Compared to previous electroplating tools, the Foundry X single-layer grinding wheel from Sain Gobain improves performance, sustainability and safety when machining cast products thanks to a new electroplating bond. This results in lower costs per good part for foundries.

New CNC and robot-assisted systems, which are also attractive for smaller foundries, promise higher production output. At the same time, the demand for higher quality castings is increasing. Andreas Eckhardt, Product Manager at Norton Winter, says: "Against this backdrop, foundries are also focusing on producing in an even more environmentally friendly way while increasing efficiency. To ensure that this is not mutually exclusive, we are now providing them with Foundry X. For example, switching to Foundry X diamond and cBN abrasives not only improves productivity and quality, but also reduces dust pollution by up to ten times."

Electroplated grinding wheels consist of a steel body with a diamond or cBN single layer. The grains are embedded in a special nickel bond. This results in a grinding wheel that is stable in terms of diameter and profile. This eliminates the need to adjust the diameter in the machine program during production. The base body can be resurfaced many times. The new product series with a very hard yet ductile nickel bond was developed to eliminate heat and load problems as productivity and quality-limiting factors in grinding and cutting work. To this end, Norton Winter Foundry X is equipped with high-quality special diamond or cBN grit in high concentrations, which are bonded to the steel base body by electroplated nickel deposition. This allows the grain to protrude more than with multi-layer discs. The new electroplating technology also ensures very good grain retention forces. This is noticeable during automated cell grinding. Foundry X offers a long service life, reduced wheel changes and minimized downtimes. The precise geometry reduces vibrations, and the constant wheel dimensions enable simpler and faster programming. The grit quality is selected according to the component material. The grit size can also be adjusted according to the application. The profile tolerance is 0.05 to 0.15 mm. Thanks to the design advantages and the precise adaptation of the tool to the specific application, the manufacturer can grind or cut cooler and increase stock removal rates.

The switch from conventional grinding wheels to diamond and cBN wheels offers improvements for the environment and safety. The steel body of the grinding wheels prevents the risk of wheel breakage during use. Dust generation is significantly reduced and odors are virtually eliminated.