61 5002 8453 6 Powertrain
61 5002 8453 6 Powertrain
61 5002 8453 6 Powertrain
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A proud history of research
Founded in 1902 to mine minerals used in grinding
wheels, 3M has grown to become one of the
world’s leading manufacturers of high-performance
abrasive products, with a broad portfolio ranging
from sandpaper for the do-it-yourself market
to advanced abrasives used by the automotive,
aerospace, electronics and medical device
industries.
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Power and precision
3M offers a complete line of high performance abrasive wheels in shapes, sizes and constructions
designed to meet the needs of the most demanding applications. They are available in three general
abrasive types within powertrain component applications:
Ferrite 50
however, use less energy than
Austenite 100 standard grinding – while diverting
Martensite 1000 heat away from the workpiece.
Cementite 1400
The free-cutting properties and
Chromium Carbide 2200
Niobium Carbide 2400
superior service life of Cubitron II
Tungsten Carbide 2800 wheels can help improve efficiency
Vanadium Carbide 2800 and drive down costs, compared to
Titanium Carbide 3200
conventional ceramic wheels.
Al2O3 2200
SiC 2700
CBN 4500
Diamond 8800
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The next generation of vitrified bonds
Most vitrified wheel bonds consist Consistency wheel integrity and safety. 3M abrasive
mainly of naturally occurring raw These grinding wheels feature materials for powertrain applications
materials such as kaolin (porcelain special bond grain surface structures are applied to wheels using one of two
clay), feldspar and glass frits, all of based on nanotechnology. The bonding methods:
which are subject to variations in grinding wheel remains free-cutting
quality. Such variability is ill-suited throughout the entire process and Vitrified wheels
to modern automated grinding life of the wheel while the machine Vitrified wheels feature a ceramic bond
processes operating with pre- uses less spindle drive power, all designed to be more free cutting than
determined machining parameters. resulting in more consistent surface metal bond wheels. Vitrified bonds
To ensure more uniform batch structures. provide the better characteristics of
quality, 3M uses fully synthetic both resin and metal bonded products.
recrystallized glasses in the bonding Economical They are brittle, but thermally stable
systems of their vitrified wheels. 3M can also offer bond systems to and suitable for in-process dressing.
Due to their high inherent strength, deliver higher material removal rates Their dressability makes them
these glasses can be used in smaller along with lower risks of burning, particularly well-suited for form grinding
quantities than standard bonding better profile holding and reduced applications, especially on automatic
materials, allowing increased reject rates. In short, this bond offers equipment. When used with diamond
porosity without compromising the end-user significantly lower abrasive, they are ideal for grinding
wheel strength. grinding costs and more stable carbide, ceramics, CVD, PCD and metal
3M™ Vitrified Grinding Wheels processes – and it is also very easy matrix composites. With CBN, ceramic
feature advanced bonding systems on diamond dressing tools. or conventional abrasives, they are
for various applications. commonly used for grinding hardened
steel, tool steels and superalloys, and
Strength are particularly suitable for powertrain
Partially crystallized glass bond The bond of a grinding wheel is components, bearings, aircraft engine
wheels have high inherent strength what holds the abrasive material and power turbine components.
and can be used in smaller quantities in place, but by itself does not
than standard bonding materials. grind. Generally, the more bond in Electroplated wheels
This allows for a reduction of a wheel construction, the higher Electroplated wheels enable high
10% in overall bond material and the danger of burning and micro- material removal rates with less
a simultaneous equal increase in cracking within the part; the less generation of heat, making them ideal
porosity, without any loss of wheel bonding material, the cooler the for hard materials such as nickel and
strength. wheel will grind. To achieve optimum cobalt-based alloys, ceramics and
performance, wheels should be tungsten carbide. Employing a single
constructed with as little bonding layer of diamond or CBN abrasive
material as necessary to preserve electroplated to a substrate, these
mineral retention and maintain wheels can be constructed with tight
dimensional tolerances. They are
Grinding Wheel Structure typically not trued or dressed.
Bond
Abrasive
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An introduction to grinding
The following diagram describes some of Changing the infeed or depth of cut ae
the most common factors that can impact
a particular grinding process:
Machine tool
Workpiece
Power
Grindability
Stiffness
Hardness
Fixtures
Dimension Increasing the infeed Decreasing the infeed
Accuracy
Increased material removal rate Reduced material removal rate
Tool Life Bigger chips Smaller chips
Dressing Surface Finish Grinding Higher load on individual grain Lower load on individual grain
Dressing tool type Cutting Force wheel
Increased friability of grain Decreased friability of grain
Diamond quality Abrasive
Dressing Part Geometry Hardness > The grinding wheel acts harder > The grinding wheel acts softer
parameters Porosity
Power
Consumption
Coolant Changing the workpiece feed rate vw
Machine
Coolant type
parameters
Filtration
Cutting speed
Coolant flow
Workpiece speed
Temperature
Depth of infeed
Lubricity
> The grinding wheel acts harder > The grinding wheel acts softer
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Changing the wheel cutting speed vc The aggressiveness factor
The specific material removal rate Qw' (also
known as Q-prime) is often used to evaluate
the performance of a grinding wheel. Q-prime
indicates how many mm3 one (1) mm wheel
width removes per second (mm3/mm/sec). To
calculate Q-prime, two parameters are needed:
depth of cut ae and the feed rate vFr.
