Carbide Processors, Inc.carbideprocessors.com › content › nl-aug-11.pdfEmily but we will get it...

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Carbide Processors, Inc. Northwest Research Institute, Inc. Newsletter August, 2011 3847 S. Union Ave. Tacoma, WA. 98409 (800) 346-8274 [email protected] www.carbideprocessors.com A Really Classy Person Neal Farnung of Saw & Specialty Corporation in Romulus, Michigan. I had a customer e-mail me. He was looking for a saw blade inspection machine. I got looking around and eventually ended up talking to Neal Farnung of Saw & Specialty Corporation in Romulus, Michigan. Mr. Farnung was incredibly generous with his time, information and offers of future help. I've never had the privilege of meeting him so I was just somebody calling out of nowhere. Yet, he gave me so much time and information that I was a bit embarrassed and afraid I was putting him out unduly. I have said repeatedly that we really enjoy this industry, here at Carbide Processors, because of all the really great people in it. Mr. Farnung is certainly an excellent example of what we mean by that. Mike Hartman Hartech Grinding Waterloo, Ontario Mr. Hartman called the other day because he was interested in doing things better and someone told him I might be able to help him. This reminded me of two things. The saw filers who are a generation or two behind mine seem to be really bright. The second thing that came to mind was that I knew something that he didn't. This brings to mind the upcoming Western Saw Filers meeting. It is a chance to meet other filters who may have a solution to your problem. A lot of the old guys know each other and a young guy might feel left out. You don't have to. I’ll be hanging around the Peerless booth. Come up and say hello and we’ll let Peerless buy us a drink. We Have Carbide Recent changes by one supplier in the carbide industry have caused a lot of disruption. We get as many as several calls a day from people who are desperate to find carbide. We saw this coming a year or so ago. We have greatly increased our carbide inventory here. We have worked with our suppliers to have them increase their inventory and to arrange for fast shipment to us or directly to our customers. As always, we maintain a long list of carbide suppliers around the world. If you need carbide please call 800-346-8274. Employee Problem My daughter, and ace employee, Emily, claims she is pregnant and that she will need time off starting in September to have a baby. She has pretty convincing evidence so it might be true. (Those of you who also have daughters that can wrap you around their little finger understand why I am skeptical.) We have Renee and Leslie to cover for her and I will help as well. We are not Emily but we will get it done. We just ask for a little patience. My New Hero Dale Nostrand Universal Saw Co., Inc. Santa Fe Springs, CA I have long noticed that it is unusual for a company to just do one thing well. Really good companies seem to do everything well. We received 20 cases of carbide scrap from Universal Saw Company in California. Mr. Nostrand used medium flat rate boxes that cost $10.85 each to ship. He had about 30 pounds of carbide in each one. The packaging was beautifully done. He used some scrap hardboard or thin plywood top and bottom inside the box. The scrap carbide was double bagged in gallon Ziplocs. The whole thing was cushioned with crumpled paper which works a lot better than peanuts. We received these 20 boxes and two more later. All 22 were in great shape inside. As you can see, they were pretty beat up outside. The packaging was so well done that not a single tip was lost. When you consider what 30 pounds of scrap carbide is worth and how little the flat rate box costs, and you can see why it makes sense to spend a little time with the shipping. Scrap Carbide $8 per pound or more - Carbide Scrap prices vary so call for a quote. 800 346-8274

Transcript of Carbide Processors, Inc.carbideprocessors.com › content › nl-aug-11.pdfEmily but we will get it...

Page 1: Carbide Processors, Inc.carbideprocessors.com › content › nl-aug-11.pdfEmily but we will get it done. We just ask for a little patience. My New Hero Dale Nostrand Universal Saw

Carbide Processors, Inc.Northwest Research Institute, Inc.

Newsletter August, 20113847 S. Union Ave. Tacoma, WA. 98409 (800) 346-8274

[email protected] www.carbideprocessors.com

A Really Classy PersonNeal Farnung of Saw & SpecialtyCorporation in Romulus, Michigan.I had a customer e-mail me. He waslooking for a saw blade inspectionmachine. I got looking around andeventually ended up talking to NealFarnung of Saw & SpecialtyCorporation in Romulus, Michigan.

