ALMT - Rotary Dresser

Forming Rotary Dresser

An Application Example of Forming Rotary Dresser

RZ type

SZ type

SX type

Types

Abrasive Surface

Linear Guide

Tap

Turbine Blades (Aerospace, Power Generation)

Abrasive Grain Array

Random

Regular

Our high concentrate and random setting technology achieves long tool life and high accuracy. Our unique precision electroforming and precision machining technologies enables us t o achieve any kind of complicated prole. Also, we offer wider variety of option.

With our precise diamond setting technology, concentration can be controlled as per your request. Higher electroforming technology as same as RZ type can achieve high precision grinding with maintaining good sharpness. This is also suitable for large-sized plunge dressing.

precision powder metallurgy technology and high-precision diamond lapping technology works greatly for dressing that requires sharpness. It is effective even for traverse dressing.

Features

Ball Screws

Wheel Hub Units (Automotive)

Engine Parts (Automotive)

Production Processes

Electro-Deposition

Sintering

Outer Diameter (mm)

φ 50–200

φ 20–180

Width (mm)

≤ 200

Various Bearings

Various Steering Parts

Hydraulic Parts

Grit Size

#20–#140

#16–#20

Prof ile

Complex / Fine

Form

Series

Optimized Sharpness, Accuracy, and Wear Resistance

★★★

★★☆

Profile Accuracy

Conventional forming rotary can be applied our Optimard spec, which specializes in sharpness, accuracy and wear resistance.

Specialize in Sharpness

★★★

★★☆

Surface Roughness

Specialize in Accuracy

★★☆

★★★

★★☆

Sharpness

Specialized for High Wear Resistance

Recommended Dressing Conditions (Plunge Dress)

Conventional Dresser (RZ,SZ, SX)

High

Conventional Grinding Wheel

Hard Conventional Grinding Wheel

CBN Wheel

Wear Resistance

Dress Direction

Down

Spitz

Luxa

Stark

Types

Peripheral Speed Ratio

0.25–0.5

0.3–0.9

Dress Amount (mm)

0.02–0.03

0.01 – 0.015

Feed Rate (µm/revolution)

0.5–1

0.1–0.5

0.01–0.5

Abrasive Surface

Dress Out (sec.)

0–3

Features

Focus on Sharpness

Focus on Accuracy

Focus on Wear Resistance

Peripheral Speed Ratio

The Spec optimized for sharpness by regular array or lower concentration treatment. Especially it works greatly for reducing dressing load, chatter and burning issue in wider grinding wheel.

High-precision specialized spec that achieves high prole accuracy as well as ne sharpness. Excellent shape stability supports quality control of workpieces.

The spec which designed for maintaining sharpness as well as improving wear resistance. It performs high prole accuracy even in high-load dressing with CBN wheels and hard grinding wheels.

Vr (Speed)=R.P.M x O.D x π Vs (Grinding wheel peripheral speed) =Grinding wheel revolution (min -1 ) ×O.D.×π * In case of up dress, please add "-", minus, to the number after the calculation.

Vr Vs

Peripheral Speed Ratio =

Features

Dressing Method

φ 50–200

Outer Diameter (mm)

Down Dressing

Width (mm)

10–100

Grit Size

#16–#40

#30–#80

Process Image

Applicable

RZ, SZ, SX

Life (Number of Dresses: Index)

Dress Resistance (Index)

Accuracy Maintenance

0 0.5 1 1.5 2 2.5 3 3.5

Conventional Dresser

Profile Accuracy Improvement

Dressing Method

Plunge

Angular

Up Dressing

Comparison with Conventional Products

Standard Value

20% Less

Grinding Method

Plunge

Angular

3 Times

Conventional Dresser

This is standard dressing method that uses same profile as a parts to be ground.

Profile grinding at end face without burn mark is available. High dressing ability spec such as Optimard Spits is highly recommended.

Conventional Dresser

Features

100

200

300

0 20 40 60 80 100 120

Number of Dress

Traverse Rotary dresser

Example of Rotary Dresser for Profile Forming

AR1

AR2

AR3

AR4

AR5

AR6

AR7

Prof ile

Used for traverse dressing of grinding wheels.

Used for total forming shape of grinding wheel.

