The Grinding Doc's
High Intensity Grinding Course
11th, 12th & 13th January 2010
Host: Dept. of Mechanical and Manufacturing Engineering in Trinity College
Location: Dublin, Ireland
Instructor: Dr. Jeffrey A. Badger, The Grinding Doc

 
 
 
Schedule
Sunday, 10th January
 
    7:00 PM — 9:00 PM   For those who arrive early, we will have a casual cocktail in the hotel bar.
 
Day 2: Monday, 11th January
 
    8:15 AM — 8:45 AM   Registration
Section A 8:45 AM — 9:30 AM   Introduction of Instructor, attendees, format of course.
Section B 9:30 AM — 10:30 AM   Fundamentals of conventional abrasives. Grinding wheel constituents: grit, bond & porosity; modes of contact: cutting, rubbing & plowing; wheel wear: attritious wear, grit fracture & bond fracture; grinding forces; wear flats & grinding forces; wheel specification: grit types, friable vs. tough, angular vs. blocky, micro- vs. macro-fracture; wheel grade; wheel structure.
Section C 10:45 AM — 11:30 AM   Heat Generation, material-removal rate; "Q-prime"; specific energy; forces & heat generation; heat generation & temperature.
  10:30 AM — 10:45 AM   Coffee Break.
Section D 11:30 AM — 11:45 AM   Measuring Power; process monitoring with The Grindometer.
  11:45 AM — 12:00 PM   Grindometer Demonstration.
  12:00 PM — 1:00 PM   Lunch.
Section E 1:00 PM — 1:05 PM   G-ratio, measurement, relationship to "grindability".
Section F 1:05 PM — 1:20 PM   Wheel wear, The No-Dress Test, How to interpret.
Section G 1:20 PM — 2:00 PM   Thermal damage, the different types, cracking and "Grinding Burn".
Section H 2:00 PM — 2:45 PM   Dressing. Single-point, blade & cluster: calculating dressing lead; effect of lead vs. depth; dressing for roughing vs. finishing. Rotary diamond: speed ratio, effect, how to calculate; plunge rate, effect, how to calculate; dwell time.
  2:45 PM — 3:45 PM   Group Assignment 1: Wheel wear, power, grade, No-Dress, Dressing.
  3:00 PM — 3:15 PM   Coffee Break.
Group Dinner 7:00 PM — 9:00 PM   Group Dinner.
 
Day 2: Tuesday, 12th January
 
    8:30 AM — 8:35 AM   Review of Day 1.
Section I 8:35 AM — 10:05 AM   Cooling. An in-depth session. Pressure vs. velocity, breaking the air barrier, nozzle design, nozzle angle, shoe type, orifice area & flowrate, how to measure, pressure drop, pump power requirements, nozzle sizing; main arc-of-cut cooling vs. cooling to reduce oxidation burn; calculating required pressure, velocity, orifice area & pump size.
  10:05 AM — 10:30 AM   Group Assignment 2: Cooling.
  10:30 AM — 10:45 AM   Coffee Break.
  10:45 AM — 11:45 AM   Group Assignment 3: Cooling.
  11:45 AM — 12:15 PM   Coolant Demonstration outside.
  12:15 PM — 2:15 PM   Open Lunch, 2 hours.
Section J 2:15 PM — 2:50 PM   Fundamentals Superabrasives. Difference in wear of CBN/diamond & aluminum-oxide/SiC; conditioning of wheel during grinding; different grit types; grit nomenclature from DeBeers & GE; optimum wheel speed; effect of grit size & concentration; wheel "sticking"; behavior of electro-plated wheels & differences; grit density.
  2:50 PM — 3:35 PM   Group Assignment 5: Superabrasives.
Section K 3:35 PM — 3:50 PM   Aggressiveness: Choosing correct parameters to find "sweet spot" of wheel.
  3:50 PM — 4:05 PM   Coffee Break.
  4:05 PM — 4:45 PM   Group Assignment 6: Aggressiveness.
  4:45 PM — 5:30 PM   Group Assignment 7: Aggressiveness.
  5:30 PM — 5:40 PM   Summary: Day 1 & Day 2.
  5:40 PM — 6:00 PM   Questions/Answers.
Evening         No scheduled events. Dinner and Guinness at a local Irish pub, visit to a downtown museum, or a quiet night studying and doing homework.
 
