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  1. The Basics of Double Disc Grinding

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    The Basics of Double Disc Grinding

    Double Disc grinding simultaneously grinds two sides of material using two opposing abrasive wheels. It is a very effective grinding technique for obtaining surface smoothness, flatness, and parallelism with tight tolerances in the appropriate applications.

    This grinding technique can remove more material, cutting the grinding time in half. Additionally, this method can efficiently process various materials — including stainless steel, tool steels, sintered metals, high-strength alloys, ferrous or non-ferrous metals, bronze, copper, aluminum, and more.

    What Is Double Disc Grinding?

    Double Disc grinding is typically employed for high-productivity manufacturing requirements. However, many factors may affect the output rates, including the size, material, stock removal,starting flatness, and tooling arrangement. Depending on these factors, outputs can be as high as 40,000 parts per hour or just a few pieces.

    This technique is very effective and can cut pre-machining costs by as much as 50% since the material is removed from both sides in equal amounts in a single operation. It is ideal for requirements under the following conditions:

    • The parts have equal surface area requirements on opposing surfaces.
    • The size of the component required is close to the size of the grinding wheels.
    • The length, diameter, and overall width should be within tight tolerances.
    • The part’s thickness should be related to the opposing face to be processed.

    Advantages of Double Disc Grinding

    Depending upon the material and start flatness high dimensional accuracy can be obtained via Double Disc grinding, with tolerances, parallelism, and flatness down to 0.0005 inches (0.0127 mm). Controlling the thickness of small metal pieces using it is also economical.

    Double Disc grinding can also improve your parts manufacturing processes in the following ways:

    Reduced Machine Cost

    Because the grinding wheels degrade throughout the conventional grinding process, they occasionally need to be changed or redressed. On the other hand, double disc grinding lowers the wear rate, resulting in fewer grinding process redressing stops.

    High Degree of Accuracy

    The ability to simultaneously grind both sides of the workpiece gives operators more control, allowing them to achieve tighter tolerances for flatness and parallelism checks. Additionally, when grinding aluminum, the method may produce surface polishes as high as 16 Ra and dimensional tolerances of 0.0005 in. Flatness tests can also achieve the same degree of precision.

    Internal Stress Relief

    Double Disc grinding lessens the workpiece’s residual load due to how it operates. During secondary operations and final machining, stability is improved when residual stress is decreased.

    Better Surface Finishes

    This technique can attain flatness tolerances that would be extremely challenging to achieve using a single-sided grinding procedure. In addition, Double Disc grinding generates a better surface polish than many other grinding procedures by lowering or removing grind patterns as pieces depart.

    Double Disc Grinding With Nifty Bar

    Materials processed through double disc grinding can be used to manufacture several products and applications, including the following:

    • Knives, handles, and clips
    • Component part blanks
    • Connecting rods
    • Cutters and dies
    • Extrusions
    • Gages
    • Gears and gear blanks
    • Laminations
    • Medical, dental, and orthopedic plates
    • Shims, spacers, and washers
    • Stampings
    • Substrates
    • Valve plates

    Nifty Bar’s double-disc grinding technology offers precisely controlled processes creating superior surface finishes. We cater even to the most difficult-to-grind materials, such as titanium, Inconel, and a wide array of metal parts. Backed by our team of grinder experts, our mission is to meet our customer’s requirements with precision and quality.

    Contact us to book an appointment or to request a quote. We look forward to working with you!



  2. Double-Disc Grinding vs. Flat Lapping

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    Double-Disc Grinding vs. Flat Lapping

    Double-Disc Grinding and Flat Lapping are cost-effective machining processes for components requiring size control or a fine or specific surface finish. Although these methods have identical purposes, their operations, advantages, and disadvantages vary.

    Nifty Bar offers Grinding, Cutting, Milling, and Finishing services for parts, tooling, dies and molds, pre-machined blanks, fixtures, and signages used in various industries. Further, our capabilities allow us to deliver Double-Disc Grinding services that satisfy our client’s need for excellent dimensional control.

    This article will discuss the differences between double-disc grinding and flat lapping and assess the best option for various applications.

    What Is Double-Disc Grinding?

    Double-Disc Grinding uses two opposing abrasive wheels to simultaneously grind both sides of a component. The wheels are side-mounted on a pair of spindles facing each other, and — because both sides of the workpiece are ground at the same time — fabricators achieve faster turnaround time. This method can also achieve tight-tolerance surface finishes, flatness, and parallelism in suitable applications.

    This method is often classified into two machine types — horizontal and vertical double-disc grinder — based on how the grinding wheels are oriented and how parts cross through them. A double-disc grinder is horizontal if the wheels are paralleled to the floor and vertical if they are perpendicular.

    The product of this grinding technique are flat plates with finishes to 16 Ra and parallel tolerances to .0005″, depending upon material type, size and stock removal.

    Applications of Double-Disc Grinding

    The most common applications for Double-Disc grinding are as follows:

    • Rotor finishing
    • Connecting rods
    • Hydraulic pump components
    • Orthopedic skeletal implant plates.
    • Aerospace components
    • Knives, Blades & Handles
    • Nontraditional components (glass, plastic, graphite, ceramic)

    Advantages and Disadvantages of Double-Disc Grinding

    Double-Disc grinding ability is to extract equal parts of material from opposite sides of a workpiece that results in applying a reduced amount of internal stress to the materials. Furthermore, it enhances stability during machining operations, leading to higher accuracy and parallelism. Moreover, up to 50% of pre-machining costs are saved since this technique can achieve flatness tolerance faster than single-sided grinding.

    On the other hand, Double-Disc Grinding fails to produce surface finishes as smooth as flat lapping. The latter grinding process is often used to correct irregularities or deterioration on the surface of metal parts.