Uses prismatic diamonds that offers consistent sharpness and wear resistance.

Diamonds set on both shoulders are

This is a double- shouldered radius type using natural diamonds. This type is used for forming wide grinding wheels and for forming a radius around the

This is a Impregnated type with ne diamond grains bonded by sintered metal. It has a long life, but the wider the abrasive grain layer, the worse the cutting ability.

Cup-shaped dresser suitable for dressing small-diameter grinding wheels.

Various Gears

Tap

Ball Screws

Various Shafts

Needle Valve

suitable for processing micro-prole.

Excellent for micro-shape machining.

Features

Allesta

Traverse Rotary Dresser for High Precision Profile

periphery of the grinding wheel.

Various customizations are available with our micro-shape machining technology at the tool edge to meet a wide range of requests.

Features • Rotary dresser for traverse forming that enables machining of fine shapes by its acute edge angle design. • The abrasive grain and grain arrangement that specialized for traverse process enables to achieve high accuracy and long life. Applications • Interpolate dressing of conventional grinding wheel and CBN wheel for profile grinding. • Bearings, Ball screws, Needle valves, Various shafts, Gears, Taps, Rolling dies

Edge R (mm)

≥ 1.5

≥ 0.25

Profile Accuracy (µm)

≥ 1.5

≥ 2

Edge Angle (degree)

≥ 40

Outer Diameter (mm)

≤180

≤ 180

≤ 200

★★★

★★☆

★★★

★★☆

Wear Resistance

Wear Resistance Evaluation Result

★★☆

★★★

★★☆

★☆☆

★★☆

Sharpness

Applicable Range Abrasive Grain Size

0.05

0.3–0.6 mm (Square Column)

0.04

Types

SX, CWN

SX, X, CWN

5 times better Wear resistance!

0.03

φ 50–200 mm

Outer Diameter

SX type: Rotary dresser with diamonds fixed by hard metal bond X type: Impregnated type rotary dresser CWN (crown) type: Rotary dresser with prismatic diamonds fixed by Ni plating

0.02

≥ 18°

Edge Angle

≥ 18°

R≥ 0.1

Criteria for Dresser Life

0.01

Edge R

≥ 0.1 mm

Radial Profile Accuracy

Recommended Dressing Conditions (Traverse Dress)

≤ 1.5 µm

5 3.5

20 21

Amount of Grinding Wheel Wear (cm 3 )

Conventional Grinding Wheel

Hard Conventional Grinding Wheel

CBN Wheel

Dress Direction

Down

Disc Dresser

Rotary Dressers for Gear Grinding Process

Peripheral Speed Ratio

0.25–0.5

0.3–0.9

As a dresser for shaping worm-shaped grinding wheels used in gear grinding, it realizes "higher precision gears" and "reduced grinding costs" by extending dresser life.

Dress Amount (mm)

0.02

0.01

Infeed Rate (µm/pass)

5–30

3–5

2–3

Features • Based on information such as Workpiece gear specifications, grinding wheel shape and specifications, we design a dresser that achieves the required tooth surface quality. • Extremely high tooth profile accuracy of 0.001 mm or less can be obtained. • High ability to maintain tooth profile accuracy shape and low dresser life variation contribute to reduced grinding costs. Applications • Dressing of worm-shaped grinding wheels used for generating the tooth form of automotive and machine gears

Dress Out (Traverse Cycles)

0–4

Feed Rate Feed Rate (mm/min) = C × Rotary Dresser Width × Grinding Wheel Revolution (min -1 )

Dressing Method

Grinding Method

Disc Dresser Contour Shape

Standard

0.025–0.1

Process Image

1mm

Efficient Grinding High Speed Grinding

0.125–0.2

Centerless Grinding

0.005 – 0.01

Dressing Method

Interpolating

Traverse

Cup Type

Dresser Shape Data （ R1000 ）・・ 1μm

Technical Data

Technical Data In dressing, the surface roughness of grinding wheels is influenced by elements such as: 1. Peripheral speed ratio (Vr/Vs), 2. Infeed per revolution of wheel (Ar), and 3. Dress out (Na).

Design Information for Forming Rotary Dresser

Tolerances of Rotary Dresser Designs (mm)

Dimensional Tolerances of Rotary Dressers Set approx half of the allowable tolerance of the workpiece.