Mr. Farnung was incredibly generouswith his time, information and offers offuture help. I've never had the privilegeof meeting him so I was just somebodycalling out of nowhere. Yet, he gave meso much time and information that Iwas a bit embarrassed and afraid I wasputting him out unduly.

I have said repeatedly that we reallyenjoy this industry, here at CarbideProcessors, because of all the reallygreat people in it. Mr. Farnung iscertainly an excellent example of whatwe mean by that.

Mike HartmanHartech Grinding Waterloo, OntarioMr. Hartman called the other daybecause he was interested in doingthings better and someone told him Imight be able to help him. Thisreminded me of two things. The sawfilers who are a generation or twobehind mine seem to be really bright.The second thing that came to mind wasthat I knew something that he didn't.

This brings to mind the upcomingWestern Saw Filers meeting. It is achance to meet other filters who mayhave a solution to your problem.

A lot of the old guys know each otherand a young guy might feel left out.You don't have to. I’ll be hangingaround the Peerless booth. Come upand say hello and we’ll let Peerless buyus a drink.

We Have CarbideRecent changes by one supplier in thecarbide industry have caused a lot ofdisruption.

We get as many as several calls a dayfrom people who are desperate to findcarbide.

We saw this coming a year or so ago.We have greatly increased our carbideinventory here. We have worked withour suppliers to have them increasetheir inventory and to arrange for fastshipment to us or directly to ourcustomers.

As always, we maintain a long list ofcarbide suppliers around the world.

If you need carbide please call800-346-8274.

Employee Problem

My daughter, and ace employee, Emily,claims she is pregnant and that she willneed time off starting in September tohave a baby. She has pretty convincingevidence so it might be true. (Those ofyou who also have daughters that canwrap you around their little fingerunderstand why I am skeptical.)

We have Renee and Leslie to cover forher and I will help as well. We are notEmily but we will get it done. We justask for a little patience.

My New HeroDale Nostrand

Universal Saw Co., Inc.Santa Fe Springs, CA

I have long noticed that it is unusual fora company to just do one thing well.Really good companies seem to doeverything well.

We received 20 cases of carbide scrapfrom Universal Saw Company inCalifornia. Mr. Nostrand used mediumflat rate boxes that cost $10.85 each toship. He had about 30 pounds ofcarbide in each one. The packagingwas beautifully done. He used somescrap hardboard or thin plywood topand bottom inside the box. The scrapcarbide was double bagged in gallonZiplocs. The whole thing wascushioned with crumpled paper whichworks a lot better than peanuts.

We received these 20 boxes and twomore later. All 22 were in great shapeinside. As you can see, they were prettybeat up outside. The packaging was sowell done that not a single tip was lost.

When you consider what 30 pounds ofscrap carbide is worth and how little theflat rate box costs, and you can see whyit makes sense to spend a little timewith the shipping.

Scrap Carbide $8 per pound or more- Carbide Scrap prices vary so call for aquote. 800 346-8274

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Simple Fixes

Plywood Truck Door

Electric Drill for Pancake Batter

Fixing a Pothole

Mercedes Hood Ornament from a CoatHanger

Ceratizit Seminars in Las VegasCeratizit put on three seminars in LasVegas. They were on: “The NewCeratizit Grades,” “Grinding Carbide,”and “Brazing Carbide without Stress.” Ithink the industry very badly needsmore education and I greatly applaudCeratizit for putting on these seminars.

Attila Szucs of AdvancedSuperabrasives and Jana Spennes ofCeratizit were the presenters. Bothspeeches were interesting and had newinformation. Ms. Spenne’s accent didmake it somewhat hard to understandher.

Unfortunately, I can't tell you anythingabout the information delivered becauseCeratizit considers it proprietaryinformation.

I don’t know how to describe thespeeches exactly and I have beenthinking about this for a couple weeks.I liked both speakers. Both speakerswere very interesting and taught methings I didn't know.

Yet somehow I was left with the feelingthat it could have been a lot better and Ididn't know why. So I called RudiSommer of Radiac Abrasives. Rudyand I both give speeches to saw filergroups. I've heard Rudi speak and hisspeeches are excellent.