    What Is Flat Lapping?

    Flat lapping is a mechanical sanding or polishing procedure where an abrasive is placed between two surfaces that are honed together. This process often results in a more accurate surface finish for elements and compounds like cast iron, ceramics, tungsten, plastics, carbon compounds, stainless steel, bronze, rubber, and silicon.

    Applications of Flat Lapping

    Flat lapping utilizes abrasive grains mixed with either oil- or water-based liquid vehicles to achieve a smooth surface. This method is typically used in the following applications:

    • Hard and brittle metals
    • Machining materials (e.g., glass)
    • Valve manufacturing
    • Polishing operations (automotive industries)

    Advantages and Disadvantages of Flat Lapping

    Due to the less complex machining process, flat lapping doesn’t require skilled laborers to complete the procedure, increasing its production rate. This technique also removes burrs on materials to achieve a high surface finish without generating heat.

    However, flat lapping is generally slower than double-disc grinding, as only one side of the workpiece is furnished for each cycle. Additionally, it is not as pocket-friendly because it can only remove a minimal amount of stock on the material, and the surface finish needs to be uniform.

    Why Choose Nifty Bar

    Double-Disc Grinding offers more advantages to consumers than flat lapping. Not only is the former a more practical alternative, but fabricators can achieve a faster turnaround time than the latter.

    Nifty Bar delivers Grinding and Cutting solutions with high-precision quality through our services, such as Blanchard Grinding, Double-Disc Grinding, and state-of-the-art Waterjet cutting technologies! Our capabilities and expertise enable us to support product prototyping and part production for the Medical, Architectural, Aircraft, and Automotive Industries just to name a few.

    Contact us to learn more about our services or request a quote to partner with us today!



  3. Waterjet Cutting: What It Is and How It Works

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    Waterjet Cutting: What It Is and How It Works

    Have you ever seen those commercials for waterjet cutting showing a guy cutting through a metal plate with a jet of water? It’s pretty impressive. But what is Water Jet cutting, and how does it work?

    Read on to learn more about how waterjet cutting works and its benefits.

    What is Water Jet cutting and how does it work?

    Waterjet cutting is a versatile and efficient way to cut various materials. It works by using a high-pressure jet of water, MIXED WITH GARNET, to cut through the material cleanly and precisely. This process can be used for both industrial and personal purposes, and it is an alternative to traditional methods such as sawing, drilling, or milling. Waterjet cutting is quick, easy, and accurate, making it a popular choice for many projects.

    The benefits of using a waterjet cutter

    There are many benefits of using a waterjet cutter over other methods, such as:

    • Water Jet cutting can cut through any material.
    • They can create very intricate cuts and designs.
    • Waterjet cutting is a very precise method of cutting.
    • There is no heat-affected zone (HAZ) when using a waterjet cutter. This means that the material being cut will not be damaged by heat.
    • Waterjet cutting is a clean method of cutting because there is no dust or debris created during the process.

    Different types of materials Water Jet cutting Could be used

    Waterjet cutting COould be used for a variety of other materials. These include, but are not limited to:

    • Metals such as aluminum, brass, and steel
    • Non-metallic materials such as glass, plastic, and stone
    • Composite materials such as carbon fiber and Kevlar

    Each type of material has its unique properties that must be considered when choosing the best waterjet cutting method. For example, metals are strong and durable but can be difficult to cut through due to their hardness. Glass is fragile but can be cut with very high precision.

    Waterjet cutting can also be used on composite materials, which are made up of multiple different types of material bonded together. This makes them extremely strong and resistant to damage. However, composite materials can be difficult to cut due to their complex structure.

    When choosing a waterjet cutting method, it is crucial to consider the type of material that will be cut as well as the desired outcome. Waterjet cutting is a versatile technology that can be used on various materials. With proper planning and execution, waterjet cutting can produce precise, high-quality results.

    Types of cuts using waterjet cutting

    Waterjet cutting is a versatile process that can be used to cut various materials. The type of cut made with waterjet cutting depends on the material being cut and the application for which it will be used. Some common types of cuts made with waterjet cutting are:

    • Straight cuts: Straight cuts are the most basic type of cuts made with waterjet cutting. They are typically used for simple applications such as trimming or shaping edges.
    • Contour cuts: Contour cuts are more complex than straight cuts and are used when more precise shapes or patterns need to be cut into a material.
    • Kerf cuts: Kerf cuts are made by directing the jet of water at an angle so that it cuts a V-shaped groove into the material. They are often used for making decorative cuts or for joining two pieces of material together.
    • Pierce cuts: Pierce cuts are made by starting the cut at an edge of the material and then moving the jet of water in a circle to create a hole in the center of the material. They are typically used for applications such as creating holes for fasteners or making openings for pipes or ductwork.

    Nifty Bar Waterjet Cutting Services

    Adding speed, precision, and efficiency to your machining projects is a breeze with Nifty Bar Waterjet Cutting. From cutting complex shapes to making quick work of intricate designs, our waterjet cutting services are perfect for various applications.

    Nifty Bar Waterjet Cutting can help you achieve the perfect finish on your project, whether you’re working with metals, composites, stone, or glass. Our state-of-the-art waterjet cutting technology can handle even the most challenging cuts with ease.

    With Nifty Bar Waterjet Cutting, there’s no need for secondary finishing operations. We can produce parts ready to use right out of the machine. That means you’ll save time and money on your project.

    If you’re looking for a way to take your machining projects to the next level, look no further than Nifty Bar Waterjet Cutting. We can help you achieve the perfect finish every time. Contact us today to learn more about our waterjet cutting services. We look forward to working with you!

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