Jeffrey A. Badger, Ph.D.

The Grinding Doc's
High Intensity Grinding Course
3rd, 4th & 5th June 2008
Rollomatic Conference Room
Mundelein, Illinois   USA
Instructor: Dr. Jeffrey A. Badger (a.k.a. The Grinding Doc)

Schedule    Cost    Instructor    Location    Accommodation    Travel    FAQ    Signing Up

 
 
 
Schedule
Monday, 2nd June
 
    7:00 PM — 9:00 PM   For those who arrive early, we will have a casual cocktail in the hotel bar.
 
Day 1: Tuesday, 3rd June
 
    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: Wednesday, 4th June
 
    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, on your own at any downtown restaurants.
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.
 
Day 3: Thursday, 5th June
 
    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.
 
 
Optional Day 4: Friday, 6th June
 
    For those who are staying an extra day, you can schedule an individual, one-hour one-on-one session with me to discuss specific issues or particularly problems you are facing in production. On your registration sheet note time you would prefer. If it is for a specific problem, please email me beforehand as many details about the process as possible.
 
    8:00 AM — 9:00 AM   Individual session Slot 1.
    9:00 AM — 10:00 AM   Individual session Slot 2.
    10:00 AM — 11:00 AM   Individual session Slot 3.
    11:00 AM — 12:00 PM   Individual session Slot 4.
    1:00 PM — 2:00 PM   Individual session Slot 5.
    2:00 PM — 3:00 PM   Individual session Slot 6.
    3:00 PM — 4:00 PM   Individual session Slot 7.
    4:00 PM — 5:00 PM   Individual session Slot 8.

 
 
 
The Course Material
Each attendee will receive a large binder containing the 1500-page course material. In addition to the subjects covered in the course, the course material covers numerous other grinding-related subjects, including numerous group exercises, along with The Grinder's Toolbox on CD. All together, it represents around 120 hours of in-depth grinding education. You will use this material long after the course is over.

 
 
 
The Grinder's Toolbox
Each attendee will receive on CD a copy of The Grinder's Toolbox, a practical, easy-to-use spreadsheet/computer program that helps you calculate optimum dressing parameters, optimum grinding parameters, coolant flowrates, velocities, pump sizes out nozzle sizes and numerous other things. After the course you will put The Grinder's Toolbox on your computer Windows desktop and use it frequently.

 
 
 
Cost
Meals included as listed in schedule, hotel & transporation not included.
  before May 1st, 2008 after May 1st, 2008
  1 attendee $1775 $1875
  2 attendees $1675 each $1775 each
  3+ attendees $1575 each $1675 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:
  • Machine operators wanting to improve productivity and quality and reduce grinding costs.
  • Salespersons selling conventional and superabrasive grinding wheels.
  • An engineer at a coolant company wanting to better understand coolant application and his customers' grinding needs.
  • Manufacturers of solid-carbide cutting tools wanting to reduce cycle times.
  • Engineers at machine shops grinding a bit of everything.
  • Engineers at companies producing aircraft components in nickel-based alloys.
  • Machine operators 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.

 
 
 
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 course will be held at Rollomatic, just outside of Chicago. Rollomatic, Inc. USA // 1295 Armour Blvd. // Mundelein, IL 60060 // 866-713-6938

 
 
 
Accommodation:
The Crowne Plaza, 510 E. Rt. 83, Mundelein, IL 60060. Special rate of $109 per night for a standard room, $124 for an executive room (847-970-6968, tell them you are with the Rollomatic/J Badger conference, quote ROL group code). Attendees are responsible for booking their own accommodation and travel to and from the hotel. Please wait for course space confirmation before booking. Travel between the hotel and Rollomatic (5-minute drive) can be done independently or via the hotel shuttle.

 
 
 
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 1500-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. Chicago is very close, as are other attractions. They'll find lots to do while you're plugging away in the grinding course.
 
Q:     Do I have to come to Chicago, 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 $1650. You can order it via credit card below or email me for other arrangements. It costs as much as the course because, in order to get the full benefit, you should 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.