1. Peripheral Speed Ratio ① Influence of Peripheral Speed Ratio on Grinding Wheel Surface Roughness • Control of the grinding surface accuracy by up-dressing is easier than by down-dressing • Higher feed rate creates more open grinding surface (grinding ability increases)

Rotary Dresser Accuracy Limits

Other tolerances available upon request

Test Condition

Item Factor

Symbol Accuracy (mm)

Illustration

WA60K #20/30 Vs=29m/s Na=0

Grinding Wheel Rotary Dresser Grinding Wheel Peripheral Speed Dress Out Infeed Per Rev.of Grinding wheel Ar = 0.18μm/rev

L L

Width

± 0.005

U value

W value RZ type ≥ 0.5Z SZ type ≥ 0.5Z SX type ≥ 4Z

Y value M value

Radius

± 0.002

RZ type ≥ 10 SZ type ≥ 10 SX type ≥ 3

RZ type ≥ 10

≥ L

Down Dressing

Up Dressing

0.002

SZ type

≥ 10

≥ L

Step

± 0.001

SX type

≥ 4

≥ 0.5L

= 0.36μm/rev = 0.54μm/rev = 0.72μm/rev

Down Dress

Up Dress

Profile Accuracy

0.002

Prof ile

0 1.5 1.0 0.5 0 -0.5 -1.0 -1.5

P P P

Concave R Convex R Convex R

Peripheral Speed Ratio (Vr/Vs)

0.002

Concave R

Angle

± 1´

② Influence of Peripheral Speed Ratio on Dressing Force • Larger peripheral speed ratio allows higher normal force (increasing in grinding ability • Tangential force shows the same tendency as normal force, but the value is much smaller

0.6

ー

Straightness

0.002

0.5

P P P

Pitch Accumulative Pitch

P nP

± 0.002 ± 0.004 + 0.005 − 0

0.4

P value

*Convex R value *Concave R value

0.3

RZ type

≥ 0.1

≥ 0.03

RZ type

≥ 0.3

φ H

Bore

0.2

0.002

SZ type

≥ 0.2

≥ 0.15

Parallel

0.002

0.1

0.002

SX type ≥ 0.15 *Value depending on diamond grain sizes ≥ 0.2

Prole

1.0

0.5

-0.5

-1.0

1.0

0.5

0.005 A

Control

Peripheral Speed Ratio (Vr/Vs)

Body

Peripheral Speed Ratio (Vr/Vs)

Perpendicularity

0.002

Prole

2. Infeed Rate ① Influence of Infeed Rate of Grinding Wheel Surface Roughness • Higher feed rates create a more open grinding surface (grinding ability increases) • Longer dress-out time diminishes sharpness of the grinding surface

Runout of Profile

0.005

② Influence of Infeed Rate on Dressing Force • Larger feed rate increases normal force. (Grinding ability increases) • Tangential force shows the same tendency as normal force, but the value is much smaller.

Runout of Control

0.002

(Na=Dress out wheel rotation frequency)

Troubleshooting

0.5

Vs Vr Down Dress =0.81

Down Dress Na=0

0.4

Corrective Action

Trouble Details

Cause

0.3

Vs Vr Down Dress =0.16

Grinding wheel, dresser, and facility specication changes

Maintenance, change of dress conditions

Up Dress Na=0 Down Dress Na=80

0.2

Large dressing noise Chatter occurs

Vibrations

Cause of abnormal vibration isn't eliminated

• Check the run-out of the dresser • Check the unbalance between grinding wheel and dresser • Increasing the peripheral speed relative to the grinding wheel Down-dress: Reduce dresser rpm Up-dress: Increase dresser rpm

Vs Vr Up Dress =0.81

0.1

Up Dress Na=80

• Reduce diamond concentration of dresser • Increase machine rigidity • Increase the driving force of the dressing device

High dressing Load

0.1 0.2 0.3 0.4 0.5 0.6

0.18

0.36

0.54

0.18 0.36 0.54 0.72

Infeed Rate (μm/rev)

• Reduce infeed rate • Increase feed rate • Shorten dress-out

3. Dress Out Influences of Dress Out on Grinding Wheel surface Roughness • Longer dress out time increases roundness of the grinding surface, but reduces sharpness.

