– 8:15 a.m.

– 12:00 p.m.

– 1:00 p.m.

– 4:30 p.m.

 

 

– 12:00 p.m.

– 1:00 p.m.

– 1:30 p.m.

– 6:00 p.m.

 

 

– 12:00 p.m.

– 12:45 p.m.

– 4:00 p.m.

 

registration, coffee available

course

group lunch at nearby restaurant, included in price of course

course

group dinner, spouses welcome, included in price of course

 

course

optional tour of host facilities

lunch, sandwiches at host

course

evening open

 

course

working lunch, pizza/sandwiches ordered in

course

course finished

 

 

 

1 Attendee

2 Attendees

3+ Attendees

Before Deadline

$4,350

$3,650 per attendee

$3,350 per attendee

After Deadline

$4,550

$3,850 per attendee

$3,550 per attendee

First course:

Courses to date:

Attendees to date:

Total company investment:

Reported company savings:

Unreported company savings:

Repeat-company attendees:

 

 

Most popular subjects:

 

 

Impartiality:

2008

40

500+

approximately $1,200,000

$14,500,000+

Unknown

40% (attendees from companies which have already sent people to the course or have had an in-house Grinding Boot Camp)

Aggressiveness, coolant application, eliminating thermal damage and grinding burn, diagnosing chatter, reducing cycle times.

The High Intensity Grinding Course is non-promotional. You will learn about grinding and only grinding. Course hosts receive no air-time to promote their products.

High Intensity Grinding Course

 

High Intensity Grinding Course – Tungsten-Carbide Focus

 

 

Topics covered in The Grinding Doc’s three-day High Intensity Grinding Course

PDF download here.

 

Day 1: Morning – introduction • how to get the most out of the course • how to use The Book of Grinding • Dr. Badger’s background • introduction of attendees, type of grinding they’re doing, issues they’re facing • abrasive types, hardness • grit/workpiece chemical reactions • chip-formation in grinding • cutting, rubbing & plowing contact mechanisms • wheel wear types, how they affect cutting, rubbing & plowing • fundamental calculation: calculating surface speed from RPM & diameter, calculating RPM from surface speed & diameter, using The Grinder’s Toolbox • milling-cutter analogy for chip thickness: how changing wheel speed, feedrates & depths of cut affect wheel wear & burn risk • wheel grade or “hardness” • relationship between normal & tangential force & grinding power • heat generation & power • wear flats • reading a conventional-wheel specification • angular/blocky, tough/friable, micro/microfracture of grits, when to use which grit • wheel structure & porosity, when porous wheels help, when they hurt • grit size & surface finish, the biggest cause of grinding burn & chatter • The Grinder’s Mantra: big-&-dull bad, small-&-sharp good • grinding power & The Grindometer • fundamental calculation: Q’ in surface grinding, in cylindrical grinding • Group Exercise: calculating Q’, choosing a good Q’ & applying it across all production • using The Grinder’s Toolbox to calculate Q’ • specific energy, what it means, how to use it • wheel wear: break-in, steady wear & wheel collapse • The No-Dress Test, using it to evaluate wheels, optimize cycles.

 

Day 1: Afternoon – diamond dressing, stationary dressing • different types of dressers • effect of depth, why typically not a problem • effect of traverse speed, why most important parameter • fundamental calculation: dressing overlap ratio • how overlap ratio affects wheel sharpness & burn • diamond wear, how this changes, how it affects overlap ratio and burn & chatter risk • Group Exercise: calculating Overlap Ratio for increasing diamond-flat size, how it affects burn risk • rotary dressing • uni-directional vs. anti-direction, sharp & dull • rotary plunge roll, calculating effective depth, dwell, how this affects sharpness, using The Grinder’s Toolbox to quantify dressing sharpness • traverse disc dressing • RPM ratios & “integer values”, how this causes wheel “eggyness” • Introduction to Aggressiveness • Group Discussion: How to quantify multiple changing parameters.

 

Day 2: Morning – Aggressiveness defined, how it’s different from equivalent chip thickness & grit penetration depth • using aggressiveness it to increase feedrates, reduce burn, reduce wheel wear, find the “sweet spot” of the wheel • Using The Grinder’s Toolbox to calculate aggressiveness • keeping the same aggressiveness to reduce set-up time • Group Exercise: calculating Q’ & aggressiveness, keeping the same aggressiveness, increasing feedrate for same aggressiveness • cooling • the hot-spot in cooling • pressure, velocity, flowrate in cooling • Cooling Rule 1: V-coolant = V-wheel • The bucket-&-stopwatch technique for calculating velocity • Group Exercise: Calculating coolant velocity & pressure • Cooling Rule 2: aim at interface • partition ratio & arc length, when good cooling is needed, when it’s not, when good cooling can actually cause problems • nozzle options: Dr. Cool Rouse/Webster-style, Grindaix needle-nose, SwivelJet, crimped-down copper tubes – when to outsource, when to build yourself • cooling for genuine thermal damage vs. oxidation burn • film-boiling “burnout” • using The Grinder’s Toolbox to calculate cooling parameters • hydroplaning in cooling, the hidden cause of chatter, deflection, taper, barreling, difficulties holding size, how to handle it • scrapers, false nips & shoe nozzles: do they work? • cleaning nozzles: why they are usually worthless, how to design them correctly.

