Due to the design advantages of the single-layer Aeon grinding tools, it is possible to economically replace competing machining processes, such as turning, with new machine concepts in large-scale production. This is demonstrated by the example of "Dressing-free high-speed plunge-cut grinding of valve needles for injection nozzles". The Norton-Winter-Aeon technology aims to improve process stability, reduce manufacturing costs and increase machine availability by combining advanced electroplating technology for the electrolytic deposition of a high-strength yet ductile nickel bond with cBN or diamond grain specifications. Andreas Eckhardt, Product Manager Direct Plated Products Superabrasives at Saint-Gobain Abrasives: "Thanks to the targeted engineering, the Aeon tool with its large chip spaces can be optimally adapted to special process requirements in terms of specification, geometry, structure and post-treatment, for example in terms of holding force, hardness and toughness of the nickel bond."

Aeon abrasive tools have very high grit retention forces, which enable large grit protrusions. Among other things, this results in high wear resistance even in heavily loaded zones and long tool life even at high stock removal rates. Due to their very uniform coating thickness, Aeon cBN and diamond tools have constant, high-precision profile and dimensional accuracy without deviation from the nominal dimension as well as very good surface quality with consistently high cutting performance.

Eckhardt says: "The profile tolerance, even for large tools weighing up to 250 kg, is ±5 μm. The high quality and hardness of the base body of Aeon superabrasives also enables multiple reapplications without any loss of quality. As the abrasives are not dressed, cost-intensive non-productive times are eliminated and no dressing unit is required on the grinding machine."

Innovative machine technology

These advantages make Aeon grinding tools suitable for exploiting the performance of modern grinding systems - such as those from Erwin Junker Maschinenfabrik in Nordrach - even when grinding nozzles, needles, pistons, valve bodies or roller bearings from materials that are difficult to machine. With the Grindstar, the specialist in the field of cBN grinding provides a machine concept that replaces turning with dressing-free high-speed plunge-cut grinding. This enables high savings potentials to be realized, particularly in the machining of large series with cBN or with diamond as the abrasive.

Eckhardt: "Complete machining in one machine significantly reduces process risks and downtimes. The production of slug-free parts is 100 percent guaranteed. Convex or flat end faces can also be produced. And even difficult-to-machine materials that previously could not be turned can be machined. Soft and hard machining is also possible." The Grindstar is equipped with a new type of coolant technology that enables long tool life. Machine availability is over 96 percent. am