In 1999, Norton “revolutionized” high metal removal rate grinding in many areas of industrial metalworking with the then novel Altos rod corundum. The new AltosX generation from Saint-Gobain Abrasives, a specialist and leading manufacturer of grinding solutions, has once again significantly increased the level of productivity and quality, according to the manufacturer: The special combination of sintered rod corundum and new microstructure offers extremely high stock removal rates with lower power consumption, resulting in significant cost savings in many areas of high-precision grinding.
“Wherever grinding processes need to be optimized, AltosX will exceed your expectations.” With this promise, Norton sets the bar high. Dr. Stefan Kemethmüller, Sales Director Engineering Markets D-A-CH at Saint-Gobain Abrasives: “Creepfeed and surface grinding, gear and gearwheel grinding, tool grinding, large external and internal cylindrical applications – in these and many other applications, AltosX is the optimal solution that ensures significant productivity increases. Tests have shown AltosX is more efficient than any other wheel on the market, delivering twice the stock removal rate for the same power consumption. The natural porosity provides better coolant diffusion and balancing of the disc, while the uniform grain distribution ensures a more stable cut.”
Norton Altos is a ceramic grain with a microcrystalline structure in rod form with an aspect ratio (length to diameter) of 8 to 1. It allows for low packing density in manufacturing, which, when combined with the new Quantum grain and bond technology, results in an open, porous structure that significantly improves coolant diffusion. Despite the porosity of the bonding matrix, the grain retention forces are very high according to the manufacturer.
Thanks to Norton Quantum technology, AltosX features improved grain breakage behavior, resulting in more stable grinding performance. Due to the self-sharpening effect, the disc remains particularly easy to cut for longer, which additionally reduces heat generation and wear. In addition, dressing cycles are extended and faster feeds and higher infeeds are possible during grinding. In addition to the productivity benefits, AltosX also protects people and the environment: The longer tool life reduces tool requirements and thus raw material and energy consumption. In addition, naphthalene is not used in the manufacturing process.
According to Dr. Axel Schwechheimer, head of application engineering, “By optimizing grinding parameters, AltosX grinding wheels achieve unmatched material removal rates (MRR) and improved part quality, minimizing scrap rates and reducing cycle and downtime – all with cool grinding and no dulling or breakdown of the grain. All of this significantly reduces costs.”
According to Saint-Gobain Abrasives, practical examples provide impressive proof of the considerable performance increases: In the internal and external cylindrical grinding of a large wind turbine bearing (diameter 2,500mm, >58 HRc), it was possible to increase the infeed by 35 percent and simultaneously reduce the spindle power by 20 percent compared to the comparative tool from the market environment. The dressing cycle decreased by 33 percent, increasing wheel life by 33 percent. This exceptional performance of AltosX in material removal and tool life also guarantees – according to the selected abrasive grit size – a stable surface finish.
In another case study involving deep grinding of STD auto steel (57 to 62 HRc; material removal 1 to 2 mm), the supplier says it was possible to increase infeed by 45 percent without causing thermal degradation of the workpiece. Scrap has been reduced from the previous 5 to 10 percent to almost 0.
Stefan Kemethmüller: “AltosX sets new standards in efficiency and will be the solution that sets the benchmark, enabling users to meet ever-increasing part quality requirements and their productivity goals.”