Engineering Software – Description & Pricing

Pricing Information: Call Dale Savington 402-334-8025

The interactive engineering software is available for use online by purchasing a subscription.

A PURCHASE ORDER, subject to approval, may be used to purchase the subscription.  Pricing for the software is as follows:

Unlimited Usage 24/7 I.D. & Password provided and required. * Pricing Varies on usage Please Call & Discuss!

$750.00 per year.*

To see PowerPoint description of software, click here!

“For best results click on “Slide Show” (icon) in bottom right hand corner after reaching the presentation. Be patient if you want to view without downloading. The file is large and can take a few seconds to load each slide”.

Software Description:

An interactive Superabrasive grinding and machining software program that develops grinding and machining operating conditions and results (actual and projected) based on the user's input. The program utilizes hyperlinks to move freely throughout the different sheets and instructions. Individual sheets and the instruction pages are full of helpful comments and hyperlinks to graphic presentations and full explanations of key input data. The program is separated into multiple sections:

Terms & General Instructions

Cylindrical Grinding Process Sheets

Capability Analysis

Cylindrical Grinding

Centerless Grinding

Surface Grinding

Grinding Cost Model

Hard Turning

Turning Insert Testing

Machining Cost Model

Terms & General Instructions

Guides the user, through detailed instructions with hyperlinks to very graphic and informative descriptions on terms used throughout the various sheets.

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Cylindrical Grinding Process Sheet

We have as of 1/1/08 added three new sections for the Cylindrical Grinding section. The new sections will allow the user to input up to 5 diameters and 5 faces per part number and work in either “inches” or “Metric” measurements. The process side allows the user to input data as would be input on the grinder for developing the actual process. A separate sheet is calculating feed rates per diameter and /or face in every conceivable process from Conventional to “Peel” grinding. At the same time all the information you have entered is being calculated so you can compare the actual to the recommended.

We have also added a Capability Analysis section so you can drop in up to 50 measurements and get Cp, Cpk, Cpu, Cpl, Estimated Sigma (STDEV), Pp, Ppk, Ppu, Ppl, Sigma (STDEV), Sigma Level and DPMO.

Sorry but we do not have samples sheets of the new sections as of this writing!

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Cylindrical Grinding Process Sheet
Separated into two cylindrical grinding processes (outside and inside diameter grinding) the software directs the user, by use of the tab key, or mouse to each successive input field. Each input leads to a suggested variable; In-feed rates, Traverse feed rates, Spark-out in seconds and number of passes, Flow rates (GPM), Nozzle design or height of nozzle opening, Coolant flow pressure (PSI), all based on the user input of Q’ (Q Prime) and subsequent input data.
Calculations based on the user’s input include:

¨ Balance head Requirements

¨ Wheel S.F.P.M.

¨ Work S.F.P.M.

¨ Vs/Vw

¨ Abrasive type (CBN or diamond)

¨ Abrasive "grit size"

¨ Coolant velocity relative to wheel velocity (%)

¨ Starting diameter

¨ Roller dresser S.F.P.M. (if relative)

¨ Diamond traverse per rotation of wheel

¨ Diamond overlap per pass

¨ Q’ (Q Prime) plunge cycle time

¨ Q’ (Q Prime) In-feed rate

¨ Total plunge cycle time

¨ Finish traverse Time

¨ Total traverse time

¨ Volume of work per wheel

¨ "G" (Grinding) ratio

¨ Percent of abrasive diameter per rotation of work (rough plunge and rough traverse)

¨ Estimated pieces per dress

¨ Estimated pieces per wheel

¨ Wheel cost per part

¨ Total in the grind cycle time

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Centerless Grinding Process Sheet

Similar in design and flow to the cylindrical grinding process sheet, it is separated into the various centerless grinding processes (end-feed or in-feed and through-feed) the software directs the user, by use of the tab key, to each successive input field. Each input leads to a suggested variable; In-feed rates, Traverse feed rates, Spark-out in seconds and number of passes, Angle of regulating wheel, Blade height above center line, Flow rates (GPM), Nozzle design or height of nozzle opening, Coolant flow pressure (PSI), all based on the user input of Q’ (Q Prime) and subsequent input data.
Calculations based on the user's input include:

¨ Balance head Requirements

¨ Wheel S.F.P.M.

¨ Regulating Wheel S.F.P.M.

