Pre-sintered or green ceramics are brittle materials requiring manufacturers to use precise and delicate processes to ensure the parts maintain their structural integrity. A manufacturer’s legacy equipment was breaking the ceramic shafts which increased scrap rates. Glebar partnered with the manufacturer to deliver a new process that integrated with their existing isostatic press. The process had to accurately handle and grind the shafts without any chipping or breaking.
Glebar delivered a fully automated PG-9DHD Centerless Form Grinder which is an adaptation of the Glebar workhorse, the PG-9BHD. Similar in basic functional configuration as the BHD machine, the DHD is a high precision version. With its 10-in. wheel, this form grinder is capable of multiple-part-per cycle grinding, also offering slide positions and controllability not achievable on the more basic PLC driven unit.
For this application, the PG-9DHD was equipped with a 6-axis robot, inspection camera station, cleated conveyor, and gantry. The 6-axis robot sensed and transferred six ceramic shafts from the press onto the cleated conveyor. Then the shafts passed through a camera station to ensure that they were defect-free. Lastly, the gantry fed and removed two shafts from the grinder, reducing scrap and maximizing productivity.
The PG-9DHD removed 0.040 in. of stock material, 0.020 in. per side, while maintaining a tolerance of +/- 0.001 in. By grinding two shafts every six seconds, the grinder was able to keep up with the ceramic press.
For operator safety and to achieve CE Certification, this PG-9DHD featured an enclosed grinding area and robot station.
Glebar’s unique Form grinding process can shape any spherical or cylindrical component into unlimited forms on a large variety of materials. This highly productive method of manufacturing surpasses competing methods where cutting tools or back knives are used. When automated, this machine’s productivity and performance is nearly impossible to surpass. Glebar machines can grind most hard to turn materials such as carbon fiber, fiberglass (including G10), Teflon, Santoprene, and polypropylene.