Tetra4000(TM) Cam Grinding Analysis Program mathematically combines cam lift specifications with practical machine performance capabilities to automatically generate optimized work-speed programs. Users of CNC cam lobe grinders can obtain optimal cycle times while avoiding thermal damage to parts. After setting up cycle time for grinding application, software enables user to perform thermal modeling to confirm that part will remain within desired temperature range.

Chicago, Ill., Sept. 8, 2004 -- Landis Grinding Systems is introducing at IMTS 2004 its Tetra4000(TM) Cam Grinding Analysis Program with Thermal Modeling capability which will enable users of its CNC cam lobe grinders to obtain the fastest possible cycle times while avoiding thermal damage to parts.

The Landis Tetra4000(TM) software package mathematically combines cam lift specifications with practical machine performance capabilities to automatically generate workspeed programs that optimize cycle time and product quality. The program was originally developed to permit off-line preparation of optimized workspeed programs in order to free CNC grinders for productive work. The thermal modeling capability, which has been added to the cam smoothing and automatic workspeed generation program, provides a means to further optimize cam lobe grinding processes for maximum productivity. The Tetra4000 program has also been updated for use with today's 32-bit operating systems.

According to Marshall Faith, test lab manager at Landis Grinding Systems, thermal modeling can help reduce manufacturing costs while allowing camshaft manufacturers to reliably meet stringent quality requirements. "As camshaft manufacturers have sought ways to increase productivity they have also intensified their concerns about product quality," explains Marshall Faith. "Thermal modeling tells us where we must slow down and where we can speed up the grinding program while controlling grinder burn. After setting up a cycle time for a cam lobe grinding application, the software enables the user to immediately perform a thermal modeling to confirm that the part will remain within the desired temperature range."

Landis engineers worked with an automotive customer when developing the thermal modeling program to conduct X-ray refraction tests on sample parts to verify the accuracy of the modeling program.

The thermal modeling software can be used to evaluate an entire grinding cycle. Alternatively, it will simulate the thermal distribution resulting from a single feed increment such as the most aggressive stock removal during rough grinding. A color contour plot of the thermal distribution is provided for analysis by the operator.

"In developing optimized cam grinding workspeed programs we need to avoid inducing excessive heat into the part to a depth that cannot be removed in the finish feed increments," said Mr. Faith. "The plot from the modeling program lets us view the temperature distribution down through the layers of the cam. After evaluating the heat values and penetration depth we then set the finish cycle to be sure that we eliminate any thermal damage to the part."

Landis engineers have recorded some significant productivity improvements by customers since introducing the cam grinding analysis program with thermal modeling. For example, at one Tier 1 supplier, cam lobe grinding cycle time on one diesel camshaft was reduced to 5-1/2 minutes from 11 minutes per shaft using thermal modeling in combination with a new Landis 3L CNC cam lobe grinder. Much of the timesaving was attributed to modifying the workspeed program using the new software. By using the thermal modeling tool, Landis engineers were also able to help the customer identify a problem with inconsistent hardness of incoming parts. The cam grinding analysis program was originally optimized for parts with 60 Rc hardness. But when burn was experienced on some parts, tests revealed that those parts were actually hardened to 65 Rc. So a second slower workspeed program was created for use with harder parts.

In the future, Landis Grinding Systems plans to offer the Tetra4000(TM) analysis program with thermal modeling for grinding crankpins as well as concentric diameters.