The simple formula for surface grinding is
as follows:
Increasing cutting speed Decreasing cutting speed
More cutting edges engaged Fewer cutting edges engaged
per unit of time per unit of time
dw · π · vFr mm3
Qw' =
Smaller chips Bigger chips
mm · s
60
Lower load on individual grain Higher load on individual grain
Decreased friability of grain Increased friability of grain
> The grinding wheel acts harder > The grinding wheel acts softer
dw = workpiece diameter in mm
vFr = radial feed rate in mm
min
Changing the wheel diameter ds
(at the same wheel cutting speed vc)
1 sec
Increasing wheel diameter Decreasing wheel diameter
Increased contact area Ak
between wheel and workpiece
Decreased contact area Ak
between wheel and workpiece
1 mm3 1 mm
1mm
Grinding forces remain Grinding forces remain
practically constant practically constant
Lower load on individual grain Higher load on individual grain
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Gear grinding
Gear grinding requires high precision throughout the process, and it Recommended products
is important to use the right grinding wheel for the application. The 3M™ Abrasives for gear grinding
selection of abrasive material and wheel configuration depends on the are engineered to help you achieve
base alloy, tooth geometry and size of the production run, among other consistent, high-quality finishes and
factors. 3M’s recently expanded abrasives portfolio can help you meet tight geometry tolerances, part after
the growing demand for tighter dimensional tolerances and shorter part – while increasing the efficiency
production schedules, even with difficult-to-grind materials. and productivity of your operations.
Gear grinding operations Abrasive materials for gear 3M™ Cubitron™ II Vitrified Wheels
grinding for gear grinding – threaded, single
Continuous generation with rib and spiral bevel configurations.
threaded (or “worm”) wheels Gears are usually made of low to For automotive applications; pinion
produces a very accurate and medium-hard alloys or quenched and shafts; planetary, spur, hollow and
pinion gears.
consistent profile. Advantages tempered steel, and for economic
include low cumulative pitch error, reasons these materials are usually
constant contact with gear profile, ground with conventional abrasives. Removal Rate, Q'w (mm3/mm/s)
and short machining cycles. CBN may be useful for grinding 25
Form or profile grinding with single multiple gear wheels that prevent 10
9.7
rib wheels is increasingly used over the use of threaded grinding wheels. 5
4.77
6.4
3.02
single flank generation. The gear Some gearbox manufacturers 0
Double Flank Double Double
tooth profile is dressed into the use electroplated CBN grinding Roughing & Helical Bull Helical
Finishing Gear Pinion
grinding wheel by means of a CNC wheels in order to reduce noise
contour controlled diamond dressing generation when paired with gears
Traditional Vitrified Cubitron II
disc. The grinding wheel is then fed manufactured by other methods. Conventional Wheel Single Rib Wheel
into the tooth gap, either vertically or CBN grinding can also generate
with a rotary infeed. This process can compressive, residual stress on the Parts per Wheel
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be compared to creep-feed grinding. gear flank surface, which increases 8
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the life of the component. 7
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Plunge grinding 5 6
4
Plunge grinding is primarily used 3
4
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American gear terminology Calculating wheel thickness for worm
or threaded gear grinding
Single-Rib Wheels Multi-Rib Wheels
p B1 = z × mn ×
B= + 2 × mn × tan
2
when = 20° B20 mn × 2.3 B = Wheel Thickness
z = Number of Teeth
when = 15° B15 mn × 2.1
mn = Module
B = Wheel Thickness h = Pitch
p = Pitch
mn = Module
z
Ordering data example
Type 1Esp 300 x 32 x 127
V = 70°, U = 5
54A80 H15VPMF904W
Shift movement x
(mm/mm/stroke) Feed rate fz max
y
(mm/rev)
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Camshaft and crankshaft grinding
3M’s comprehensive abrasives portfolio offers solutions from rough Recommended products
grinding to superfinishing of steel and cast steel alloys – ideal for
camshaft and crankshaft applications.
