Glebar (www.Glebar.com) has developed a centerless grinding process on its GT 610 CNC for automotive manufacturers that expedites the development process of fuel injector nozzle valves, leading to reduced tooling costs, lower inventory levels and quicker integration of new technology for prototyping or proof of concept for a new component.
The centerless grinding development process for manufacturing a fuel injector nozzle valve can be an arduous task sometimes incorporating up to 20 critical dimensions, all of which need to be centerless ground. Glebar’s process increases the efficiency of the centerless grinding prototyping process by using a single disk CVD dress roller as part of its grinding system with the full CNC work wheel dressing.
“Glebar’s CNC dressing system, running on our GT 610 CNC machine platform, has sub-micron positional accuracy which allows intricate forms to be dressed into the work wheel to generate critical dimensions required in the manufacture of the fuel injector nozzle,” said Sean Riess, senior applications engineer, Glebar Company. “By utilizing a single disk roller, this allows the end user to generate a multitude of profiles using one roller rather than being required to purchase a reverse-plated roller for every different profile when generating a proof of concept. This leads to shorter lead times and reduced inventory and initial tooling costs in development projects.”
As part of the Glebar solution for advancing the development processes for fuel injection nozzle valves, the company offers its P4K non-contact measurement system as an essential set up and inspection tool. Adjustments are made from the P4K by feeding back radii, steps, diameters and angle measurement to automatically adjust the wheel shape (the company has filed for a patent on correcting the wheel shape) via the CNC dressing system. The utilization of the off-line gauge eliminates trace measurement systems as well as optical comparators. All of the interface software is custom generated internally to feedback to the machine for infinite wheel shapes.
“Historically, project development lead times for ground components of finished ground fuel injector nozzle valves can take upwards of 16 weeks to complete,” said Riess. “This is due to the extremely long lead time of a reverse-plated dressing wheel which can be very accurate, but an expensive tooling cost when proving out a component concept. With Glebar’s single roller solution, the need for reverse plated wheels is eliminated, resulting in tremendous cost savings.
The Glebar GT 610 CNC will be exhibited at the International Manufacturing Technology Show in Chicago beginning on September 12 in booth N7317.