3M Abrasive Systems Division - Swissmem · 3M Abrasive Systems Division Helmut Gaisberger, Global Manager Machine OEM Relationship Development ... Flute Grinding of HSS Drill Bits

3M Abrasive Systems Division

Helmut Gaisberger, Global Manager Machine OEM Relationship Development

© 3M 2014. All Rights Reserved.

“HOW TO CHOSE THE RIGHT ABRASIVE TOOL”


Helmut Gaisberger, Global Manager Machine OEM Relationship Development


Outlook for a Revolutionary Tool forFlute Grinding of HSS Drill Bits


A Short Company Presentation

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� Employees Worldwide 88,667 (Total)

34,719 in USA

3M at a Glance End of 2013

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� Patents Awarded U.S. 671; Total 3,330

� Sales Worldwide $30.87 billionShare of International sales $19.720 billion (64%)

� R&D Expenditures $1.715 billion© 3M 2014. All Rights Reserved.


46 Technology Platforms

Technologieplattformen

AbAbrasives

BiBiotech

AcAcoustics

CeCeramics

Ad Dd

EmElectronicMaterials

Fc Mi

NtNano-

technology

Nw

PoPorous

Materials & Membranes

PmPolymer Melt Processing

SuSurface

Modification

SmSpecialty Materials

Pp Tt

5

AdAdhesives

DdDrug

Delivery

AmAdvancedMaterials

DiDisplay

AnAnalytical

DoDental &

Orthodontic Materials

AsApplication

Software

EcEnergy

Components

FcFlexible

Converting & Packaging

FeFlexible

Electronics

FsFiltration,

Separation, Purification

FiFilms

ImImaging

FlFluoro-

materials

InInspection &

Measure-ment

IsIntegrated Systems Design

LmLight Mgmt

MdMedical

Data Mgmt

MeMetal Matrix Composites

MfMechanical Fasteners

MiMicrobial

Detection & Control

MoMolding

MrMicro-

replication

PePredictive

Engineering & Modeling

NwNonwoven Materials

RpRadiation

Processing

SeSensors

WoWound Mgmt

VpVapor

Processing

OpOpto-

electronics

PdParticle & Dispersion Processing

PrProcess Design & Control

PpPrecision

Processing

TtTrack and

Trace

WeAccelerated Weathering



System Supplier for the Grinding Industry

APPLICATION

KNOW-HOW

APPLICATION

KNOW-HOW

GRINDING

TOOLS

GRINDING

TOOLS

SPINDLE

DRIVES

SPINDLE

DRIVES

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MACHINE TOOLS

+ SERVICE

MACHINE TOOLS

+ SERVICE

PERIPHERALSPERIPHERALS



The Ideal Abrasive?

� Does not exist! Selection depends on:

• Lot size

• Material to be ground

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• Process economics

• Surface finish

• Risk of grinding abuse (burning)

• Dressing tool


Scope of Presentation

Limited to:� Abrasives:

Ceramic abrasives(micro-crystalline aluminium oxides)

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� Bond Type(s):Resin bonded grinding wheels

� Cost ComparisonsWheel price versus performance


Abrasive and Bond Selection for Grinding HSS

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Definition of Grinding

German DIN Standard 8580

Grinding = Machining with geometrically undefinedcutting edges

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cutting edges

Milling / Turning = Machining with geometricallydefined cutting edges



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DIN definition of grinding is no longer general valid!

New = Grinding can be machining with geometrically

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New = Grinding can be machining with geometricallydefined cutting edges



Precision Shaped Grain (PSG)

1 mm

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Wheel Structures (Vitrified)

Wheel structurewith standardceramic abrasives

CubitronTM IIwheel structurewith PSG grain

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Cutting Behavior of Conventional Abrasive Grains

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Chip Formation with CubitronTM II Grinding Wheels

16Idealized image



Grain Comparison

Cubitron

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Flowing ChipsGrinding swarf that looks like the chips generated by turning ormilling operations.

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Flute Grinding of HSS Drills

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Performance Comparison of Five Criteria

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Process Data of Different Abrasive Grains

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Performance Comparison of Five Criteria

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Calculating Total Costs (Input)

ExcelSpreadsheet

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Calculating Total Costs (Output)

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Process Data of Ceramic versus Cubitron II

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Process Data of Ceramic versus Cubitron II

Ceramic Cubitron II

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Process Data of 5TG versus Cubitron II

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Process Data of 5TG versus Cubitron II

Cubitron II

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Process Data of Cubitron II versus Cubitron IIat different Feed-rates and Dressing Cycles

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Process Data of Cubitron II versus Cubitron IIat different Feed-rates and Dressing Cycles

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In this case, the 3 times higher wheel consumption (2 pieces/cycle)of the wheel in the right column is compensated in the overallcosts by the higher feed-rate of 1’600 mm/min.


Cost Calculation Conclusions

The main cost criteria is not the wheel price

Dressing frequency and cycle time are

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Dressing frequency and cycle time arethe principal cost determiming factors


This presentation was an outlook of a revolutionary tool for HSS-flute grinding that will come.

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Further tests are necessary to achieve the best possible results with different specs and bonds.



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www.3m.com

www.winterthurtechnology.com

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3M Abrasive Systems Division - Swissmem · 3M Abrasive Systems Division Helmut Gaisberger, Global Manager Machine OEM Relationship Development ... Flute Grinding of HSS Drill Bits