Grinding technology has advanced significantly during the past 25 years. Unfortunately, the great majority of the machine tool industry has not kept up with those advances and has fed the industry with poor, lackluster designs that will not allow the new technologies to be exploited to their fullest potential.

There are, however grinding processes operating reliably in the industry today, successfully competing with “large chip” processes like broaching, milling, planing and even some turning operations. The principles of creep-feed grinding, high-speed grinding and the proper use of superabrasives are not only better alternatives to the conventional “large chip” machining processes, they also allow the next generation of materials like ceramics, whisker-reinforced metals and fiber-reinforced polymers to be machined easily where there is no alternative.

That is an important point to ponder. As materials become more difficult to machine, it is of paramount importance that the principles of grinding technology are understood. Abrasive machining practices cannot be brushed aside.

Much of the manufacturing industry today is entrenched in the traditional methods of machining. Actually, their rationale is that they are being conservative by maintaining the “status quo.” This is not being conservative at all, it is settling for mediocrity and that breeds the loss of profit and the ability to compete in new markets. Typically, if a company’s operation is milling, then it looks for better ways to mill; if it is broaching, then it looks for better ways to broach, etc. etc. Grinding today is often the overall better alternative method. This is a most difficult message to get across.

Historically, grinding has been most problematic and is traditionally visualized as the process for fine finishing and providing a close tolerance part. Modern grinding processes can offer substantial stock removal rates coupled with high dimensional tolerances and superior, virtually burr-free, surface integrity. Just because abrasive machining is neither milling, nor broaching, nor turning, the conservative traditionalists sweep it aside, mostly because it is something unknown – something new to have to learn and master.

There is inertia and great apathy to want to adopt what appear to be unusual methods. This is generally what the industry calls “being conservative.” Let someone else try it first. Many years ago, EDM and wire EDM were designated “non-conventional” or “non-traditional” processes; today they are well-established techniques and part of the everyday manufacturing world. It is strange that the basic principles of grinding – a process used by Stone-Age man – are viewed by many with such disbelief and contempt.