Rudy pointed out that he and I givespeeches to audiences that wantsomething specific. They wantsomething they can take back and useimmediately. I think Rudy is right. Heand I make the assumption that theaudience wants something brand-newthat they can use now to make their jobsmuch easier and do much better work.

Again, Ceratizit is to be highlycommended for doing this and thespeeches given were a really good start.Now that they know the audience islikely to include people such as RonSerwa of Vortex Tool, Gene Veening ofRoyce/AYR and Mike Lindsay ofEastside Saw / ISKA I am sure theywill gear the presentations in thatdirection.

Notes:1. I have never given a presentationthat could not have been a lot better.2. This was a very sophisticatedaudience. Giving a presentation tothem really requires you to bring your“A” game.

Rudi SommerRadiac Abrasives503 [email protected]

5 Pearls of Wisdom1. Money cannot buy happiness, butsomehow it's more comfortable to cryin a Mercedes Benz than it is on abicycle.2. Forgive your enemy, but rememberthe bastard's name.3. Help a man when he is in trouble,and he will remember you when he is introuble again.4. Many people are alive only becauseit's illegal to shoot them.5. Alcohol does not solve any problem,but then neither does milk.

The Greatest Doctor inthe World

Paul Smith, Smith Sawmill Service inGarrison Texas may have the greatestdoctor in the world. His lovely wife,Debra, doesn't quite agree.

I went to the AWFS show in Las Vegasand was fortunate to have dinner withsome of the boys from Peerless as wellas Paul Smith and his wife.

Paul told a lot of great stories. Myfavorite was the one about him going tothe doctor. I would try and tell it but Ican't do it justice. Call Paul and havehim tell it.

Best of all take them both to dinner andhear it that way. It is even better if youget Paul telling the story and Debracorrecting him on it.

Smith Sawmill Service Garrison, TX800-598-6344

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Router Bit Breakage

These are router bits designed forplastic. They are really designed forCNC routers cutting ordinary plastic.The customer used them that way. Thecustomer also used them in a handheldrouter to cut fiberglass which is wherethe problem arose.

The customer was good enough to sendthe router bits back so we couldexamine them. Here are three picturesof the router bits. You can see that thebreakage on the router bits is practicallyidentical from bit to bit to bit.

In my experience, when cutting toolssuffer practically identical breakage, itgenerally means a misapplication of thetool or that the wrong tool was used forthe job. (Same thing - just differentways of looking at it).

It could be a poor tool design where aweak spot was engineered or machinedin.

I generally think of carbide defects asoccurring randomly and look fordifferent kinds of breakage in differentparts of the tool.

Another thing to notice is the ‘beach’(wave, tide, etc.) marks especiallyprominent on the right hand part. Thesemarks are a series of lines one rightafter the other. You can see themmarching up through the light gray area,right next to the dark black area. Thisshows that the router bits did not breakin a single incident. Instead there is aseries of dozens of tiny breaks or ripssucceeding one another. Each beachline indicates a separate rip. There's ahuge difference between a carbiderouter bit that snaps and a carbide routerbit that has to be beaten apart withdozens of blows.

Spokeo – New Web SiteThere's a site called www.spokeo.comthat's a new online USA phone bookw/personal information: everythingfrom pics you've posted on Facebook orweb, your approx credit score, homevalue, income, age, family member'snames. Remove yourself by searchingyour name, find your page, highlightthe URL and right click, select “copy”,then go to the bottom right of the page& click on the Privacy link to removeyourself. You will have a chance topaste the URL in the first link. Copy &re-post so your FB friends are aware.The private info listed for me wasextremely accurate.

Super Thin Saws Now ManagementOwned

The management team at Super ThinSaws of Waterbury, Vermont is pleasedto announce that we have purchased theportion of the company recently ownedby UCT Coatings of Stuart, Florida.John Schultz, Rob Bisbee and DaveStrom now own 100% of the company.We are more committed than ever togiving our customers the very highestquality of product, service, and support.

“Biodegradable” DoesNot Mean “Safe”

We were offered a product to sell andwe were assured it was 100% safebecause it was biodegradable.

This is just not true. If anything, it maymean the opposite. Biodegradablemeans it breaks down naturally. Thismeans it reacts very well with things inthe environment. Safety in chemicalsmeans that it does not affect people atall or that it affects people in a positivemanner.

