Grinding Solutions For Automotive Engine Manufacturing Processes

Kaiser is lower than that of the traditional product, which shows that the cutting ability isGrinding Solution: Cam lobe Grinding

improved. In addition, Fig. 4 compares the grinding results between Sharp Kaiser and thetraditional product when grinding with equivalent power consumption. After dressing bothwheels so that they each produce the same quality, the Sharp Kaizer had held It’s surface ﬁnish

In order for an engine to achieve high power output andFig. 1 Outline of Cam lobe grinding

low fuel consumption, the cam’s concave proﬁle isby 1.9 times longer, and the roundness by 2.9 times longer than the traditional product. The
surface roughness is 12% ﬁner and the residual stress is 75% lower, thus improving the overallbecoming more crucial. Grinding issues, such as grinding

workpiece quality. Sharp Kaizer is able to achieve such long life because of the improved bondcracks and residual stress, are more likely to occur

structure uniformity and the improved cutting ability due to its higher grain protrusion (Fig. 5). In

compared to traditional shapes. In addition, materials that

other case studies, not only does the Sharp Kaizer improve the work ﬁnish quality and reduce

have high strength and toughness, such as ductile cast iron,scratches, but it also increased it’s dressing interval by 1.5 to 2 times compared to the traditional

will be more difﬁcult to grind compared to the gray castproduct.

iron because of the high heat buildup. This issue will lead
into the problem mentioned previously, which will be prone
Fig. 4 Test results

there will be more frequent wheel changes. This will lead to production loss, and end up
wheel for cam lobe grinding that has both high cutting ability and long wheel life. Noritake
would like to introduce Sharp Kaizer as the Vitriﬁed bonded CBN wheel suited for such cam lobe
grinding.

100

Power consumption(index)increasing the cost per part, due to machine down time. We would need to look into a CBN

40080604020Sharp Kaiser (Vitriﬁed-bond CBN wheel)
Feature: Good balance between cutting ability andshows the power consumption of the Sharp Kaiser and thetraditional products. The power consumption of the Sharp

Fig. 3 Power Consumption[Grinding conditions]

Speciﬁcations

CBX140-V

Grinding method

Dimensions

ø350×T35×ø20mm

Grinding wheel speed 140m/s

Dresser

Rotary dresser (SD30)

Coolant

Water base coolant

100Power consumption(index)

FCD700110mm3/mm • s

120

75% reduction

30% improvement10080808060400604040

20200
Traditional product Sharp Kaiser

600
Traditional product Sharp Kaiser

Traditional product Sharp Kaiser

120Cam lobe grinding

Grinding efﬁciency

Traditional product Sharp Kaiser

100

20Table 1 Test conditions

100100Residual stress(index)

Surface roughness(index)carried out under the test conditions in Table 1. Fig. 3

2000120

12% ﬁner

The cam lobe grinding test of ductile cast iron material wasMaterial

100

2.9 times
300

Traditional product Sharp Kaiser

120

increased grain protrusion.

[Workpiece]

1.9 times
200

Traditional product Sharp Kaiser

wheel life due to the homogeneous structure and[Grinding wheel]

300

00Fig. 2 Sharp Kaiser

400

Estimated dressing interval
besed on straightness(index)

120

Straightness(index)ability is favorable. But these types of wheels tends to have a short wheel life, which means

Estimated dressing interval basedon surface roughness(index)

to occur more easily. In these types of applications, utilizing a CBN wheel with a high cutting

11% reduction

Fig. 5 Abrasive grain protrusion condition on grinding wheel surface

8060High40
200Low

Traditional product Sharp Kaiser

11

Traditional productSharp Kaiser

12