Precision grinding: where every µm counts

The demand for high-precision measurements hasn't developed by accident. As an experienced master technician in mechanical engineering, in the automotive industry, as a manufacturer of medical devices or in the aviation and aerospace industry, you know that precision is everything when it comes to the final machining of metals or, optionally, ceramics.

It is only at the precision grinding stage that you can get so close to your final dimensions that your design needs are completely met – regardless of whether you are machining a prototype or producing it in series. Here, we explain which applications can help you to achieve the precision grinding you need. We present specific applications and their tools, as well as the best approach to take for the precision grinding itself – including tips and tricks.

There’s no job too challenging: the right way to approach precision grinding

As a master technician in industrial production, you are measured by only one thing: quality, quality, quality. These methods for precision grinding are the best way to rise to this challenge:

External cylindrical grinding
Profile grinding, tool grinding
Surface grinding, reciprocating surface grinding
Internal cylindrical grinding
Tool grinding

Don’t cut corners – external cylindrical grinding done correctly

As a master technician in the automotive industry, for example, external cylindrical grinding comes into its own when you need the best quality for manufacturing cam, crank or gear shafts. Likewise, everything also has to be perfectly coordinated when machining cast or non-ferrous metals. With external cylindrical grinding, your results are influenced by factors including the power consumption, structure, material and, of course, the hardness of the wheel. As such, selecting the right tool is key to ensuring an optimum service life and thus a cost-effective solution.

Deliberately go in a different direction: reciprocating surface grinding

If you need both a high removal rate and the very best surface quality when producing assemblies and components, reciprocating surface grinding is the method of choice. The grinding wheels used here are rather coarse, highly porous and have a relatively low hardness.

A smooth operator – crucial for surface grinding

If you want an effective way to grind and machine materials in industrial production with µ precision, look no further than surface grinding. This method usually requires special grinding tools or machines and changes the structure of the workpiece surface. The aim is to ensure accurate dimensions and perfect surface quality in equal measure.

Perfect shapes don't happen by accident – internal cylindrical grinding

If your working day in industrial production revolves around finishing inner functional faces, you will know that the quality and, above all, the size of your grinding wheels are key factors, particularly for internal cylindrical grinding. For example, wear-resistant grit types can influence the service life of the wheel – making your internal cylindrical grinding process even more economical.

For all dab hands at manual work – working on bench grinders

Anyone who uses classic bench grinders when cutting and grinding is sure to be well versed in manual work! As a master technician in production halls, this will be a familiar aspect of your day to day, from the simple machining of tools such as turning tools or drills. The nature of your grinding tool depends on the material of the object being ground.

The very best tools for workers – tool grinding

If there’s one thing that’s considered unacceptable in manufacturing, it’s blunt tools. CNC tool grinding has therefore become an established method for high-quality reconditioning. The level of wear on your tool – i.e. how blunt it is – determines which grinding device should be used and which grinding media is the most appropriate. The goal is always the same: to remove material from the tool and ensure full functionality again. In the long term, this also influences the cost-effectiveness.

Out of shape – sharpen profiles by dressing

Computer-aided surface grinding enables results that adhere exactly to the specifications and impress with their top quality. The process focuses on the accuracy of the shape, achieves the required surface quality and complies with the desired shape and position tolerances. As such, the results produced by CNC surface grinding stand out with their accuracy, robustness and durability. As a master technician, you will be well aware that you have to dress your grinding wheels regularly depending on which material you have ground and how this was done. A similar approach is taken with profiled wheels, which you adapt to new workpiece geometries by dressing them. This shaping and sharpening of a grinding disc is part of conditioning, which also includes cleaning.

How accuracy becomes precision

As with any other grinding process, you must inspect the surface of the workpiece for dirt, grease and material residues before starting precision grinding.
The process used for your industrial production, as well as the size and shape of your workpiece, then define which grinding process you should use.
Choose a grinding device and grinding media suitable for your workpiece, its size and its shape.
Start off by moving your grinding device across the grinding surface cautiously, applying only little contact pressure.

Tip: If the first result is not what you are looking for, it is better to “play around” with the speed instead of the contact pressure. Gradually work up to the result you need, preferably in very small steps. You can also influence the result by means of the grinding media or grit used.

Important: To achieve the best results, you must move the tool/grinding media continuously. Keeping it in one position may in some cases remove more material and thus impair quality.

Does your day-to-day working life revolve around precision grinding?

Are you looking to improve quality and prolong the tool life? We would be pleased to advise you on this – and, of course, on the various applications and suitable grinding media.