 

Day 2: Afternoon – superabrasives, definition, chemical reactions, why diamond doesn’t like iron, why CBN doesn’t like water • coatings/claddings • reading a superabrasive-wheel specification • concentration, when to choose high, low • grit size & surface finish, common mistakes • CBN on steel & nickel alloys, how they work, getting the wheel to “open up” quickly, then slowly • Group Discussion: choosing CBN parameters to avoid the early burn period • tungsten-carbide/cobalt “hard metal” • the ooze layer • loading in carbide grinding, how to cope • cleaning nozzles to reduce loading, why they usually don’t work • sticking to reduce loading • sticking speed, sticking aggressiveness • sticking grit size • truing of diamond wheels with SiC & alumina, which grit size to use, which parameters • hybrid-bond wheels, when to use, how to use • Paradigm wheel, when to use, how to use • electroplated wheels • extending life of electroplated wheels • water-based coolants & CBN, why so much trouble? • grinding of ceramics, fundamental contact mechanisms, how different • depth of damaged layer.

 

Day 3: Morning – loading, types, causes, in “soft” materials, in “hard” materials, ways to reduce loading, the “coolant quench effect” • burr, causes, how to reduce, dummy workpiece • up-grinding vs. down-grinding, is there a difference, cooling in up - vs. down-grinding • reducing cycle times, cycle mapping, “low hanging fruit”, where not to waste your energies • chatter: forced vs. self-excited • determining root cause from chatter spacing • out-of-balance & out-of-true chatter • snakeskin chatter, cause of • bouncy-diamond fishscale chatter, cause of • resonant frequencies, avoiding, frequency response function • why you should dress & grind at same RPM • wavelength obliteration • Group Exercise: determine source of chatter from number of chatter marks • thermal damage & “grinding burn” • different types: oxidation burn, thermal softening, residual tensile stresses, rehardending “white layer” burn • the biggest cause of burn: big-&-dull • testing for burn: nital etching, Barkhausen, x-ray diffraction, hardness testing • the danger of thinking “no cracks = no burn” • the danger of thinking “no discoloration = no burn” • material “sensitivity” & the risk of thermal damage.

 

Day 3: Afternoon – “ceramic abrasives”: how they work, how to get them to work, Norton SG, Cubitron, Cubitron II tortilla grit, Norton TG spaghetti grit, when it’s worth the cost, with which workpiece materials • cylindrical grinding: traverse & plunge • calculations in plunge grinding, in traverse grinding, overlap ratio in traverse, common mistakes in traverse, how to reduce cycle times & reduce burn risk in cylindrical traverse grinding • cup-wheel grinding, taper development • centerless grinding, choosing formulas, getting height-above center, swivel angle, dressing angle & dressing offset correct • Group Exercise: choosing cylindrical parameters wisely • using The Grinder’s Toolbox for cylindrical grinding • avoiding RPM-ratio “integer values”, the cause of waviness • 30-degree swivel, using The Grinder’s Toolbox • face-grinding, pain-&-suffering in face grinding, how to cope, sidewall relieving • barber-pole thread-pattern in traverse grinding, cause, how to eliminate it • barreling, taper, bell-mouth, deflection, thermal expansion, causes • inner-diameter ID grinding, challenges, cooling in, hydroplaning as cause of taper, bell-mouth • new developments in grinding, in grinding machines, in abrasives, when they’re worth the effort, when they’re not • closing, creation of a game-plan.

 

1Note that time and day where particular topics are presented may shift slightly.

2At the end of the course, each attendee will receive a framed, personalized diploma.

3All of The Grinding Doc’s courses center around the 4000-page Book of Grinding. Each attendee receives a copy of The Book of Grinding and The Grinder’s Toolbox.

 

 

 

Topics covered in The Grinding Doc’s three-day High Intensity Grinding Course – Tungsten-Carbide Focus

PDF download here.

 

Day 1: Morning – introduction • how to get the most out of the course • how to use The Book of Grinding • Dr. Badger’s background • introduction of attendees, type of grinding they’re doing, issues they’re facing • abrasive types, hardness • grit/workpiece chemical reactions • chip-formation in grinding • cutting, rubbing & plowing contact mechanisms • wheel wear types, how they affect cutting, rubbing & plowing • fundamental calculation: calculating surface speed from RPM & diameter, calculating RPM from surface speed & diameter, using The Grinder’s Toolbox • milling-cutter analogy for chip thickness: how changing wheel speed, feedrates & depths of cut affect wheel wear & burn risk • wheel grade or “hardness” • relationship between normal & tangential force & grinding power • heat generation & power • wear flats • reading a wheel specification • angular/blocky, tough/friable, micro/microfracture of grits, when to use which grit • why diamond doesn’t like iron, steel/carbide combinations • coatings/claddings • reading a superabrasive-wheel specification • concentration, when to choose high, low, edge-holding • wheel structure & porosity, when porous wheels help, when they hurt • grit size & surface finish • grinding power & The Grindometer • fundamental calculation: Q’ in surface grinding, in cylindrical grinding • Group Exercise: calculating Q’, choosing a good Q’ & applying it across all production • using The Grinder’s Toolbox to calculate Q’ • specific energy, what it means, how to use it • wheel wear: break-in, steady wear & wheel collapse • The No-Dress Test, using it to evaluate wheels, optimize cycles.

