STUNNING Process of Grinding a Flawless Surface Finish on a STUDER S41
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- Опубліковано 20 кві 2022
- Chris shows you how to achieve a beautiful surface finish on the STUDER S41 from United Grinding.
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#CNC #Machining #Machinist - Наука та технологія
I work in an engine factory where we grind all of our cams and cranks. Although the systems are mostly automated for higher productivity, the principals are still the same. Clean centers, perfectly dressed wheels and coolant. A gantry loader/unloader handles the parts and inline gauges check diameters and send real-time comp data back to the machine. The operator runs all the surface finish checks and one of every 10 goes to the CMM for complete inspection. We do 60 crankshafts per hour, or one a minute.
damn, that's crazy. (I'm the dude that has to replace them when that fancy surface is scored to hell because the owner never changes their oil)
This guy seems super knowledgeable and confident!
He is… and he is just a Great Guy😁🤙
How much is that knowledge worth tho?
@@TellURide447 enough to get him a high paying, laid back job at a company with a great culture, great co-workers, and great CEO in a great state.
@@jamescerven4400 I wasn’t being a smart ass. I’m curious to know what a guy like that makes. I know he has a great job with a great company. Just wondering what he earns.
@@TellURide447 I wonder too! I have literally no idea 😂
Chris is the perfect addition to the team. Obviously he's very knowledgeable about grinding as evidenced by the result. Great work!
Thanks for the support!
Finally a parameter and detail oriented grinding video, earlier ones were lacking, but only a bit :D Always great work none thes less :D
Thanks for the support!
Would love to send you one of our cbn wheels to try . I can Guarantee a better RA 3.5 or lower. Nice work very well done. I learn so much from team Titan . Thanks for everything you guys do . Literally paving the way for the younger generation.
Find the address and send one out!
I'll take one to try :)
Cubic Boron Nitride is a hella win compound.
Runs cooler, is harder than other abrasives, superior chemical stability (does not evaporate or absorb into the steel like diamond can do), produces better finishes, has an extremely long life, etc.
And its just amazing its made from a gas and a brown powder.
@@renecastro6110 steel is never processed with diamonds but ok
@@hephaistosthesmith2069 thats exactly why they dont use them lol. Ferrous metals fuck them up.
Awesome video Chris! We are excited to have you join the team. You bring a lot of great knowledge and experience and I am glad you chose to share it with the world for FREE!
Hey everyone just putting some background in the world of comments. I’ve done some quality work on pieces that were going to to a portable quadrupole mass spectrometer and we needed metal conical inserts at 3 places to reduce airflow with specifications for exit flow within 5 milliliters per hour with an inflow pressure of around 1 bar. Specifications and standard operating procedures are a complete must for any operations aiming close to your his type of standards. Some of our manufacturers were unable to deal with the standard operating procedure as the cleaning and packaging step made it so these nozzles couldn’t even go into a plastic bag as some of their off gassing vole tile chemicals would interfere with the finish. Thank you every single machinist out there that deals with engineers like me and the details we barely provide yall
Thanks for the comment! Always great hearing some new stories! Boom!!
Nice work Chris, loved the clear explanation of everything!
15 years ago i have run parts with 2-6 ra tolerance on surface finish… As long as the part is heat treated and leave at least 0.002 stock after final dressing, no problem on a cnc Kellenberger grinding machine.
I also work on kellenberger
I also run a Kellenberger, nice machines
@@digbybowring8362 what machine exactly ?
When I entered machining I was in a high precision ceramic grinding facility. It was all manual machines and ever part had to be polished by hand after grinding. My best finish was a .36 ųin.
When I was in the grinding department we where doing parts+/-.0002. I told the sales department we could do +/-.0001 all day long with the Okamoto's. They got some parts that were indeed held to. 0001. Just for fun I set a goal of holding .00005. One of my parts actually hit a full .00005. the rest. 00002+.00003. plain Okamoto, aluminum oxide wheels. Retired now! I scrapped a few parts over the years but it was never a machine issue. It never took more than I asked not once!!!
Thought I might say we were using electronic indicating heads and certified Jo Blocks for measuring!!
How do you temp control something that tight?
