Diamond Roller Dressers The dressing and truing of the grinding wheel to the correct form, condition and tolerances during the grinding operation is one of the most important factors in maintaining efficient cutting of the wheel. The efficiency gives good control over productivity and quality of components especially in mass production. Diamond Roller Dressers have been developed to remedy the disadvantages of conventional single point or multi-point diamond tools; down time for wheel dressing and tool changes are virtually eliminated as are inconsistencies in quality caused by variations between...

THE METAL SINTERING METHOD produces a long lasting tough wear resistant matrix which can withstand the corroding effects of the matrix holding the diamond, which is associated with frequent heavy dressing operations. THE ELECTRO-DEPOSITION produces roller dressers having small and sophisticated profiles and conforming to the high tolerances. Asahi Diamond provides three types of metal sintered roller dressers - as specified below by the code numbers R-1, R-2, R-3, - and one type of electro-deposited roller dresser - as specified below by the code number N-2 -this is manufactured by the reverse...

Configuration and Tolerance Possible geometry and tolerance are primarily and necessarily determined by the design limit related to the actual roller structure, diamond size in relation with the required roller configuration, production technology and economy. Asahi Diamond has established its own design standard from the close examination of the above factors, whose details are described below: 1) Diameter and Diameter is normally determined from the economical viewpoint, and width of impregnation width diamond impregnation is fixed by adding 3 to 4 mm to the wheel thickness. Diameter:...

L ±0.03 H ±0.005 R ±0.003 Max. R =60mm Wavinessil = 0.002 Taper check is done with a standard taper gauge and the contact area must be more than 80%. L | ±0.015 R ±0.05 Cylindrical! <0.003mm (convex tendency) Diameter difference when a roller composed of 2-3 parts <0.005 Positional deviation of the Y coordinate from the X coordinate: ±0.005 Positional Deviation from the nominal line

Dressing Methods and Features Dressing methods are broadly divided into two categories. : Plunge Dressing and Traverse Dressing: Plunge dressing is done by plunging a roller into a grinding wheel to be dressed and is commonly and effectively applied in form grinding and in production grinding of identical components, especially under the heavy grinding conditions, including shoulder grinding, that often causes excessive wheel wear in a short period and, as a result, less yield per dressing cycle. Traverse dressing is done by traversing a roller in one direction along its own axis on the grinding...

Operating Conditions Diamond roller dressers give shearing and compressive forces to abrasives and binding material in abrasives wheels in order to vary their shape and distribution of cutting edges and, as a result, influences wheel performance such as cutting ability, surface finish, and geometry of components etc. Thus the optimum operating conditions must be set up to obtain the best performance. The following figures indicate the various influences of dressing conditions on performance of abrasive wheels taken from test results obtained by Mr. T. Murray and Mr. S Malkin. Dressing Conditions...

3. Effect of Dress-out Time on Grinding Resistance. The dress-out (Zero-cut) time affects surface finish and grinding resistance, as shown by Fig. 14. Thus the shortest possible dress-out time should be applied for good results. Attention must be paid to dress-out time especially with manual fed machines. 4. Effect of Revolution Ratio on Profile Transfer. Perfect roller to wheel profile transfer Is unfeasible as it is impossible to produce rollers of perfect roundness, completely even and smooth diamond protrusion, and due to run-out of driving spindles which cause irregular wheel profiles, improved...

Life of Diamond Roller The wear pattern of individual diamonds varies considerably according to the crystal orientation as well as to the operating conditions, including coolant supply and pressure. The variation causes uneven diamond protrusion on a diamond roller after a certain period of use and produces variable waviness and surface finish of components. (Fig. 15). The service life of a diamond roller is determined by tolerance allowed on components as the result. Diamond rollers may be reprofiled and trued unless they are badly worn out or damaged.

Finish Grinding of Ball Screws An increase of 33% in yield was achieved with sharp reduction of time required for dressing, exchanges of dressing tools and inspection of components resulted from consistent and accurate dressing with diamond roller dressers to realize high accuracy and consistencies of component geometry and configuration. An average life of the diamond roller was 100,000 dressings. Grinding of Triangular Screws An increase of 5% in yield was achieved in this case although diamond roller dressers have been confirmed as more effective on grinding triangular screws with a screw...

Quotation and Ordering Quotation and Ordering When quoting for (and manufacturing) a Diamond Roller Dresser the following information is needed in order that the best service is provided: Before and after grinding Composition : Hardened or Not Max. Material removal: Required Finish : Rough ness_ Inspection Method 2. Grinding machine Type : Cylindrical, Angular Slide, Centreless, Surface, Internal, Thread, Other Manufacturer : 4.lnformation on the machine and the shaft if a drive unit is not used. Vitrified, Resin, Rubber, others Manufacturer : 6. Position of Diamond Roller Dresser...

Diamond roller dressers must be rotated with a rigid and accurate machine independently in order to obtain maximum dressing performance unlike crushing rolls which co-rotate with abrasive wheels. The diamond roller drive Model RDU unit, having back-to-back duplex roller bearing in the fixed bearing box at one end of the spindle and double row cylindrical roller bearing in the movable bearing box at the other, enable long profile transfer intervals as well as precise transfer due to their superiority in rigidity and rotating accuracy over ball bearings. The diamond roller drive unit Model RDU...