Nitroglycerin and cyanide are twochemicals that are very readilybiodegradable. The formula forNitroglycerin is C3H5N3O9 which iscarbon, hydrogen, nitrogen and oxygen.So nitroglycerin very rapidly breaksdown into chemicals that are reallygood for life. Cyanide is CN and comesas Hydrogen Cyanide (HCN), acolorless gas, Sodium Cyanide (NaCN)or Potassium Cyanide (KCN). Socyanide is carbon and nitrogen whichvery rapidly breaks down and carbonand nitrogen are essential for life.

However nitroglycerin and cyanide gasare not considered safe.

Following is a letter from theWashington State Department ofEcology explaining a bit about whatbiodegradable really means.

“Dan Ferguson, Washington StateDepartment of Ecology

Tom,

I just finished doing some research onyour behalf. There is no legaldefinition of “biodegradable.” I foundthis very good article that discusseswhat the definition could be if there wasone.

http://environment.about.com/od/earthtalkcolumns/a/biodegradable.htmhttp://www.ftc.gov/bcp/grnrule/guides92.htm#G2

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The article basically states, while youdon’t legally have to prove a product isbiodegradable, a company can still besued by the FTC (Federal TradeCommission) or other parties if the“biodegradable” claim is “misleadingand/or deceptive.” I could help youdetermine this if you can get your handson the product’s MSDS sheet. Once Iknow the chemicals in the product, Iwould have a good idea on whether ornot the product can break down readily.At the very least I could make sure thechemicals in it were not long lasting.

As for your second question, I realizedafter I tried to answer the black andwhite version, you may have meant“how do you certify a product to bebiodegradable (or green) in WashingtonState or in the US?”

For the original question, I contactedWashington State Consumer ProtectionAgency as well as other Department ofEcology coworkers. The short answeris you do not need to certify a productin order to sell it. You do have toperform due diligence to make sureyou’re not selling a dangerous orinferior product as that could causelegal/business issues, but you don’thave to go through a state or federalagency to sell something. The thingyou do need to do is to make sure youcan legally and safely ship or transportit. To make sure you can ship theproduct, you will need to check with thePost Master General (US PostalService) and probably the Departmentof Agriculture as well. Their basicconcerns will probably center aroundthe toxicity and/or level of hazard theproduct may have.

As far as certifying a product asbiodegradable or green in WA/US,there’s a number of non-profitorganizations that can do this, but themost recognized (most bang for yourbuck) is probably the EPA’s DfEprogram (Design for the Environment).Now if I remember correctly the xxxxxxxxxxxx was not your product, but thecompany wanted to have it sold on yourwebsite or by your company.

Depending on how much they want tomarket their product as“biodegradable,” they could pursue theDfE certification. More informationabout the DfE program is below and itmight even be something your companymay want to look into for otherproducts if you’re interested in findingother products that are DfE certified.As far as I know the DfE programusually certifies mostly consumergoods, but I would not be surprised if itstarts branching out into the commercialsector as well.

http://www.epa.gov/dfe/pubs/about/index.htmhttp://www.epa.gov/dfe/pubs/projects/formulat/label.htmhttp://www.epa.gov/dfe/pubs/projects/formulat/about.htm

I hope that helps and if you have anyother questions, feel free to contact meeither by phone or email. I would bemore than happy to help.

Regards,Dan Ferguson”

MSDS FraudI ran across a case of what I believe tobe a deliberately fraudulent MaterialSafety Data Sheet.

We were asked to sell a new product.We requested a material safety datasheet and any other information theyhad.

The MSDS only mentioned onechemical and said that the chemical wassomewhere between 1% and 5% of thetotal.

I do not like this. According to OSHAan MSDS sheet is supposed to list allthe chemicals that could harm a worker.You can get into a situation where evenwater could harm a worker if usedimproperly. There are a lot of chemicalreactions where water is verydangerous. Perhaps the simplest tounderstand is water on a grease fire or agas fire.

The one chemical mentioned wasn't toobad safety wise but they also mentionedthat there was an organic catalyst in theformula. When you take the chemicalmentioned and combine it with the rightorganic catalyst you get a prettydangerous chemical created as a result.The chemical created is very volatileand has several health effects includingcancer.