@@adammiller4879 it was a relatively well controlled temperature environment but certainly not a class 1000 clean room The parts were 440 C about 57-58 Rc They were 2.25 inches square. So if it "warmed up" it wouldn't grow that much. I'd start the day by sneaking several parts down to plus. 0005. I'd take a few of those down to+.0002. I'd size them very carefully and mark the tops with red sharpie marker. Then i'd load of 24 (3 rows of 8. Putting a +.0005 in the mix with red and, also a + .0002. I'd grind till I hit the+.0005 then dress the wheel very lightly. Mark the top again sneak down to pick these up then let the Okamoto do what it does best, and drive it down to size. Zero stress. I always went home and slept good. My favorite work environment ever. Never scrapped a load in about e years of running this process. A few parts would fall out along the way but never a full load.
so what
it's not like you're the one doing the grinding by hand
It's a machine which executes a set of orders, all you have to do is give the right input to the machine with respect to the material your using.
I don't applause when my 3d printer does exactly what I'm asking it to do.
@@xl000 you obviously have never actually ran a cnc machine before if you think it’s that simple. Your comment is extremely ignorant.
shoulder grinding nitride faces with a straight wheel can produce some excellent surface finishes & a nice crosshatch pattern.
My best result was Ra0,03 (metric). But ID, with oil coolant, a vitrified bonded grinding wheel and a contour grinding operation.
Greetings from good old Germany
thanks for explaining this so good!
we have an old cylindrical grinder at work and i was always interested in getting to know how this process works.
sadly I'm not going to learn that properly there because I'm not going to be trained in cylindrical grinding.
You're amazing Chris! I'm sure some great parts will come out that Studer S41 thanks to your knowledge.
Thank you for the video Chris! You explained the process well! I'm going to have to rewatch and take some notes :-)
Knowing the intricacies and idiosyncrasies of a machine and it's tooling is everything.
Excellent video, and I can see the satisfaction you got from your results.
I used to ID/OD grind in the 10th's too, I always loved pushing for finer finishes even better than the print specs!
Fascinating! Nicely done Chris, thank you for sharing.
Nice performance on S41. We have S33 in house and also doing great job:)
I would love a quick video about the filtration system for the coolant that it uses, like if yall reuse the coolant after filtering or if its just waste after cleaning out the chips and stuff
Outstanding Chris! Nice job 👍 Looking forward to more from you.
You guys always do crazy precise stuff.
This guy is really good so far
Great work Chris! Awesome first video
Had some parts that required a grind op after the mill op to achive an adequate surface finish, curiosity got the best of me and I attempted to achieve the finish with a 6" face mill. With proper feeds and speeds I was able to eliminate the grind op and save about a day of processing time.
I run a Studer S31 ,great machines .
Welcome to the crew Chris great job.
I really like that new guy! It was very informative video.
Definitely easy to understand! Thank you!
New to grindin and im happy to be holding .0001 and even .00005 but now for the best possible finish 💪 new animal new possibilities higher pay grade thank you titan off cnc " can't rush perfection dawgg"
Nice video Chris! Welcome to the team!
No RPM adjustment on the stone on the old TOS grinder i ran for a few years.
Doing stainless axles the surface lasted a lot longer than doing regular steel ( not hardened )
Smallest tolerance i did was 8 mm r4 ( 8.023 / 8.019 mm )
Before i got on that machine i worked a grinder on trade school for maybe 45 minutes, and i got to that machine after being away from the trade for 20 years.
By way of " if the old guy can tell me how the machine work,,,, i can do it "
Watching this guy's hand movements is the proof in why robots won't replace tradesmen.
Thanks Alexander for the support!
Awesome video very complicated you guys are the best
Beautiful finish .. thanks for sharing the knowledge
Thanks for the support!
@@christophervillalpando5865 eres hispano y trabajas Ahy ??
Good video, Chris. Keep em comin!
Great job, Love the toys you guys have
Wheel specs are also fundamental when aiming for a specific finish
Best I’ve ever gotten was a 4RA on a lathe with a wiper insert. We were trying to avoid grinding but it wasn’t consistent enough.
thanks Chris. all in the tweeks 🎉
Great explanation, thanks for sharing . Charles
Thanks Charles! Setup is everything, no matter if its lathes, mills or grinding!
I've gotten sub 4 facing ductile cast iron in a lathe with a .060 radius insert, and sub 3 burnishing a 1.5 diameter 8620 in a lathe.
Dug that man! Super informative. Well done.
I like this dude. Great at explaining
seems like chris is a good addition to the shop.