Burn mark

Temperature rise of workpiece Grinding wheel is dull

• Use softer grinding wheel • Use larger Grit grinding wheel

• Increase total dressing amount

• Reduce diamond concentration of dresser

• Avoid end-face grinding with angular grinding

Coolant is not supplied sufciently

• Increase coolant amount

• Increase the amount of diamond protrusion of the dresser

• Adjust coolant nozzle position • Avoid end-face grinding with angular grinding

Down Dress Up Dress

Grain shedding due to early bond retreat

Insufcient evacuation of grinding debris

• Increase coolant amount • Adjust coolant nozzle position • Increase coolant amount • Reduce infeed rate • Shorten dress-out • Check the run-out of the dresser

Abnormal wear

Diamond wear

Dresser temperature rise

80 150 240 320 Grinding Wheel Rotation Speed During Dress-Out (Na)

Dresser vibrations

• Increase machine rigidity

• Check the unbalance between grinding wheel and dresser

Precautions for Use of Rotary Dressers

Unsuitable Dresser selection

• Increase diamond concentration of dresser • Reduce the size of the abrasive grains

1. Do not directly touch the diamond part of the rotary dresser, which has a small edge angle and edge radius. Use cut-resistant gloves and handle with care. 2. When mounting and removing a rotary dresser on and from the spindle, do not strike it with a hammer. 3. When a rotary dresser is mounted on the spindle, be sure that the runout of the reference surface is less than 2µm in both the radial and axial directions. If the runout is large, turn the rotary dresser by a half turn and set it again. 4. Prior to starting dressing, run the grinding wheel and rotary dresser under no load to check for abnormal noise and vibration. 5. During dressing, keep supplying an ample amount of grinding fluid. This will improve the dressing performance and prolong the life. Make sure the nozzle is located properly and the nozzle is not clogged. Never use the rotary dresser without coolant. 6. When bringing the rotary dresser in contact with the grinding wheel for dressing, exercise special care. Do not hit the rotary dresser against the grinding wheel with a shock. Be sure that the infeed rate will not exceed the setting. The rotary dressers are precision equipment. When using them, be sure to observe the following precautions.

Poor surface roughness

Unsuitable grinding wheel spec Grinding wheel grain size is too large

Workpiece contamination

Clogging of grinding debris

• Increase coolant amount • Adjust coolant nozzle position

Dirty or contaminated coolant

• Clean the coolant path • Replace coolant

Vibrations

Cause of abnormal vibration isn't eliminated

• Check the unbalance between grinding wheel and dresser • Increase machine rigidity • Check the run-out of the dresser

Poor grinding wheel roundness Insufcient grinding wheel forming • Check the run-out of the dresser

• Increasing the peripheral speed relative to the grinding wheel Down-dress: Reduce dresser rpm Up-dress: Increase dresser rpm • Reduce infeed rate • Apply longer dress-out

For safe use of the rotary dresser, read and understand Rotary Dresser Instruction Manual thoroughly.

Technical & Reliable Network for A.L.M.T. Corp. ■ Head Office

Sumitomo Fudosan Shiodome Hamarikyu Building, 8-21-1, Ginza, Chuo-ku, Tokyo, 104-0061 Japan Phone +81-3-6733-3617 Fax +81-3-6733-3621

Domestic Production Network (Diamond / CBN Tools) ■ Harima Works (Grinding Wheel, Cutting Tool, Rotary Dresser) 1816-174, Kotaka, Kato-city, Hyogo 679-0221 Japan Phone +81-795-48-5067 Fax +81-795-48-5071 ■ Awaji Plant (Diamond Drawing Dies, Wear-Resistance Products) 628, Yura, Yura-cho, Sumoto-city, Hyogo 656-2543 Japan Phone +81-799-27-0317 Fax +81-799-27-2485