The manufacturer may have found alegal loophole. He may think that hecan just list the two chemicals he addswithout listing the dangerous chemicalthey create.

In any case, I definitely don't like it. Icount on the MSDS sheets keep mystaff, my customers and myself safe.When I speak on safety and health Ioften start out a speech by saying that itis a bad business practice to kill youremployees. Then there is a nervouslaugh from the audience. Then Iexplain that it is also a bad businesspractice to make your employees sick.

When I get an MSDS sheet I want tosee all the chemicals listed. And I wantan honest explanation of all the hazards.I then check the MSDS sheet I wasgiven to see how accurate it is. Here isan address to the website I have foundextremely helpful over the years.Http://hazard.com/msds/

Exercise1. If walkingis good foryour health,the postmanwould beimmortal.2. A whaleswims all day,only eatsplankton,drinks waterand isfat.3. A rabbit runs and hops and onlylives 15 years.4. A tortoise doesn't run, does nothing -- yet lives for 450 years.

AND YOU TELL ME TO EXERCISE!

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Cat Ordered To Do Jury ServiceA cat has been summoned to do juryservice, even after his owners told thecourt he was "unable to speak andunderstand English".

Anna Esposito, wrote to SuffolkSuperior Crown Court in Boston, US, toexplain that a mistake had been made,but a jury commissioner replied sayingthe cat, named Tabby Sal, "must attend"on March 23.

Mrs. Esposito had included a letter fromher vet confirming that the cat was "adomestic short-haired neutered feline."

Tabby Sal had been entered by Mrs.Esposito under the 'pets' section of thelast census. "When they ask him guiltyor not guilty? What's he supposed tosay - miaow?" She said.

"Sal is a member of the family so Ilisted him on the last Census formunder pets but there has clearly been amix-up."

A website for the US judicial systemstates that jurors are "not expected tospeak perfect English."

Protecting SheepJohn Schultz

The Sierra Club and the U.S. ForestService were presenting an alternativeto the Wyoming ranchers forcontrolling the coyote population. Itseems that after years of the ranchersusing the tried and true method ofshooting or trapping the predators, theSierra Club had a "more humane"solution to this issue.

What they were proposing was for theanimals to be captured alive. The maleswould then be castrated and let looseagain. This was ACTUALLY proposedby the Sierra Club and by the U.S.Forest Service. All of the ranchersthought about this amazing idea for acouple of minutes. Finally an old fellowwearing a big cowboy hat in the back ofthe conference room stood up, tippedhis hat back and said:

"Son, I don't think you understand ourproblem here... these coyotes... theyain't humpin’ our sheep... they're eatin''em!"

The meeting never really got back toorder. . ..

Man and Animals – God’s PlanOn the first day, God created the dogand said, "Sit all day by the door ofyour house and bark at anyone whocomes in or walks past. For this, I willgive you a life span of twenty years."

The dog said, "That's a long time to bebarking. How about only ten years andI'll give you back the other ten?"

So God agreed......

On the second day, God created themonkey and said, "Entertain people, dotricks, and make them laugh. For this,I'll give you a twenty-year life span."

The monkey said, "Monkey tricks fortwenty years? That's a pretty long timeto perform. How about I give you backten like the dog did?"

And God agreed......

On the third day, God created the cowand said, "You must go into the fieldwith the farmer all day long and sufferunder the sun, have calves and givemilk to support the farmer's family. Forthis, I will give you a life span of sixtyyears."

The cow said, "That's kind of a toughlife you want me to live for sixty years.How about twenty and I'll give back theother forty?"

And God agreed again......

On the fourth day, God created humansand said, "Eat, sleep, play, marry andenjoy your life. For this, I'll give youtwenty years."

But the human said, "Only twentyyears? Could you possibly give me mytwenty, the forty the cow gave back, theten the monkey gave back, and the ten

the dog gave back; that makes eighty,okay?"

"Okay," said God. "You asked for it."

So that is why for our first twenty years,we eat, sleep, play and enjoy ourselves.For the next forty years, we slave in thesun to support our family. For the nextten years, we do monkey tricks toentertain the grandchildren. And for thelast ten years, we sit on the front porchand bark at everyone.