3M™ Cubitron™ II Vitrified Wheels
Camshaft and crankshaft grinding operations – for automotive and truck
applications, including journals,
Main contour grinding is performed Cam lobes with concave/negative crank and thrustwall.
by CBN wheels with either contours cause less friction and
Camshaft Grinding:
continuous or segmented rims; allow higher valve lift acceleration. 3M™ Cubitron™ II wheels vs.
both centerless and OD cylindrical This lobe design helps reduce fuel traditional vitrified conventional
wheels
grinding operations are used. consumption and increase engine
Applications include bearings/ efficiency. These contours are Parts per wheel
journals, crankpin, flange and ground with vitrified CBN wheels
post end. in the range of Ø 70 to 100 mm Avg. 3× parts
(Ø 3 to 4 inch). processed
Pin Bearing
7B151-VY150L/411 Thrust Faces
B126-VR150N/156 Post End
B151-V062 Traditional Vitrified
Cubitron II Wheel
Conventional Wheel
Avg.
13.6%
less
cycle
time!
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Cylindrical grinding Applications
• Balance shafts
• Piston rings
As cylindrical grinding technology continues to evolve, 3M has invested • Turbine components and shafts
in the development of a wide variety of high-quality grinding wheels • Steering racks
to remove material faster, at precise tolerances, without damaging the • Fuel injection systems
substrate. We have wheels available for the most popular worm grinding, (pumps, injectors)
form grinding, plunge grinding and transverse grinding machines. • Drive shafts
Type 1
DxTxH
Type 5
3M™ Vitrified CBN wheels
DxTxH For hardened steels from 55 to 70
1 - PxF
Type 1B Type 1C Type 1D Type 1E HRc. Ideal for high-speed automotive
applications – particularly on modern
Type 7 materials that cannot be economically
DxTxH ground with conventional abrasives,
2 - PxF/G
such as powder metallurgical steel
and high-alloy tool steel.
Type 1F Type 1M Type 1N Type 1P
Applications
• Piston pins
• Turbine components
• Valve/valve train
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Microfinishing
A microfinishing process employs 3M™ Microfinishing Film Recommended products
rigid shoes to support the abrasive 3M Microfinishing Film is a fast
film. The workpiece, such as a 3M™ Microfinishing Films
cutting abrasive that can produce
crankshaft or a camshaft, is turned consistent, predictable and 372L, 373L and 272L
and oscillated between centers as repeatable high quality finishes. The
2shoes introduce the abrasive to abrasive particles are electrostatically
the workpiece. Fresh abrasive is oriented, then resin-bonded to a
incrementally indexed after each part polyester film backing to give an
is processed, resulting in uniform aggressive cut with a uniform finish.
stock removal and finish, part after Available in 9–100 micron grades.
part. Microfinishing removes the
damaged or amorphous layers
to improve the surface finish and
roundness of the part.
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3M™ Dressing systems
3M develops and supplies precision dressing systems for all types of grinding machines. Dressing system
quality has a determining influence on the efficiency and economy of the overall grinding process. For this reason,
dressing systems require high-quality components in terms of both stiffness and precision. 3M dressing systems
meet the highest requirements, whether for standard versions or custom built solutions.
Outboard support
dresser spindles
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Flexibility vs. set-up time
In general, every dressing technique
involves a compromise: the more
time spent during set-up, the more
flexibility you have during operation,
and vice-versa.
Less
• Integrated profile
one operation using the plunge-cut
dressing method
• Extreme accuracy, even with highly
complex profile contours
• Highest cost-effectiveness
Vr
Diamond profile roller Full profile diamond roll
• Modules < 1.3
frd • Multi-ribbed
Vsd • Negative electroplating
• Integrated radius dressing and
root radius grinding
Set-Up Time
Grinding wheel
Flexibility
3M™ Diamond Form Dressing Rollers
• Profiling of the grinding wheel along Diamond profile roll
the desired contour by moving the • Independent of module size
diamond dressing roller • Positive electroplating
• Extreme accuracy for simple and • Radius dressing and root radius
grinding not integrated
highly complex profile contours
• Highest cost-effectiveness
Vfa
More
More
VR
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Warranty, Limited Remedy, and Disclaimer: Unless a different warranty is specifically stated on the applicable 3M
product packaging or product literature (in which case such warranty governs), 3M warrants that each 3M product
meets the applicable 3M product specification at the time 3M ships the product. 3M MAKES NO OTHER WARRANTIES
OR CONDITIONS, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OR
CONDITION OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR ARISING OUT OF A COURSE OF
DEALING, CUSTOM, OR USAGE OF TRADE. If a 3M product does not conform to this warranty, then the sole and
exclusive remedy is, at 3M’s option, replacement of the 3M product or refund of the purchase price.
Limitation of Liability: Except for the limited remedy stated above, and except to the extent prohibited by law, 3M will
not be liable for any loss or damage arising from or related to the 3M product, whether direct, indirect, special, incidental,
or consequential (including, but not limited to, lost profits or business opportunity), regardless of the legal or equitable
theory asserted, including, but not limited to, warranty, contract, negligence, or strict liability.