Harima Works

Domestic Sales Network ■ Tohoku Office

■ Hamamatsu Office

■ Osaka Office

■ Kita-kanto Office

■ Hiroshima Office

■ Tokyo Office

■ Kyushu Office

■ Mikawa-anjo Office

Global Network (Diamond / CBN Tools) <North America> ■ Sumitomo Electric Carbide, Inc. (Chicago) ……(Sales of Diamond Tools) 1001. Business Center Drive, Mt. Prospect, IL 60056-2181, U.S.A. Phone +1-847-635-0044 Fax +1-847-635-9335 ■ Sumitomo Electric Carbide, Inc. (Detroit) …… (Sales of Diamond Tools) 26800 Meadowbrook Road,Suite 120 Novi, MI 48377, U.S.A. Phone +1-734-451-0200 Fax +1-734-451-5338

<Central America> ■ Sumitomo Electric Hardmetal de Mexico. S.A. de C.V. (Mexico)

…… (Sales of Diamond Tools)

Avenida Eugenio Garza Sada No. 42 Pocitos Aguascalientes, Ags., 20328, Mexico Phone +52-449-993-2740 〜 41

<Asia> ■ A.L.M.T. Diamond Dies (SUZHOU) Co., Ltd. (Suzhou, China)

■ A.L.M.T. Asia Pacific Pte. Ltd. (Singapore)

…… (Sales of Diamond Tools and Diamond Drawing Dies)

…… (Manufacture and Sales of Diamond Drawing Dies) Unit 24E, 25D, 25E of Suchun Industrial Square, #428 Xinglong Street

No.2 Boon Leat Terrace #03-02 Harbourside 2 Singapore 119844 Phone +65-6271-9252 Fax +65-6274-2915 ■ A.L.M.T. Asia Pacific Pte. Ltd. (Malaysia)

Suzhou Industrial Park, Jiangsu, P.R. 215024, China Phone +86-512-62836195 Fax +86-512-62836176 ■ Sumitomo Electric Hardmetal Trading (Shanghai) Co., Ltd.

…… (Sales of Diamond Tools and Diamond Drawing Dies)

8F-1A,Tower 4 @PFCC Jalan Puteri 1/2, Bandar Putei 47100, Puchong,Selangor Malaysia Phone +60-3-8069-1090 ～ 91 Fax +60-3-8069-1094 ■ A.L.M.T. (Thailand) Co., Ltd. (Bangkok, Thailand)

…… (Sales of Diamond Tools) Room J, 6/F Huamin Empire Plaza, No.728 Yan An Road(W), Shanghai, 200050, China Phone +86-21-6212-9271 Fax +86-21-6212-9272 ■ Sumitomo Electric Hardmetal Trading (Shanghai) Co., Ltd. (Guangzou) …… (Sales of Diamond Tools) Room 21, A22F, China Shine Plaza, No.3-15 Lin He Xi Road, Tian He District, Guangzhou, 510610, China

…… (Sales of Diamond Tools and Diamond Drawing Dies) 54 B.B Building 15th Floor Room 1511 Sukhumvit 21 (Asoke), North

Klongtoey Wattana, Bangkok 10110 Thailand Phone +66-2-2612231 ～ 2 Fax +66-2-2612230 ■ A.L.M.T. (Thailand) Co., Ltd. (Wellgrow, Thailand)

Phone +86-20-3881-5582 Fax +86-20-3891-0904 ■ Sumitomo Electric Hardmetal Taiwan Co., Ltd.

…… (Manufacture of Diamond Tools)

90/2 Moo 9 Wellgrow Industrial Estate Bangna-trad Road., T.Bangwua A.Bangpakong Chachoengsao 24180 Thailand

…… (Sales of Diamond Tools) 13F, No.156, Section 1, Zhongshan Rd., Banqiao District, New Taipei City, 22065, Taiwan Phone +886-2-29596721 Fax +886-2-29596720

Phone +66-38-522291 ～ 5 Fax +66-38-522290 ■ A.L.M.T. (Thailand) Co., Ltd. (Korat, Thailand)

…… (Manufacture of Diamond Drawing Dies)

Mooban Bannaklang 567 Moo 1 T.Naklang A.Soongnuen Nakhonratchasima 30380 Thailand Phone +66-44-335190 Fax +66-44-335300

Sumitomo Fudosan Shiodome Hamarikyu Building, 8-21-1, Ginza, Chuo-ku, Tokyo, 104-0061 Japan Phone +81-3-6733-3617 Fax +81-3-6733-3621 https://www.allied-material.co.jp/en.html

* Specifications are subject to change without prior notice.

2024.09 (T) 500

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