Paul Smith’s DoctorThis is the way I remember the story.It's a lot better if you hear Paul andDebra do it over a half hour but not allof you are in Texas so I will do the bestI can. Remember that there are severaldifferent versions but this is the one Iremember.

Debra Smith had Paul Smith check hisblood pressure. It seems like it wassome astronomical number, maybe 350over 150. (There were differentopinions on exactly what it was. This isjust the way I remember it). AnywayDebra convinced Paul to see a doctor.

Paul went into the doctor and they startdiscussing his lifestyle. The doctorasked Paul about his drinking habitsand Paul said that he drank Jack Danielsand Coca-Cola mixed 50-50. Iremember him mentioning that he drankabout 3 Liters of Coca-Cola a day. Thiswould also have meant about 3 Liters ofJack Daniels a day.

The doctor hears this and decides it is areal chance to help Paul improve hishealth. So the doctor tells Paul to cutout the Coca-Cola and just drink hisJack Daniels straight or with water.

Now Paul can be a really funny guy buthe's nobody's fool. He said “YesMa'am” to the lady doctor and wenthome to give Debra the good news.Somehow Debra was not as thrilledwith the news as Paul was.

That's the way I remember it. I thinkthere's some truth in this version butprobably not very much. Call Paul.

Page 6: Carbide Processors, Inc.carbideprocessors.com › content › nl-aug-11.pdfEmily but we will get it done. We just ask for a little patience. My New Hero Dale Nostrand Universal Saw

Cup-Wheel GrindingBy Dr. Jeffrey A. Badger

The Grinding Doc

Cup-wheel grinding is a peculiar typeof grinding as the wheel-workpiececontact geometry changes throughoutthe process.

After truing the wheel, grinding occurson the face of the wheel as shown in(a). The forces on this face areextremely large, and the wheel takes ahell of a beating during the “break-inperiod”. Quickly, a taper develops (b)and grinding moves from the face of thewheel to the bottom of the wheel. Herethe forces on the wheel are lower, andwheel wear is typically (but notalways!) lower as the forces aredistributed over a larger area.

Why does the wheel take a beating? Ithas to do with the contact area. Let’ssay you have a rim width of 3 mm(0.12”) and a workpiece width of 5 mm(0.2”) and you take a depth of cut of0.050 mm (0.002”). During the face-grinding break-in period, the contactarea is Area = depth of cut X part width= 5 mm X 0.050 mm = 0.25 mm2. Afterbreak-in the contact area increase toArea = rim width X part width = 3 mmX 5 mm = 15 mm2. That’s 60 timesmore area to cope with the samematerial-removal, meaning 60 times thenumber of grits doing the same work.

So what does this mean? Here are somethings to consider:

1) If you take different depths of cut –say 0.050 mm (0.002”) on one pass,then 0.025 mm (0.001”) in the nextpass, the taper will develop based onthe largest depth of cut. So here thetaper will be 0.050 mm (0.002”) high,and when you take the 0.025 mm(0.001”) depth of cut, you’ll be usingonly half of the available wheel face.This is shown in (c). Then you’ll wearonly on that face of the wheel and whenyou take the 0.050 mm (0.002”) depthagain, you’ll be grinding partially onthe face again. In other words, yourtaper will be inconsistent and messedup, and you’ll pay the price with a

rougher surface finish, more wheelwear and more frequent truings.

2) Consider whether you’re infeedingonly on the forward pass or on both theforward and back passes. If you’reinfeeding on both, you’ll develop ataper on both sides as shown in (d).Now you’re contact area consists ofonly half of the rim width, meaningmore wheel wear.

Can you measure the taper? Sure. Justtake a chunk of material and plunge thewheel axially (not radially) straightdown into it. Then take that and look atthe profile under a low-magnificationmicroscope. You won’t see a perfecttaper as shown in the diagrams, butyou’ll see something close to it.