 

Day 1: Afternoon – Aggressiveness defined, how it’s different from equivalent chip thickness & grit penetration depth • using aggressiveness it to increase feedrates, reduce burn, reduce wheel wear, find the “sweet spot” of the wheel • Using The Grinder’s Toolbox to calculate aggressiveness • keeping the same aggressiveness to reduce set-up time • Group Exercise: calculating Q’ & aggressiveness, keeping the same aggressiveness, increasing feedrate for same aggressiveness • grinding of tungsten-carbide/cobalt “hard metal”: how it’s different to “soft” materials • the ooze layer, how it affects adherence of coatings • loading in carbide grinding, how to cope • choosing parameters to get a “self-sharpening wheel” to minimize sticking • cleaning nozzles to reduce loading, why they usually don’t work, how to design them correctly • sticking to reduce loading • sticking speed, sticking aggressiveness • Group Exercise: calculating sticking velocities with auto-stickers, hand-held stickers • sticking grit size • truing of diamond wheels with SiC & alumina, which grit size to use, which parameters • hybrid-bond wheels, when to use, how to use • Paradigm wheel, when to use, how to use • electroplated wheels • extending life of electroplated wheels • grinding of cermets: a quick introduction.

 

Day 2: Morning – cooling • the hot-spot in cooling • pressure, velocity, flowrate in cooling • Cooling Rule 1: V-coolant = V-wheel • The bucket-&-stopwatch technique for calculating velocity • Group Exercise: Calculating coolant velocity & pressure • Cooling Rule 2: aim at interface • partition ratio & arc length, when good cooling is needed, when it’s not, when good cooling can actually cause problems • nozzle options: Dr. Cool Rouse/Webster-style, Grindaix needle-nose, SwivelJet, crimped-down copper tubes – when to outsource, when to build yourself • cooling for genuine thermal damage vs. oxidation burn • film-boiling “burnout” • using The Grinder’s Toolbox to calculate cooling parameters • hydroplaning in cooling, the hidden cause of chatter, deflection, taper, barreling, difficulties holding size, how to handle it • scrapers, false nips & shoe nozzles: do they work?

 

Day 2: Afternoon – On a tool grinder: evaluating the process • Cycle mapping with the power signal • evaluating wheels with the No-Dress Test • Increasing feedrates while keeping the aggressiveness constant.

 

Day 3: Morning – Group Exercise: discussion of shop-floor results • up-grinding vs. down-grinding, is there a difference, cooling in up- vs. down-grinding • reducing cycle times, cycle mapping, “low hanging fruit”, where not to waste your energies • chatter: forced vs. self-excited • determining root cause from chatter spacing • out-of-balance & out-of-true chatter • snakeskin chatter, cause of • bouncy-diamond fishscale chatter, cause of • resonant frequencies, avoiding, frequency response function • why you should dress & grind at same RPM • wavelength obliteration • Group Exercise: determine source of chatter from number of chatter marks • thermal damage & “grinding burn” • oxidation burn • cooling just for oxidation burn.

 

Day 3: Afternoon –  wheel balancing, results of Vollmer/Grinding-Doc collaboration • cylindrical grinding: traverse & plunge • calculations in plunge grinding, in traverse grinding, overlap ratio in traverse, common mistakes in traverse, how to reduce cycle times & reduce burn risk in cylindrical traverse grinding • Group Exercise: choosing cylindrical-traverse parameters • cup-wheel grinding, taper development • centerless grinding, choosing formulas, getting height-above center, swivel angle, dressing angle & dressing offset correct • Group Exercise: choosing cup-wheel parameters, break-in period, taper period • using The Grinder’s Toolbox for cylindrical grinding • avoiding RPM-ratio “integer values”, the cause of waviness • 30-degree swivel, using The Grinder’s Toolbox • face-grinding, pain-&-suffering in face grinding, how to cope, sidewall relieving • barber-pole thread-pattern in traverse grinding, cause, how to eliminate it • barreling, taper, bell-mouth, deflection, thermal expansion, causes • inner-diameter ID grinding, challenges, cooling in, hydroplaning as cause of taper, bell-mouth • peel grinding & pinch/peel grinding • new developments in grinding, in grinding machines, in abrasives, when they’re worth the effort, when they’re not • closing, creation of a game-plan.

 

1Note that time and day where particular topics are presented may shift slightly.

2At the end of the course, each attendee will receive a framed, personalized diploma.

3All of The Grinding Doc’s courses center around the 4000-page Book of Grinding. Each attendee receives a copy of The Book of Grinding and The Grinder’s Toolbox.