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
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Schedule
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| Sunday, 10th January |
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7:00 PM |
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9:00 PM |
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For those who arrive early, we will
have a casual cocktail in the hotel bar. |
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| Day 2: Monday, 11th January |
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8:15 AM |
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8:45 AM |
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Registration |
| Section A |
8:45 AM |
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9:30 AM |
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Introduction of Instructor, attendees, format of
course. |
| Section B |
9:30 AM |
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10:30 AM |
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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 |
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11:30 AM |
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Heat Generation, material-removal rate; "Q-prime";
specific energy; forces & heat generation; heat generation &
temperature. |
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10:30 AM |
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10:45 AM |
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Coffee Break. |
| Section D |
11:30 AM |
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11:45 AM |
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Measuring Power; process monitoring with The
Grindometer. |
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11:45 AM |
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12:00 PM |
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Grindometer
Demonstration. |
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12:00 PM |
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1:00 PM |
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Lunch. |
| Section E |
1:00 PM |
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1:05 PM |
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G-ratio, measurement, relationship to
"grindability". |
| Section F |
1:05 PM |
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1:20 PM |
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Wheel wear, The No-Dress Test, How to
interpret. |
| Section G |
1:20 PM |
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2:00 PM |
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Thermal damage, the different types, cracking and
"Grinding Burn". |
| Section H |
2:00 PM |
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2:45 PM |
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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. |
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2:45 PM |
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3:45 PM |
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Group Assignment 1: Wheel wear,
power, grade, No-Dress, Dressing. |
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3:00 PM |
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3:15 PM |
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Coffee Break. |
| Group Dinner |
7:00 PM |
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9:00 PM |
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Group Dinner. |
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| Day 2: Tuesday, 12th January |
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8:30 AM |
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8:35 AM |
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Review of Day 1. |
| Section I |
8:35 AM |
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10:05 AM |
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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. |
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10:05 AM |
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10:30 AM |
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Group Assignment 2:
Cooling. |
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10:30 AM |
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10:45 AM |
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Coffee Break. |
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10:45 AM |
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11:45 AM |
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Group Assignment 3:
Cooling. |
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11:45 AM |
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12:15 PM |
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Coolant Demonstration
outside. |
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12:15 PM |
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2:15 PM |
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Open Lunch, 2 hours. |
| Section J |
2:15 PM |
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2:50 PM |
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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. |
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2:50 PM |
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3:35 PM |
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Group Assignment 5:
Superabrasives. |
| Section K |
3:35 PM |
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3:50 PM |
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Aggressiveness: Choosing correct parameters to find
"sweet spot" of wheel. |
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3:50 PM |
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4:05 PM |
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Coffee Break. |
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4:05 PM |
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4:45 PM |
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Group Assignment 6:
Aggressiveness. |
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4:45 PM |
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5:30 PM |
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Group Assignment 7:
Aggressiveness. |
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5:30 PM |
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5:40 PM |
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Summary: Day 1 & Day 2. |
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5:40 PM |
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6:00 PM |
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Questions/Answers. |
| Evening |
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No scheduled events. Dinner and Guinness at a local Irish pub, visit to a downtown museum, or a quiet night studying and doing homework. |
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| Day 3: Wednesday, 13th January |
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8:30 AM |
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8:40 AM |
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Review of Day 1 & Day 2. |
| Section L |
8:40 AM |
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8:55 AM |
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Loading: different types; chemical reactions;
uniqueness of stainless steels; methods to reduce loading. |
| Section M |
8:55 AM |
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9:10 AM |
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Burr: causes; how to reduce it. |
| Section N |
9:10 AM |
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9:25 AM |
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Chatter: Two types, forced & unforced; origins,
how to pinpoint; how to reduce/eliminate. |
| Section O |
9:25 AM |
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9:45 AM |
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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. |
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9:45 AM |
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10:30 AM |
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Group Assignment 8: Ceramic
Abrasives. |
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10:30 AM |
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10:50 AM |
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Coffee Break. |
| Section P |
10:50 AM |
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11:25 AM |
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The Mountain of Burn. Understanding the speeds &