3) Consider how is the taper affectingsurface finish. When the taper fullydevelops, your final part dimension isbeing formed by a line-contact at theend of the taper instead of an area-contact. This will mean a larger roughersurface finish. This brings me to point(4):

4) Can we dress that flat into the wheelto begin with? Let’s say you don’t relyon the break-in period to form yourwheel, but rather you form it yourself.Now you can say, “I want to use 2.5mm of my rim for rough-grinding and0.5 mm of my rim for finish-grinding.”This is shown in (e). Here the forces onthe wheel during rough-grinding areeven throughout and you have a flatarea to really polish off surface finish.Most truing stations will let you anglethe wheel. Let’s say you want to take aconsistent (never larger) depth of cut of0.100 mm and use 2.5 mm of your rimfor roughing (and 0.5 mm forfinishing). Then a truing angle ofangle=atangent(0.1/2.5)=2.3º.

5) Am I grinding too timidly andgenerating lots of heat? Since the forcesare so large during the break-in periodwhen grinding on the small-area face,grinders will slow down their feedrateto avoid chipping and burning.However, once the taper breaks in, thisslow feedrate hurts them, as now theforces on the bottom of the rim are too

small! (Remember how the areaincreased by a factor of 60?) Thatmeans that the grit penetration depth istoo small. Tungsten-carbide is acombination of hard tungsten-carbideparticles held in a soft cobalt matrix.When the grit penetration depth is toosmall, the grits don’t easily form a chip– the tungsten-carbide particles just getpushed around within the cobalt,leading to lots of rubbing and heatgeneration. This heat causes “diamondburn”, or graphitization of the diamond,and “bond burn”, or softening orburning away of the resin. This meansexcessive temperatures and excessivewheel wear.

The in-the-ballpark magic number hereis one micron. When the gritpenetration depth is much below onemicron, we get lots of rubbing, heatgeneration, diamond burn and bondburn. When it’s around 1.5 micron, weget nice chip-formation. If it gets in thetwo- or three-micron range, we get “gritripout”, where the forces on the gritsare so large that the grits quickly rip outof the bond material before they’ve hada chance to do much work. How do youcalculate it the grit-penetration depth?This is something I talk about in mygrinding courses.

In other words, if you’re grinding like awimp, expect lots of burn and wheelwear.

Those are five key points when doingcup-wheel grinding. Take a look at yourgrinding process and see how they fitin. If you make changes, implementthem one at a time and see how theywork out.

Dr. Badger's BackgroundThis is the same Dr. Badger who writesa full page column every month inCutting Tool Engineering magazine.

He has worked with several people inour industries and is very highlyregarded. He is willing to put onseminars and training sessions. If youwould be interested in a seminar in yourplant please contact Dr. Badger.

Jeffrey A. Badger, Ph.D.

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The Grinding DocExpert in grindingIndependent Consultant(+1) [email protected]://www.cuttingtoolengineering.com/

Grinding CourseThe next three-day High IntensityGrinding Course is scheduled forOctober 19-21 in Columbus, Ohio,hosted by Diamond Innovations.

Half the reason to attend the course is toget The Book of Grinding and TheGrinder’s Toolbox. The Book ofGrinding is 1500 pages of hardcoregrinding information presented in astraightforward, practical, down-to-earth and often funny way. Previousattendees tell me they refer back to itover and over for years after the course.Is it better to dress uni-directional oranti-directional? Check The Book ofGrinding. Am I truing my resin-bondeddiamond wheel correctly? Check outThe Book of Grinding. How should Isize my coolant nozzle and whatflowrate do I need? It’s in The Book ofGrinding. Why isn’t my cleaningnozzle removing loading? The mostcommon mistake is given in The Bookof Grinding.

The Grinder’s Toolbox is an Excelspreadsheet with tabs for surfacegrinding, cylindrical-traverse grinding,cylindrical-plunge grinding, single-point and blade dressing, plunge-rolldressing, plunge-disc dressing, diamondtruing, and cooling. Input yourparameters and get hard-hitting advicefrom The Grinding Viking.

If you want to take control of yourgrinding operations in a steady, long-term and significant way, whetheryou’re a grinder, a wheel salesman, or amachine builder, The High IntensityGrinding Course is the place to be.

Details at www.TheGrindingDoc.com.

Western Saw Filer'sEducational Association

Conference in SeptemberSeptember 16th and 17th at theMonarch Hotel in Portland, OR.

This year's workshops will be allbandsaws. It will cover bandmillalignment, bandmill maintenance, sawgeometry and many other issues relatedto bandsawing. There will also beworkshops on band wheel grinding andtooling.

