Establish the OBJECTIVE.
PREPARE for the test.
RECORD the results.
EVALUATE the results.
Expert Advice – Stephen Cahill, Regional Product Engineer, Indianapolis, IN
1. Establish the OBJECTIVE.
What are the desired result(s) for testing, for example: To reduce abrasive costs, New operation or machinery, To reduce cycle time, To reduce rejections, To improve finish and/or geometry, Change in material, coolant, etc, Increase parts per dress, Shorter cycle time.
2. PREPARE for the test.
Have sufficient parts on hand. Choose machine and parts of representative condition. Inform the operator and supervisor of the OBJECTIVES. Run all tests on the same machine. Try to eliminate variables such as diamond condition, wheel size, and part size.
3. RECORD the results.
Don't rely on memory or word of mouth. Use a Test Data Form to set and capture all the pertinent test information. Record operating parameters. Record test results. Be open to changing parameters. To improve current results, change grinding parameters by increasing wheel infeed, reducing the number of dresses, and/or reducing dress infeed.
4. EVALUATE the results.
Determine what the data means in relation to your OBJECTIVE. Look at the total cost picture. Use the attached Evaluation and Cost Analysis Form to determine: Abrasive cost. Diamond cost. Labor and overhead. Cost of rejections/rework. Wheel change/downtime. Other criteria such as finish, form, and metallurgical damage.