521.5See the science in animationUse this QR code to viewa product demonstration video or visitwww.saint-gobain-abrasives.com20%MORE MATERIALREMOVED15%LESS POWERNEEDEDEdge radius (mm)2.521.5Test 2:VBE BOND HASA PROFILEProfile holding after OF 1.5MM five cycles1After five continuous VITRIUMcycles 3 HAS (without dressing) the profile radiusor ‘edge 0.5corner’ AofPROFILEwheels with standard bonds has a considerablyOF 1MMhigher wear than that of Vitrium 3For a given 0 Material Removal Rate (MRR), Vitrium 3 holds the wheel0 5 10 15profile better than the existingTheor.ceramicMRR’VX(mmbond 3 /mm/s)and even thetraditionally high profile holding VBE bond.Product strength (relative index)250200Test 3:150WHEEL STRENGTHVX BOND HASA PROFILEOF 2.3MMKEY:Norton Vitrium 3Norton VXNorton VBENorton Vitrium 3+20%STRONGER100Product strength and module of elasticity are linked to theamount of bond used in grinding wheels. Wheel strengthincreases50as the module of elasticity goes up. Norton Vitrium 3always provides higher product strength than any other bond.At the same grade, a Norton Vitrium 3 product is more resistantthan any other 0 comparable product. 100 200 300Module of elasticity (relative index)This allows higher pressure grinding at higher working speeds.SoftHardWheel gradeProfile breakdown radius (mm)Product strength (relative index)2.521.510.501250200150100500 50 100 150 200 250 300MMR (index)VITRIUM 3 HASA RADIUSOF 1MMVX BOND HASA RADIUSOF 2.3MMVBE BOND HASA RADIUSOF 1.5MM0 5 10 15Theor. MRR’ (mm 3 /mm/s)KEY:KEY: BondNorton VXNorton VBENorton Vitrium 3TraditionalNorton Vitrium 3+20%STRONGERKEY: BondStandardNorton Vitrium 30 100 200 300Module of elasticity (relative index)SoftHardWheel gradeKEY: BondStandardNorton Vitrium 3

PRECISION GRINDING APPLICATIONSINTERNALDIAMETERGRINDINGMARKETS• Bearing (cylindrical)• Internal track, bore• Gears• Bore• Hydraulic components• Fluid diffusion• Pipe connectionsorAPPLICATIONCHARACTERISTICS• Large contact area• Low grinding force per grainand bond post• Difficult access for coolant• Risk of part deformationwhen cut quality is not highenoughKeyContact surface betweenwheel and partWheelWork pieceRotation optionsBENEFITS of VITRIUm 3in ID grinding• Decreased risk of partdeformation (ovality) on thinrings• Excellent coolant diffusionthroughout the wheel forcooler cutting and reducedburn on the work piece• Free cutting capabilities, andimproved cut rate• Faster cycle with limitedgrinding force on part• Longer wheel lifeCASE STUDYid grindingWheel with Vitrium 3 bond:Size:9.3 x 11 x M4Shape:Threaded Spindlemounted PointGrain:Norton QuantumSpecification: NQ 120-11 N 8 VT3Competitor Wheel:Specification: 32A 120 M 8 V BE TR22Component:Material:Bearing Steel60 to 64 HRcDiameter:15 mmRough Cycle 1 - Infeed: 0.13 mm/sRough Cycle 2 - Infeed: 0.07 mm/sRough Cycle 3 - Infeed: 0.03 mm/sCurrent DressingFrequency: 3New DressingFrequency: 8RESULTSDressing Skipimproved by:2.3 times2 timesWheel Lifeimproved by:Cycle time15%reduced by:OUTERDIAMETERGRINDINGMARKETSor• Bearing (cylindrical)• Centerless, external track• Automotive components• Cam/crank/gear box shafts• General engineering• Bars/tubes (centerless)APPLICATIONCHARACTERISTICS• Small contact area• High force per grainand bond post• In general, no problem withcoolant accessKeyContact surface betweenwheel and partWheelWork pieceRotation optionsBENEFITS of VITRIUm 3in OD grinding• Improved profile holding• High wheel speed capabilityfor increased throughput• Increased free cuttingwithout wheel speedreduction• Shorter cycle time withlimited risk of burn,improving part quality• Lower stress on work piece,especially on longcomponents (bars, tubes)CASE STUDYCRANKSHAFT JOURNALGRINDINGWheel with Vitrium 3 bond:Size:750 x 37.1 x 304.8 SBShape: Shape 01/AGrain:Aluminium OxideSpecification: 32A 54 M 8 VT3Competitor Wheel:Specification: XX 46 T 7 V XXComponent:Material:Forged Steel 60 HrcDiameter:76 mmShoulder Feed - 1: 18 mm/minShoulder Feed - 2: 22 mm/minGrinding Feed - R1: 6.5 mm/minGrinding Feed - R2: 3 mm/minGrinding Feed - F1: 1.5 mm/minGrinding Feed - F2: 0.6 mm/minGrinding Feed - Micron: 0.05 mm/minGrinding Feed - Spark Out: 0.0001 mm/minRESULTSCycle Time reduced by:Wheel Lifeincreased by:Cost per componentreduced by:20%66%44%At the same wheel grade and bondvolume, the Vitrium 3 bond allowsfaster process time, with limitedrisk of burn on the work piece.