Yep, He is super knowledgeable and confident. Just an experienced super solid addition. Chris, he has a great name also😉
3.2 RA once on 15-5 stainless with COGSDILL burnishing tools (rollers)
I see a new member of titans good job bro 👏
I wish see you in another videos 👌
Great video , great attention to detail and explanation
Thanks Paul!
do you know cold rolling - basically like knurling but with a smooth polished wheel? i got RA4 with that on a CNC lathe on a hydraulic valve stemm replacement - doesnt work with really hard parts tho- it just smushes the surface to smooth out all tool marks
I see you Chris! Good video bro!! Keep knocking it out the park!!! 💪🏾
Hey Thanks man! I hope all is well! Thanks for watching!
Nice video, love the content! We usually lie in the 0.5 ra or less, best probably just shy of 0.2ra. we grind centerless thou
impressive!
I worked at an old factory where we would hit counter bores at 1.23Rz and at 6.3Rz we would have to change out our diamond inserts. Problem was, the other shifts would run past their tool life counter, back it off like 100 and we would have to change that insert the start of the shift. That Rz would be all over the place.
I run a S31 and a S33. Best finish I’ve had with our 80grit wheels is 2.7. We often have to get below 4 for match fitting. Very challenging to get that low without burning and hold a .0001 diametrical clearance to mating part.
We also have some nickel seals we grind where we hold the finish between 28-32. I find that harder to hold a specific finish consistently on a 100 +pcs. Especially one so rough on a grinder.
Man, I wish I had Chris as a supervisor where I work at.
Ricky! Good to hear from you man! Thanks for watching!
What is your grinding wheel grit size and other specificatons please? I use Tyrolit grinding wheels too here in Czech Republic.
What coolant and concentration are you using
Thanks in advance
Great video
Love it, tenx ❤❤✌
Would it make sense that the correct centre pressure would be the same as the correct bearing pre-load for each side? Rather than just guessing by the feel.
Hello, I have a grinder with 1200rpm, diameter 500, the product is the same diameter 540,,, what rpm do you recommend and the displacement m/min
i did get a walter tool grinder as collateral when a company didnt pay, imma try to get a nice finish on that
Ground a part on an old cincinnati centerless tollerance of zz- and 16 microfinish came out to about 2 microfinish bust the part was harder so it was easy
Boom. Good shit Chris. Welcome to titans of CNC. These videos help the people making the parts in CAD. What tolerance would someone ask for fit the procession you got in that peace. .00065 of an inch?
must be nice being able to rotate the part at a decent rpm with the door open. The Gioria cnc grinder i use only rotates at 3rpm with doors open :/ . we arent allowed to remove the interlocks to rotate it faster
Is the UMC-750 SS A STROMG ENOGH SPINDLE TO RUN AT THOSE SPEEDS??
I know that dude. He still owes me a fair one. 😁 Great work Chris!
Wow, he really knows what he is talking about.
Do you you ever have a situation where there is kind of re-cutting chips so to speak ? I see there is a lot of coolant and direction of part/wheel spin wonder if it could become an issue.
Hi Jonathan, sometimes in OD/ID grinding we get what is called grit scratches. This is when pieces of the stone or material being removed ride with the wheel. The machine has a filter that assists with minimizing the grit scratches. Great question! I hope I answered it.
Chris remember Your formula for part speed is approxamately 100SFpm, so a 4" part times 3.1415" equals 12.5" inches or about 95 rpm. your part looks close to 3 inches so 3" X 3.1415= 9.5 sf inches 125 rpms would be approx 100SF. I think you said 115 which is close enough. Also note that if your arbour and driver are out of balance (They are running out) that can lead to out of roundness and a bad finish too.
Yes SIr! Thanks for the knowledge! I hope your doing well!
Nice work Chris! What's the story behind your Never Forget tattoo? That's a pretty nice tat
yo titan. l was wondering: you talk about turning metal into dust and chips. could you go a bit about how the background works for you guys? like how to you assign machinig tasks to machines and track/control your manufacturing ... without secrets or going into details but just generally how your company works u know
how do you handle the wear on the grinding wheel ?
Not sure if it's really important for this operation
We dress the wheel using a diamond, the wheel can be dressed in cycle or before.
