One of the things that separate competent machine shops from a precision shop is the ability to grind shapes to close tolerances. In prototype work, this means having the ability to grind parts with in ±10 microns with some companies grinding to a precision level of +1.00 micron. To give some perspective, a human hair is 75 microns thick. That’s how exact things have to be to meet the engineer’s original designs of today.
In order to get precision, it is paramount that all inputs in the process are strictly controlled. For example, slight differences in atmospheric temperature can effect feature size because of expansion/contraction factors (steel expands 2½ microns/25 mm/10°F). So, it’s important to have close tolerance parts measured between 68°F-72°F to ensure accuracy and repeatability of measurement.
As the demands for precise fits and finishes increase, grinding processes will be improved to meet the need. There are four basic grinding processes in prototype manufacturing; Surface Grinding, JIG Grinding, ID grinding, and OD Grinding. Surface Grinding is a processes referred to mostly when grinding flat surfaces. Jig Grinding is mostly used for grinding small diameter holes, such as dowel holes, in fixtures tool and dies. ID and OD Grinding pertain to grinding internal and external cylindrical shapes. These parts include bushings, shafts, rollers bearings, tubing, etc.
Grinding is an important component of prototype development and needs to be handled by an experienced shop that takes accuracy very seriously.
Mike Webster, Webster Engineering is a prototype and low-volume machine shop specializing in complex and precision metal work since 1962. Located in Roseville, Michigan, Webster Engineering is privately owned and certified to the ISO 9001:2000 International Standard. Webster Engineering has a reputation for providing solutions that exceed expectations for speed, accuracy, delivery, quality and cost – achieving real customer satisfaction. Contact Webster Engineering at 586-777-0116 or CNC Machining or Close Tolerance Grinding
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