Our versatile precision grinding machines are workhorses which require a smaller footprint than similar machines yet excel in demanding high production environments where the name of the game is high volume at low cost, with exceptional precision. Glebar engineers can tailor an Aerospace Solution which can offer the customer a machine with intelligence, in-process inspection, ease of use, and mulitple part-per-cycle capability -- maximizing up time and production rates.
Conventional cutting processes use an abrasive chop saw, band saw, lathe cutoff, or shear cutting machine. Each method has its disadvantages. Tooling wears quickly and is expensive, driving up costs.
The material used to manufacture aerospace fasteners is difficult to cut using conventional equipment. Cutting oil is expensive, messy, and creates a hazardous work area. Band saws leave a rough surface finish and inaccurate length tolerance, requiring secondary processing. Cutting bars individually on a lathe is a slow process limiting output per shift. The thickness of the lathe cutoff tools wastes expensive material, generating a high cost per cut. Carbide tooling wears quickly leaving a large burr. The burr gets worse as the tool wears. Shear cutting is very loud and leaves a deformed end. Conventional saws are noisy and have minimal safety features.
Glebar Company’s position in the machine tool industry is driven by its solution orientated leadership and skilled engineering staff. Market studies have indicated a healthy growth cycle in the specialty carbide cutting tool industries especially in the aerospace sector. Glebar identified this opportunity and introduced a new machine platform, the GT-610 EZ Thrufeed Centerless Grinder. This machine was designed specifically for the thru-feed processing of carbide cutting blanks with the intention of meeting a certain price point for that industry.
Narrow grinding wheels are used applying more pressure to the part wearing the wheel out faster. Multiple thrufeed grinds are required occupying skilled operators and accelerating wear on the grinding machine and tooling. Legacy machines are extremely large in comparison to the small diameter of the carbide cutting blanks and take up valuable square footage on the manufacturing floor.
Carbide is one of the hardest metals on Earth, ranging in hardness between 65 and 85 Rc, and after sintering has a rough surface finish and chips easily making it difficult to grind. Deliver a process to grind carbide cutting blanks while maintaining cylindricity of 2 microns over a 4” long part.
The customer was outsourcing grinding of components and came to Glebar looking for a way to reduce lead times on parts, reduce costs, and bring grinding capability in-house.
Original challenge was to thrufeed 1-½” diameter, 15’ aluminum tubes removing 0.003”-0.006” per pass. The second requirement was for the machine to be capable of grinding 8’ steel tubes which featured a 1” diameter bearing surface in the middle of the tube which could not be ground. This meant that the grind would have to begin in the middle of the tube where the machine had to infeed into that section and then initiate a thrufeed process. The part also had a thin wall that had to be maintained and the grinding process had to be controlled to avoid burning.
Challenge: To grind diameters on parts of many sizes and lengths for a manufacturer of aerospace fasteners. The goal was to provide a solution that gave the customer a machine with intelligence, in-process inspection, ease of use and to maximize up time and production rates.
The grinding of stainless-steel shafts used for Hydraulic Spring Lifters was outsourced. This resulted in higher costs, as well as quality and consistency issues.
Deliver an in-house process to automatically grind a high volume of stainless-steel shafts used for Hydraulic Spring Lifters. The process had to remove a large amount of stock and maintain an 8Ra surface finish. The customer requested that the new process be integrated with their existing automation and superfinishing line.
Ideal for grinding components in the aerospace industry, this system excels in a high production environment using a high level of automation, significantly outperforming alternative processes. Configurable with pick/place gantries or six-axis robots, this machine ensures a hands-off, high production or frequent changeover operation with the assurance of automatic size compensation and 100% inspection – giving customers the capability of running millions of titanium fasteners per year, for example, (up to 8 pieces at a time) to micron precision. The machine can run up to 12,000 parts before the need to redress the wheel (on certain components). The in-line gauging system auto-corrects the wheel dress profile by station.
Reflective of other high-performance Glebar machines, the highly configurable and automated GT-610 is another viable option for high-volume aerospace industrial grinding production – able to be fitted with robots, pick-and-place gantries, cleaning and drying stations, laser inspection systems for a hands-off turnkey solution. Ideal for grinding applications that demand ultimate precision such as titanium, Inconel and/ or steel bars and rods, where the challenges of quality, cost control, lead time and cycle time are paramount.
The GT-610 EZ is the newest addition to the GT Series Centerless Grinder suite. A lean version of the GT-610, the GT-610 EZ brings slide motion control to the operator at an affordable price point. Operating on a much smaller footprint than the competition, this system excels at thrufeed grinding hard materials such as steel, carbide, pcd inserts and technical ceramics. Slide positioning allows for precise diameter control on close-tolerance components. The machine is also capable of gauge feedback for even more precise diameter control.
The GT-610M is an affordable, compact, precision centerless thrufeed grinding system, originally designed and built for the machine shop, it can also be adapted to address aerospace component grinding challenges to produce parts such as titanium and/or steel rods. The GT-610M includes independent upper and lower slides, and a blade height ramp system for finite blade adjustment.
The DD-7 is one of the most compact double disc grinding machines on the market. Designed for grinding small diameter components, it accurately controls their length and perpendicularity. In a recent aerospace component case study, composite strip material (insulation) was successfully ground from spool to spool. The machine’s tractor feed extractor and 10” grinding wheels were instrumental in making this happen.
Glebar’s P4K inspection system is ideal choice for inspecting aerospace components in a high-volume production environment such as titanium fasteners. With the push of a button the software can profile the geometric shape and can automatically communicate production results, enabling the most basically skilled operator to measure complex dimensions. The system drastically reduces setup times by scanning all parts in a cycle (all stations) and feeding back diameter length & geometric position adjustments to correct the wheel dress shape automatically in a matter of seconds.
The CS1-A Precision Abrasive Cutoff machine from Tridex Technology features superb accuracy and multiple bar cutting for applications requiring tight tolerances in medical, aerospace, fasteners, and automotive industries. The Precision Abrasive cut leaves almost no burr on the bar or tubing.
The SG-2060 Burr Free Electrochemical CNC Surface Grinder from Tridex Technology provides burr free and low force cutting leaving no heat affected zones while cutting. It has numerous applications across many materials and industries including medical device, automotive, and aerospace.