Our precision centerless grinding machines are used to manufacture bone pins, anchors, arthroscopic shavers, and numerous other implants and instruments required in the surgical repair of sports injuries such as joint repairs, bone fractures, and torn soft tissue. Our centerless grinders consume minimal footprint in your factory and deliver a precision product at high volumes and low cost.
Our electrochemical grinding (ECG) machines from Tridex Technology are used to manufacture burr-free tubes, arthroscopic shaver teeth, castle nuts, and numerous other applications that require an accurate, burr-free grind that leaves no recast or heat-affected zones. Our Point Grinding System from Tridex is used to manufacture a wide variety of medical device points on tubing or solid wire using electrochemical grinding technology (ECG).
Our versatile precision centerless grinders 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. Glebar engineers can turnkey a precision centerless grinder, complete with a series of pre- and post-grind inspection steps, ensuring the product going into the Glebar grinder meets the requirements of the final ground product with guaranteed accuracy.
Wheel balancing is crucial to achieving a good surface finish on the workpiece and is critical to the spindle bearing life. A technician balances the wheel using an offline, static system manually moving weights. The process is time-consuming, taking 30 to 45 minutes, delaying setup and production. The results are varied and not repeatable.
Significantly reduce setup time, changeover time, and the variability of results driven by manual wheel balancing.
Machines that run on outdated operating systems such as Windows XP or Windows 7 are more vulnerable to malware, viruses, and other security issues. Microsoft no longer supports previous versions of Windows making it difficult to fix operating system related issues generating more downtime until a solution is found.
Deliver a solution that allows legacy machines to be protected from security threats and allows for easier technical support.
Biopsy needle notches are machined using milling, conventional abrasive grinding, or wire EDM.
Exposing the material to high heat can affect the chemistry and mechanical properties of the material requiring manual secondary finishing operations. Setup and production are slow, requiring extensive mechanical adjustments. Frequent wheel dressing causes faster wearing, resulting in higher tooling costs.
Kirschner wires, also commonly known as K-wires, are ground using a manual OD grinder.
Low production output, as only one wire can be ground at a time. Changeover between wire diameters is time-consuming, delaying production. Grinding can leave burrs requiring secondary processes to deburr, lengthening production time.
The melamine fuse bodies are ground using a legacy hydraulically operated centerless form grinder. Decades of use have prompted customers to replace existing machines with newer versions.
Simplify the setup process and create a consistent operation. Ensure that the OD dimensions of the melamine fuse bodies are uniform and within the allowed tolerance.
Castle Nuts, also referred to as Castellated Nuts, are used for applications in aerospace and automotive markets where the nut cannot loosen. A cotter pin or safety wire is inserted through a cross-drilled bolt extending through the opposing slots to mechanically prevent the nut from loosening. Without the Castle Nut, the nut would separate from its shaft potentially leading to catastrophic results.
Slotting Saws, Abrasive Grinders, Wire EDM, and Sinker EDM are popular mechanical and abrasive processes used for slotting Castle Nuts. The slotting operation requires three cuts per part, cutting two slots per pass. Parts are loaded manually.
Typical saws and grinding processes require frequent wheel dressing or saw changing, dramatically reducing productivity and throughput. Current manufacturing processes can distort the slot, damage the thread, or deform the thread. Secondary deburring or re-tapping is often required after slotting. This results in increased scrap rates, increased cycle times, and reduced throughput.
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.
Manufacturers use grinding machines with a narrow work wheel requiring several passes to reduce the diameter and achieve acceptable surface finish. Thus creating longer cycle times. Machines are difficult to adjust for setup and changeovers requiring highly skilled technicians. Heavy material removal in a short distance deforms thin walled tubing and causes burns.
Deliver a process with a small footprint that can grind tubes while maintaining a high quality part. Decrease downtime related to maintenance, troubleshooting, and complicated changeovers.
Challenge: Customer wants to increase output for steel taps used to drill threaded holes as used in the machining and tooling industry. In addition to speeding up the throughput time, achieving the exact tolerances is critical for the component to create the proper threads.
Glebar’s Applications Division conducts research and development of innovative cutoff and grinding technology. Their most recent focus was to innovate the existing design of our PG-9 series of Centerless Plunge Grinding Machines. The goal was to help customers reduce setup times, increase throughput, and maintain tighter tolerances.
Current Process: Lathes and Hydraulic Form Grinders
In order to shape spherical and cylindrical parts, manufacturers rely on lathes and hydraulically powered form grinders.
Challenges: Complicated Setup, Inconsistent and Slow Process, Manual Operation, and Open Work Environment
Lathes form parts from bar stock one at a time limiting throughput. The setup for a lathe is complicated and labor-intensive requiring a skilled technician. The cutting process relies on a skilled operator working the different gears and levers to bring the cutting tool closer or further from the part affecting the tolerance. With several manually controlled parts, the setup and cutting processes are difficult to replicate, creating inconsistent surface finishes. The open, high-speed cutting environment and manual operation increase the potential of operator injury.
While hydraulically powered form grinders can produce multiple parts per cycle, they too rely on skilled technicians for setup. Several microswitches must be configured to set the grinding sequence. As the hydraulic system warms up, the speed of the regulating wheel fluctuates, making it difficult to control the tolerances. The grinding cell of most hydraulic form grinders is exposed, raising the risk of potential operator injury.
Manufacturers use lapping machines which are unable to hold consistent tolerances or capacity, creating inconsistent surface finishes and longer cycle times.
Provide a form grinding solution for 1" and 1.4" deodorant balls while meeting the customer's cycle time and surface finish requirements.
Zirconium tubes are cut one at a time using carbide tools on a lathe. A lathe cutoff leaves burrs requiring deburring to achieve a smooth surface finish. Carbide tooling wears quickly when cutting zirconium and is expensive.
Deliver a cost-effective process to cut zirconium tubes which reduces the number of steps in production. Zirconium is highly flammable, and a dull carbide tool can cause the material to overheat and catch fire. Zirconium fires are dangerous and very hard to extinguish.
Challenge: To process carbide and polycrystalline diamond with complete automation, conserving grinding wheels and using little power, all on a machine within a small footprint
The DM-9CNC Wheel Dressing Machine allows a grinding wheel to be contour dressed offline using a fully programmable single diamond or rotary diamond roll. Having the ability to dress wheels offline allows the wheels to be ready for production, reducing setup time and improving machine efficiency.
The wheel is dressed on the grinding machine during setup or using a manually held contour dresser. Contour dressers require a skilled operator who moves a stylus along a metal template of the ball form as a single point diamond removes material from the wheel.
Dressing the wheel on the grinder reduces OEE and increases setup time, delaying production. Manual Template Tracing is operator dependent and inconsistent, which affects the quality of the grind, increases scrap rates, and requires more frequent dressing which shortens the life of the wheel. Deliver a process to dress the work wheel for a 1" diameter ball. The process has to improve OEE, reduce setup time, and improve consistency.
The balls are formed one at a time from bar stock on a lathe in multiple roughing and finishing tool paths. Molded balls are purchased from a contract manufacturer, then turned to achieve the desired diameter and to remove mold imperfections such as parting lines.
Purchasing the balls can be expensive, and long lead times create a need for increased inventory levels and consumption of cash. Turning can be slow and inconsistent, resulting in long cycle times, high scrap rates, and surface finishes that generally require downstream grinding or honing to meet specifications.