Some of the most knowledgeablepeople in the industry will be presentinga series of workshops designed toaddress a wide variety of problems andsolutions to those problems.

We encourage any and all sawmills tosend their Saw Filers to this program.Dollar for dollar you will not find amore comprehensive one day workshopanywhere. For less than the cost of aconsultant for a day you can send thewhole Filing crew to these workshops.The information they bring back to themill will pay dividends for years tocome.

As always, Filers are welcome to invitetheir Management or Maintenancepersonnel to join them at theworkshops.

For more information please contactBill Saily at [email protected] [email protected] to see you all there.

There will be Free FoodAnd Beverages plus Door Prizes

“Hi Perry. I tried to be more careful inmy proofreading this month.”

How the Convention Works(In case you have never been)

This is a really friendly group and agood chance to meet fellow filers aswell as new vendors. If you don’t knowanyone ask for Mike West or BillSailly. They will be happy to see youand will introduce you.

Friday night is a social night. There is afree buffet for everyone, filers andvendors. Each vendor has free drinktickets. Vendors have booths setupdisplaying their wares. In order to get afree drink you just go up to the vendorand ask for a drink ticket. It'sconsidered polite to show interest in thevendor's products. This is not a bigdeal but they are paying for your foodand drinks.

Saturday is full of training sessions. Thesessions start on time and tend to beintensely focused on practical matters.At the end of the sessions time isallowed for questions. It doesn't hurt totake notes on things you might want askabout at the end of the session.Questions are answered by the speaker,by other filers or both.

There are drawings for door prizesthroughout the day.

Lunch is a buffet and it is a good buffet.There are a bunch of tables set up. Afteryou go through the line you look aroundand find a table and sit down. You maysit wherever you wish and this is a goodway to get to meet speakers or otherfilers. In many cases this is also a kindof informal training as a lot of thingsdiscussed at the table are work related.

The four o'clock session is a free beersession sponsored by CarbideProcessors. Free beer, wine and sodasduring the last speech.

The greatest benefit comes formcontacts. Meet some people. Get cardsfrom Vendors. Then you havesomeone to call when you have aproblem. They may not know but theycan refer you on. Two or three calls oremails and you can have a straightanswer and a real solution.

Page 8: Carbide Processors, Inc.carbideprocessors.com › content › nl-aug-11.pdfEmily but we will get it done. We just ask for a little patience. My New Hero Dale Nostrand Universal Saw

PRESORT STDUS POSTAGE

PAIDTacoma, WA

Permit No. 356

Carbide Processors, Inc.3847 S. Union Ave.Tacoma, WA 98409

Inside

1. Make Money Selling ScrapHow to ship 30# for $11 and makeabout $225.00

2. Western Sawfilers MeetingSeptember 16 & 17 in Portland, OrAll Bandsaws - all Day

3. Solving Filing ProblemsOne of the huge advantages ofattending the Sawfiler meeting is tomeet other filers. Show up at thePeerless Booth and tell them you wantto be introduced to other filers. Nexttime you have a problem you may beable to solve it with a couple phonecalls to other filers. (Plus free food,beer and door prizes.)

We Have CarbideWe saw the problem coming andgreatly increased our inventory.

We have been multi-sourcing carbidefrom around the world now and we arepretty good at it.

If you are having problems with yourcurrent supplier we can probably help.

Braze Alloy in SmallQuantities at Good Prices

800 346-8274

We Also Sell FluxWhite, Black and Purified Black

ADDRESS SERVICE REQUESTED

Chinese CarbideWe are the experts on pretinningChinese Carbide. We are on the westcoast so there is no additional shippingand very little extra delay.

Carbide Grades to Solve Problems,Cut Costs and Improve Productivity

You really should try our Super C andCermet 2 grades of saw tips.

Super C replaces all grades from abouta C 1 ½ to a C 3 1/2. It gives muchlonger life and is much harder to breakthan any of these grades.

Our Cermet 2 replaces C-4 and givesmuch, much longer life. The Cermet 2is much better than the original cermetgrades. Cermet 2 grades braze and grindjust like C-4 carbide but stays sharp alot longer.