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
- Gears and gear blanks
- Medical, dental, and orthopedic plates
- Shims, spacers, and washers
- 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!