Day 3: Wednesday, 13th January
 
    8:30 AM — 8:40 AM   Review of Day 1 & Day 2.
Section L 8:40 AM — 8:55 AM   Loading: different types; chemical reactions; uniqueness of stainless steels; methods to reduce loading.
Section M 8:55 AM — 9:10 AM   Burr: causes; how to reduce it.
Section N 9:10 AM — 9:25 AM   Chatter: Two types, forced & unforced; origins, how to pinpoint; how to reduce/eliminate.
Section O 9:25 AM — 9:45 AM   Ceramic Abrasives: How they're different; how they fracture; how to find the "sweet spot" for ceramic abrasives; Cubitron vs. Norton SG; when to use them; economics.
  9:45 AM — 10:30 AM   Group Assignment 8: Ceramic Abrasives.
  10:30 AM — 10:50 AM   Coffee Break.
Section P 10:50 AM — 11:25 AM   The Mountain of Burn. Understanding the speeds & feeds that give lowest temperatures and lowest risk of burn.
Section Q 11:25 AM — 11:35 AM   Grinding parameters and interdependency. How to choose wheel speed, workspeed, depth of cut for achieving less wheel wear, better self-sharpening, a better surface; up-grinding vs. climb-grinding.
Section R 11:35 AM — 12:00 PM   Cycle Mapping: A tool to analyze an entire process, gain an understanding of it and then develop strategies to improve it, usually in reducing cycle times.
  12:00 PM — 1:00 PM   Lunch.
  1:00 PM — 2:15 PM   Group Assignment 9: Cycle Mapping.
Section S 2:15 PM — 2:45 PM   Continuous-dress grinding: plunge rate vs. power; reducing wheel consumption.
  2:45 PM — 3:00 PM   Coffee Break.
Section T 3:00 PM — 3:15 PM   Cost-savings in grinding. Where to focus your energies.
Section U 3:15 PM — 3:30 PM   New developments in grinding. the latest high-tech developments; how practical are they; will they make it to real production.
  3:30 PM — 3:45 PM   Summary: Day 1, Day 2 & Day 3.
Section V 3:45 PM — 4:15 PM   Final: Where to from here?
  4:15 PM — 4:30 PM   Questions/Answers. End of the course.
 
Subjects Not Covered in the Course but Given in the Course Material:
 
  Section A Literature on Grinding
  Section B The Grinder's Toolbox
  Section C Up-grinding vs. down-grinding
  Section D Tungsten-Carbide Grinding
  Section E Cylidrical, ID & OD Grinding
  Section F Grindability, G-ratio & Carbide Size in HSS
  Section G Surface finish & its effect on tool performance. Extensive section; surface finish, scratch direction, scratch depth, maximum carbide or defect size, Ra values, effect on tool fracture. Threshold on improved Ra values leading to better tool impact resistance.
  Section H Temperature Models
  Section I Typical Trends
  Section J Continuous-dress Creep-feed Grinding
  Section K Intro to Grinding of Ceramics
  Section L The World's Greatest Grinders
  Section M Miscellaneous Reference Material
  Section N List of All Equations
 
Optional Day 4: Thursday, 14th January
 
    I will be holding optional sessions on the following specific topics:
 
    9:00 AM — 10:30 AM   Grinding of aerospace materials – Inconels and continuous-dress creep-feed grinding.
    11:00 AM — 12:30 PM   Tungsten-carbide grinding.
    2:00 PM — 3:30 PM   Cylindrical grinding.

 
 
 
Cost
Meals included as listed in schedule, hotel & transporation not included.
  before 5th January 2010 after 5th January 2010
  1 attendee €1800 €1900
  2 attendees €1700 each €1800 each
  3+ attendees €1600 each €1700 each

 
 
 
Who Should Take the High Intensity Grinding Course:
  • People who already have some experience and knowledge in grinding.
  • People grinding steels, high-speed steels, carbide, nickel-based alloys and other metals.
  • People who want to develop an in-depth understanding of grinding from the ground up.
Examples of people who have taken the course:
  • A machine operator wanting to improve productivity and quality and reduce grinding costs.
  • A salesperson selling conventional and superabrasive grinding wheels.
  • An engineer at a coolant company wanting to better understand coolant application and his customers' grinding needs.
  • Manufacturer of solid-carbide cutting tools wanting to reduce cycle times.
  • Engineer at a machine shop grinding a bit of everything.
  • Engineer at a company producing aircraft components in nickel-based alloys.
  • Machine operator regrinding turbine blades.

 
 
 
Who Should NOT Take the High Intensity Grinding Course:
  • People who want a light overview of grinding. The Intense Course is for those who want an in-depth understanding of grinding from top to bottom
  • People with absolutely no grinding experience or knowledge.
  • People grinding only ceramics or aluminum.
  • People using only coated abrasives, or looking for information on honing, lapping, polishing or abrasive-jet machining.

 
 
 
Requirements:
  • You will be expected to take part in group discussions.
  • You must be capable of reading simple graphs and charts.
  • You must be capable of doing simple math and understanding basic equations.

 
 
 
Dublin, Ireland:
    Trinity College is located in the center of Dublin, a fun town known for its pubs, music, people and history. Attendees are encouraged to stretch their time over an adjoining weekend.