feeds that give lowest temperatures and lowest risk of burn. |
| Section Q |
11:25 AM |
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11:35 AM |
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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 |
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12:00 PM |
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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. |
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12:00 PM |
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1:00 PM |
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Lunch. |
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1:00 PM |
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2:15 PM |
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Group Assignment 9: Cycle
Mapping. |
| Section S |
2:15 PM |
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2:45 PM |
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Continuous-dress grinding: plunge rate vs. power;
reducing wheel consumption. |
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2:45 PM |
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3:00 PM |
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Coffee Break. |
| Section T |
3:00 PM |
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3:15 PM |
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Cost-savings in grinding. Where to focus your
energies. |
| Section U |
3:15 PM |
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3:30 PM |
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New developments in grinding. the latest high-tech
developments; how practical are they; will they make it to real
production. |
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3:30 PM |
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3:45 PM |
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Summary: Day 1, Day 2 & Day 3. |
| Section V |
3:45 PM |
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4:15 PM |
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Final: Where to from here? |
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4:15 PM |
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4:30 PM |
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Questions/Answers. End of the course. |
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| Subjects Not Covered in the Course but
Given in the Course Material: |
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Section A |
Literature on Grinding |
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Section B |
The Grinder's Toolbox |
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Section C |
Up-grinding vs. down-grinding |
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Section D |
Tungsten-Carbide Grinding |
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Section E |
Cylidrical, ID & OD Grinding |
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Section F |
Grindability, G-ratio & Carbide Size in
HSS |
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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. |
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Section H |
Temperature Models |
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Section I |
Typical Trends |
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Section J |
Continuous-dress Creep-feed Grinding |
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Section K |
Intro to Grinding of Ceramics |
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Section L |
The World's Greatest Grinders |
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Section M |
Miscellaneous Reference Material |
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Section N |
List of All Equations |
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| Optional Day 4: Thursday, 14th January |
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I will be holding optional sessions on the following specific topics: |
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9:00 AM |
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10:30 AM |
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Grinding of aerospace materials Inconels and continuous-dress creep-feed grinding. |
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11:00 AM |
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12:30 PM |
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Tungsten-carbide grinding. |
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2:00 PM |
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3:30 PM |
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Cylindrical grinding. |
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Cost
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| Meals included as listed in schedule,
hotel & transporation not included. |
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before 5th January 2010 |
after 5th January 2010 |
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1 attendee |
1800 |
1900 |
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2 attendees |
1700 each |
1800 each |
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3+ attendees |
1600 each |
1700 each |
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Who Should Take the High Intensity
Grinding Course:
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- 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.
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Who Should NOT Take the High Intensity
Grinding Course:
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- 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.
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Requirements:
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- 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.
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Dublin, Ireland:
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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.
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Dr. Jeffrey Badgers Biography:
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- 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 |
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Location:
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| 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.
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Accommodation:
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| 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 Docs 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.
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FAQ:
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| Q: |
Why should I attend your course and not somebody
elses?
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My course is practical and down to earth. You wont
get any fancy formulas or obscure grinding theory. Youll come away
with a no-nonsense, practical understanding of grinding. You'll also
learn useful tools to help you analyze a grinding process. Whats
more, I have nothing to promote and nothing to sell. Youll hear
about grinding, not about how great my companys products are.
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Any other reason?
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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.
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| Q: |
Will I get bored in the course?
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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. |
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| Q: |
Should I bring my
wife/husband/girlfriend/boyfriend/Children?
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| A: |
Yes. Dublin is a fun and interesting town. There's lots for them to do while you're plugging away in the course. |
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| Q: |
Do I have to come to Dublin, or can you do this
course at my facility?
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| A: |
Yes, I can do this course at your facility. Give me a
call. |
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| Q: |
I can't come to the course. May I buy the course
material?
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| 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. |
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| Q: |
What have previous attendees said about the
course?
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| A: |
Some quotes from the last two courses.
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