SURFACEGRINDINGororKeyContact surface betweenwheel and partWheelWork pieceRotation optionsMARKETS• Aerospace (creep-feedor regular surface grinding)• Blades, NGV• Gear• All modules, including bevel• Bearing (linear)• Track, base, top• General engineering• Flat surfaces with profiles• Toolroom• MROorAPPLICATIONCHARACTERISTICS• Average size contact area• Medium grinding force pergrain and bond post• Wide variety of applications:horizontal spindle (wheels)and vertical spindle (cylinders,segments, cups, disc)FIXED orBENEFITS of VITRIUm 3SURFACE grinding• Improved form holding• Reduced dressing• Longer wheel life• Higher working speed,for improved productivity• Faster and deeper cuttingcapabilities• Cool grinding (significantlyreduced burn risk)CASE STUDYid grindingWheel with Vitrium 3 bond:Size: 21 x 24 x 9.57Shape: Shape 01/AGrain:Norton QuantumSpecification:NQ 100-11 L 8 VT3Competitor Wheel:Specification: Cxz K 8 V 104Component:Material:Bearing Steel60 to 64 HRcDiameter:30 mmRough Cycle 1 - Infeed: 0.1 mm/sRough Cycle 2 - Infeed: 0.075 mm/sRough Cycle 3 - Infeed: 0.025 mm/sOvality and Taper Control:

RESHAPING THE WORLD OF PRECISION GRINDINGExclusive bond chemistry allowshigher wheel speed, improved profileholding and reduced work piece burn.Theultimate highPERFORmancegrindingTECHNOLOGYVITRIUM 3Cutting edge, high performance ceramic graintechnology. Multiplies cutting efficiency formaximum performance and unrivalled precision.High precision, high performancediamond dressing tools.EnvironmENTAL benefitsNO CHEMICAL PORE INDUCERSPore inducers used in the manufacture of many high porosity products are harmfulto the environment. Vitrium 3 wheels require no artificial pore inducers (chemicals) toachieve a high level of permeability, unlike other porous vitrified wheel technologies.By choosing Vitrium 3 technology for your grinding operation, you help to preservethe environment. In addition, Vitrium 3 eliminates costly revalidation of processesassociated with using certain chemicals.REDUCED carbon foot printIncrease productivity with existing machine capacity. Work with higher feedrates, speed and pressure, significantly increasing production leveraging existingequipment. In addition, Norton Vitrium 3 is manufactured using a low firingtemperature, reducing energy consumption and lowering carbon footprint.www.grindwellnorton.comGrindwell Norton LimitedAbrasives Marketing GroupLeela Business Park, 5th LevelAndheri-Kurla Road, Andheri (East)Mumbai 400 059. IndiaTel: +91 (22) 40 21 21 21Fax: +91 (22) 40 21 21 02Grindwell Norton LimitedBonded Abrasives PlantMora-NAD-Karanja, UranDist. Raigad 400 074.IndiaTel: +91 (22) 27 23 00 21-2-3-4Fax: +91 (22) 27 23 00 12Norton is a registered trademarkand Vitrium 3 is a trademark ofSaint-Gobain Abrasives.