Hey! Studer used to be a reel to reel tape deck manufacturer :D
Two different companies. The one that made this machine was founded by Fritz Studer in 1912. The one that made the tape recorders was founded by Willi Studer in 1948. I thought the same thing you did, so I had to look it up.
How would you grind a shaft 10 inches long that has chrome plate to a requirement of 16 to 22 RMS?
Geez, I want a grinder now
Is this RA in an different scale? I daily grind piston pins (big, for trains, power plants, ships etc), and grind them to Metric Ra ~0.20-0.10, before finalizing lapping. Not always easy finding dressing parameters that allows for both grinding-speed and surfacefinish, and part cylindricity, while also no deep scratches are allowed (of which most wont go away with lapping). Some models we make have cylindricity of under 4μm metric AFTER lapping
Yes, our RA in in micro-inches. Our 6RA is roughly .15RA metric
You guys are f..cking amazing.
BOOM Baby…
Are ra numbers diffrent in the imperial system compared to the metric? I work as a grinder in europe an had ra of 0.04. On a studer s42. Thank fore those who could help
Great Question.
We put our machining parameters in imperial and metric in our UA-cam machining videos… will look to do the same for grinding.
They have acheved a ra of 0.156 in metric and an ra of 0.04 in metric would be about 1.57 in imperial
Hey Jonas, the metric system uses micro meters to measure surface finish whereas in imperial we use micro inches. Thanks for watching.
Ja, du hast recht. Da bei Ra der durchschnitt von "Entfernungen" angegeben werden und die amerikaner haben dabei inch und wir meter. Deshalb haben europäer die Ra und Rz angaben auch in mm und die amerikaner in inch.
Than you all for the awnsers! I love your videos. I always stop the video whenever you talk about feeds and other parameters and i try to calculate it to our metric system. I am always impressed about your speeds. I would love to work one day like that. However i have always low part numbers (2 to 5 pieces) wich are experimental without existing programs. It would also be risky if i make a fault because i am at the end of the producing chain. So i try to stay on the "save" side of speed. ;-)
For me it was a pleaseure to see that you baught an "expensive" swiss grinding machine. I told this to my boss, as an argument to buy an otherone. ;-) he was convinced🙂
Keep it up.
Best finish I've ever gotten was 0.97 few dresses with 5 micron cut and few more 2 micron cut , with 20 micron cut around 2.3
ive gotten 0.2
Keep in mind that the lowest Ra (Rz or Rm) isn't always a winner. Sometimes you need a little roughness to hold fluids back in a seal. Precision is the goal.
Freaking awesome
So nice b❤️❤️m grinding machine thanks for your company all days video upload UA-cam channel
nice bro
On longer parts preload is key.
I've gotten 0.1 but not with a studer. It was on a lapping table. 😆 I guess you could still say that's a form of grinding.
Do your S41’s have 3 balance points on the balancer or is it a clownshow like Bell?
Hey Long you did one hell of a job programming this part🤣
Chris programmed the part
that surface finish looked really good. especially when you look at that wheel. it loaded up terribly! but an Ra of 6.24 ? thats a lot. i grind in between 0.2 and 0.8! (surface grinder)
I'm guessing you work in metric units the equivalent of 0.8Ra in metric would be 20Ra imperial
@@scottetheridge2845 then his 6.24 is impressive
@@scottetheridge2845 almost
0.8 metric Ra is 32 imperial Ra and 0.2 metric Ra is 8 metric Ra
this is another level above!!!!!!
best finish i had was on a 5' long part 7' dia with a 5.1RA
please use units => 6.24 microinch = 0.156 micrometer
30 degree wheelhead is a good tip, dressing for shoulders would be easy.
Are the wheelhead bearings angular contact or plain and thrust with an oil pressure film?
My best finish was a literal mirror finish. It took forever to achieve that.
4.0 on a 13. All day.
I never worked on CNC grinder and from the video it is not clear to me, how the machine knows, how far to move the wheel to achieve certain diameter. I did not see you offsetting it or measuring some kind of hight - like on CNC mill or lathe. I would appreciate more in depth explanation. Thank you
I've ground a 2.0 then a 1.7 ra finish on a plain old Okamoto 6x18.
My German tool maker boss didn't believe it either. We checked the finish on dedicated HP profilometer. Not a little hand held Mitutoyo
Falta só a dublagem para Português 👌
Is it possible to make a video about milling C-surfaces?
Not turning. 😜
👍👍👍👍👍🙏