¨ Vs/Vw

¨ Truing angle setting

¨ Diamond holder setting

¨ Abrasive type (CBN or diamond)

¨ Abrasive "grit size"

¨ Coolant velocity relative to wheel velocity (%)

¨ Starting diameter

¨ Roller dresser S.F.P.M. (if relative)

¨ Diamond traverse per rotation of wheel

¨ Diamond overlap per pass

¨ Q’ (Q Prime) plunge cycle time

¨ Q’ (Q Prime) In-feed rate

¨ Total plunge cycle time

¨ Finish traverse Time

¨ Total traverse time

¨ Volume of work per wheel

¨ "G" (Grinding) ratio

¨ Percent of abrasive diameter per rotation of work (rough plunge and rough traverse)

¨ Estimated pieces per dress

¨ Estimated pieces per wheel

¨ Wheel cost per part

¨ Total in the grind cycle time

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Surface Grinding Process Sheet

Again, similar in design and flow to the cylindrical grinding process sheet, it is separated into three surface grinding processes (conventional, creep-feed and High Efficient Deep Grinding or HEDG) and the variety of process types are:

¨ Tool & Cutter

¨ Jig

¨ Horizontal Reciprocating

¨ Vertical Reciprocating

¨ Top & Bottom (Disc.)

¨ Horizontal Rotary

¨ Vertical Rotary

The software directs the user, by use of the tab key or mouse, to each successive input field. Each input leads to a suggested variable; In-feed rates, Traverse feed rates, Spark-out in seconds and number of passes, Work table rpm (if applicable), Cross feeds (if applicable), Flow rates (GPM), Nozzle design or height of nozzle opening, Coolant flow pressure (PSI), all based on the user input of Q’ (Q Prime) and subsequent input data.

Calculations based on the user’s input include:

¨ Balance head Requirements

¨ Wheel S.F.P.M.

¨ Work S.F.P.M.

¨ Vs/Vw

¨ Abrasive type (CBN or diamond)

¨ Abrasive "grit size"

¨ Coolant velocity relative to wheel velocity (%)

¨ Starting diameter

¨ Roller dresser S.F.P.M. (if relative)

¨ Diamond traverse per rotation of wheel

¨ Diamond overlap per pass

¨ Rough grind cycle time

¨ Finish grind cycle time

¨ Total Grinding Time

¨ Volume of work per wheel

¨ "G" (Grinding) ratio

¨ Percent of abrasive diameter per rotation of table(rotary table grinding)

¨ Percentage of abrasive diameter per in-feed (rough conventional grinding)

¨ Estimated pieces per dress

¨ Estimated pieces per wheel

¨ Wheel cost per part

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Grinding Cost Model

This software product calculates a true "Total Grinding Cost". Guiding the user by use of the tab key or mouse, to each successive input field. The program requests input relative to the cost of each of the following process variables:

¨ Operation manpower cost

¨ Wheel cost

¨ Wheel change cost

¨ Dressing roll cost

¨ Dressing roll change cost

¨ Maintenance labor cost

¨ Scrap cost

¨ Coolant cost

¨ Filter cost

¨ Coolant disposal cost

¨ Inspection cost

¨ Inventory cost

Input is then totaled and calculated to show total costs for each of the above variables. The final true cost of the grinding application is calculated by adding together all the total variables.

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Hard Turning Process Sheet

Guides the user by use of the tab key, to each successive input field. Considering more than 20 user variables to determining if the cylindrical process would be acceptable for "hard turning". Based on the user’s input, calculations are made for:

¨ Work S.F.P.M.

¨ Work RPM

¨ Depth of cut

¨ Feed rate (IPR)

¨ What grade of PCBN to test (if applicable)

¨ Cutting time (diameters)

¨ Cutting time (faces)

¨ In³material removal rate (diameter and faces)

The user can have a work sheet for hard turning and run a work sheet for the same product using the cylindrical grinding sheet and have a comparison between hard turning and grinding.

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Turning Insert Test Sheet

Allows the user to develop on the machine “base line” for each turning application. It allows the user to compare new product and technology relative the “base line” developed with the present process. Guided by the tab key to each successive input field, each test sheet will allow up to 4 diameters and 4 faces per part. When the user is finished with real time input, calculations are made for:

¨ Time in cut for all diameters

¨ Time in cut for all faces

¨ Total time in the cut per part

¨ Total time in the cut per tool

¨ In³and mm³of machined material per tool

¨ Linear inch and mm of machined material per tool

Comparing data from the baseline the user can make easy calculations relative to the various products and technology being tested.

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Machining Cost Model

This software product calculates a true "Total Machining Cost", milling and turning. Guiding the user by use of the tab key, to each successive input field. The program requests input relative to the cost of each of the following process variables:

¨ Tool insert cost

¨ On-line labor cost

¨ Set up cost

¨ Tool change cost

¨ Scrap cost

¨ Rework cost

¨ Inspection cost

¨ Inventory cost

¨ Maintenance cost

¨ Coolant cost

¨ Filter cost

¨ Coolant Disposal cost

Input is then totaled and calculated to show total costs for each of the above variables. The final true cost of the machining application is calculated by adding together all the total variables.

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