 
 
 
Dr. Jeffrey Badger’s Biography:
  • B.S. in Mechanical Engineering from the University of Texas at Austin
  • M.S. in Mechanical Engineering from Penn State University
  • Ph.D. in Mechanical Engineering from Trinity College, Dublin Ireland with a specialization in grinding
  • Has worked for numerous companies around the world in grinding, including the U.S., England, Ireland, Sweden, Spain, Germany, Italy, Switzerland, Poland, Czech Republic, Bulgaria, India, Brazil, Australia, New Zealand, Thailand, Israel, Japan and Korea
  • Author of question/answer column “Ask The Grinding Doc” in the American magazine Cutting Tool Engineering
  • Works “in the trenches” (as opposed to in the lab) and has a practical, down-to-earth understanding of grinding
  • Emphasizes practice over theory
  • Is well known for his practical and useful seminars and educational courses in grinding
    Dr. Badger takes the "mystery" out of grinding and breaks the grinding process into a step-by-step form that can be applied to a continuous improvement program. With this newly acquired knowledge, we have already started to implement lessons learned from his presentation.

    Manufacturer of valves, Texas

 
 
 
Location:
The host for this course is Trinity College, which lies right in the center of Dublin.

Previous hosts have been Rollomatic in Chicago, IL USA; Blaser Swisslube in Hasle-Rόegsau, Switzerland; Erasteel in Paris, France; the Indian Institute of Technology in Madras/Chennai, India; and Greelee Diamond Tool in Chicago, IL USA. If you are interested in hosting a course, contact Dr. Badger. Requirements: a conference room, good facilities, and a central location.

 
 
 
Accommodation:
Trinity Capital Hotel//Pearse St.//Dublin 2, Ireland// Tel +353 1 648 1221 //Fax +353 1 6481222//special rate of €59 per night; kingsize room: €74; executive room: €84 //quote The Grinding Doc’s Grinding Course// Irish breakfast: €15, Continental: €13. Guests are responsible for making their own travel arrangements. Reduced rate applies for those who want to come sooner or stay later for sightseeing//booking available after December 30, prior to December 30 email Lisa Maloney at info@capital-hotels.com.

 
 
 
FAQ:
Q:     Why should I attend your course and not somebody else’s?
A:     My course is practical and down to earth. You won’t get any fancy formulas or obscure grinding theory. You’ll come away with a no-nonsense, practical understanding of grinding. You'll also learn useful tools to help you analyze a grinding process. What’s more, I have nothing to promote and nothing to sell. You’ll hear about grinding, not about how great my company’s products are.
 
Q:     Any other reason?
A:     Yes, included in the course is the 1000-page course material. You will use this material long after the course is over. It contains useful reference information such as how to choose dressing parameters (dwell time, feed rates, etc.), tables showing the correct coolant pressure for a given wheel velocity, required pump power, the correct grit size for a required surface finish, the correct grit size for a given corner radius or thread pitch, etc.
 
Q:     Will I get bored in the course?
A:     This course is not for those who want to sit back and passively receive information. A large portion of the course is Group Assignments and Brainstorming Sessions, where you analyze a process in-depth. It's taxing to the brain. By the end of the day, you won't be bored, you'll be mentally fatigued.
 
Q:     Should I bring my wife/husband/girlfriend/boyfriend/Children?
A:     Yes. Dublin is a fun and interesting town. There's lots for them to do while you're plugging away in the course.
 
Q:     Do I have to come to Dublin, or can you do this course at my facility?
A:     Yes, I can do this course at your facility. Give me a call.
 
Q:     I can't come to the course. May I buy the course material?
A:     Yes, it is available for €1900. You can order it via credit card below or email me for other arrangements. However, you will get far more out of it if you attend the course.
 
Q:     What have previous attendees said about the course?
A:     Some quotes from the last two courses.
    This is the best technical course I have ever taken, in any subject. It is very practical without getting too scientific.

    Boris — grinder of aircraft engines

    The Doc's course gave me an entirely new way to look at things.

    Jim — grinder of solid-carbide tools

    Far better than the grinding seminar took at the grinding-wheel company.

    Andy — Cylindrical Grinder

    The thing that I liked best about the Grinding Doc seminar was that you did not present yourself to us as a PhD. You understand that the people that you are teaching know their business and know about grinding. What you try to get through to us is your deep understanding of the grinding process itself, and how having a clearer vision of just how the process works at the level of the grit and the grain will help us to make better practical decisions on the shop floor. I have already employed some of the concepts from the course in our shop, and anticipate using many more in the coming months. This was a great course for learning practical grinding information – the only one that I have seen to this point.

    John Shegda — M&S Centerless Grinding

 
 
 
Signing Up
To sign up, you need to (1) download the registration form and email it back to me, and (2) pay.

You can pay either by (1) check: follow the instruction on the registration form; or (2) Credit Card: click on the box below.