Application Engineering
Engineered for Performance.
Proven in Production.
Every SuperAbrasives wheel is application-engineered — not catalog-selected. We work with your machine, your material, and your process to deliver results you can measure on the floor.
Our Application Engineering Process
Every engagement follows the same proven methodology — from first contact to full production.
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1
Evaluate
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2
Analyze
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3
Recommend
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4
Implement
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5
Support
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Application Results
Crankshaft Grinding
Crankshaft Pin Grinding
Global automotive supplier needed to reduce grinding costs on nodular iron crankshaft pins on a Fives Landis machine.
69%
Reduction in cost per unit
$54,755 annual savings · 2x parts per dress
Crankshaft Grinding
Crankshaft Flange End Grinding
Manufacturer needed improved wheel life and fewer annual wheel changes on steel crankshaft flanges — profile grinding on Fives Landis.
33%
Reduction in cost per unit
$14,253 annual savings · 6 wheel changes vs 40 per year
Crankshaft Grinding
Crankshaft Mains & Post Grinding
High-volume automotive line needed dramatically more parts between dresses on a Cinetic-Landis crankshaft machine.
250 PPD
Parts per dress vs 11 with incumbent wheel
Better finish: 0.2–0.3 Ra vs 0.5–0.6 · 10% more parts/shift
Camshaft Grinding
Camshaft Journal Grinding
Automotive OEM needed to reduce wheel changes and dressing downtime on a 5-journal cast iron camshaft line — KOYO centerless machine.
44%
Reduction in cost per unit
1,000,000 parts per wheel set · 2 hrs less dressing/day
Camshaft Grinding
Camshaft Lobe Grinding — Advanced Bond
Carburized steel lobes on a 2-spindle Fives-Landis machine required a new bond to eliminate burn and dramatically extend tool life.
80–100%
Increase in tool life
50% CPU reduction · 25,000 parts/wheel vs 10,000–15,000
Centerless Grinding
Through-Feed Centerless Grinding
Bearing manufacturer grinding 100CR6 needed tighter roundness tolerance and much longer wheel life on a Cincinnati through-feed machine.
17x
Longer wheel life
40% more daily production · Roundness held to <0.001mm
Centerless Grinding
Centerless Plunge Grinding
D2/M2 tool steel components needed more consistent finish and far less dressing time on a Cincinnati rotary dresser setup.
20x
Longer wheel life
1,200 PPD vs 50 · 1.5 hours dressing time eliminated daily
Gear Grinding
Gear Flank Grinding — Single Flank
Gear manufacturer needed faster cycle times and better wheel utilization on 8620 steel gears using a Niles ZE1200.
57%
Faster cycle time (13.6 min vs 32 min)
$300 savings per 3-shift day · 833 parts/wheel vs 471
ID / Face Grinding
ID & Face Grinding — 5 Features, 1 Wheel
Complex part required grinding 3 IDs and 2 faces in one setup on a Campbell vertical grinder. Excessive dressing time was the bottleneck.
20 min
Dressing time saved per part
1 dress pass vs 22 passes · One wheel handles all five features
Broach Grinding
Broach Grinding — New & Resharpening
Global automotive manufacturer needed improved part integrity and cycle times grinding T13/M2 broaches on a Star machine.
5mm
CBN usable wheel life — reduced cycle time
Improved part geometry · Better surface finish · Increased daily production
Punch Grinding
Punch OD Grinding — D2/M2 Tool Steel
Tool manufacturer grinding D2/M2 punches on a Unison machine needed far more parts between dresses and shorter cycle times.
30x
Longer wheel life
150 PPD vs 1 · 10x increase in daily production
Double Disc Grinding
Double Disc — Connecting Rods
Engine con-rod manufacturer needed to replace conventional abrasive on a C&B double disc machine — cycle time and wheel life were critical.
30x
Longer wheel life
10x more daily production · Cycle time cut by 30+ seconds/part
Angle Head Grinding
Angle Head Grinding
Shop running an Okuma angle head at 200,000 parts/year needed to eliminate downtime from frequent wheel changes and reduce cycle time.
$134,000
Documented annual savings
40% productivity increase · 44.4 sec cycle vs 70.5 sec
Cylindrical Grinding
Cylindrical Shaft — Steering Column
Automotive supplier grinding 4140 steel steering column shafts on an Okuma GP26 needed to cut cycle time and reduce wheel usage.
50%
Cycle time reduction
8 min cycle vs 16 min · 17,500 parts/wheel vs 1,680
Oil & Energy
PDC Pilot Hole Drill Bit Grinding
Global drill bit manufacturer needed increased wheel life and reduced change frequency across multiple facilities — Landis machines.
40%
Increase in daily production
300 bits per wheel vs 188 · Wheel changes cut nearly in half
What could we do for your operation?
Tell us your application — machine, material, and what you need to improve. Our engineers will evaluate it and come back with a recommendation.
