In the world of precision grinding, every micron counts. Recently, we partnered with a leading manufacturer to grind a gear spindle shaft – a critical component requiring exceptional dimensional stability and surface finish.
The workpiece dimensions: Ø180mm × 800mm.
The machine of choice: STUDER S242, known for its high-performance cylindrical grinding capabilities.
The challenge? Achieving consistent, high-quality results on a large, sensitive workpiece – while maximizing efficiency and wheel life.
To meet the customer's requirements, we provided two types of custom CBN grinding wheels, each optimized for specific stages of the grinding process.
Size: D400 × T30 × H127, B126 C200
Speed: 60 m/s
The vitrified bond CBN wheel delivered excellent form retention and high material removal rates, making it ideal for preliminary grinding of the gear spindle shaft. Its rigid structure maintained profile accuracy throughout the operation.
Two resin bond CBN wheels were used for finer, more delicate grinding tasks:
| Wheel | Size | Speed |
|---|---|---|
| Wheel 1 | D400 × T50 × W8 × X10, B126 C100 | 45 m/s |
| Wheel 2 | D350 × T50 × W5 × X10, B126 C100 | 45 m/s |
The resin bond design provided smoother cutting action, reduced heat generation, and produced a superior surface finish – critical for the functional performance of the gear spindle shaft.
Exceptional surface quality achieved on the Ø180mm × 800mm shaft
Consistent dimensional accuracy across all production batches
Optimized cycle times thanks to the combination of high-speed vitrified CBN and flexible resin bond CBN wheels
Extended wheel life reduced downtime and tooling costs
This project demonstrates that with the right combination of machine technology (STUDER S242) and application-engineered CBN grinding wheels, even the most demanding cylindrical grinding tasks can be mastered – efficiently, accurately, and cost-effectively.
Whether you are grinding gear shafts, spindles, or other precision components, our custom grinding wheel solutions can be tailored to your specific machine, material, and performance goals.
[Contact us today] to discuss how we can help you improve precision, productivity, and wheel life – just like we did for this gear spindle shaft application.
