Challenges
-Grinding Kirschner wires, or K-wires, using a manual OD grinder poses challenges that directly impact production efficiency.
-The slow output of grinding one wire at a time, lengthy changeovers between wire diameters, and the need for additional deburring processes all contribute to delays in production, hindering overall efficiency.
Solution
MMT’s Tridex division optimized efficiency by using the Burr-Free Electrochemical Grinders SG-1645 and SG-2060, integrated with the Tridex PGS-100 ECG Point Grinding System to grind points in large batches, resulting in the following efficiencies:
-Electrochemical Grinding (ECG) provides burr-free and low-force cutting for applications with tight tolerances and heat sensitivity. This eliminates the need to deburr, reducing production time.
-This solution is capable of grinding almost any point geometry, including trocars, drills, and multi-faceted points on exotic and difficult-to-machine materials
-Only a simple CNC program edit is necessary to change the point geometry.
-The PGS-100 can be added to the SG-1645 or SG-2060 to grind points on the wires in large batches.
Results
In one test batch, 55 K-wires with a .065″ diameter were efficiently pointed, with each wire processed in a cycle time of 2.2 seconds. The PGS-100 ECG Point Grinder’s streamlined design enables quick changeovers between diameters, requiring an average of only 5 minutes. Additionally, the ECG technology substantially extends wheel life, leading to reduced consumables costs. This versatile system ensures the production of plain or threaded parts with consistent precision. Moreover, the process can be seamlessly applied to the grinding of Steinmann Pins, showcasing its adaptability across various applications.
MMT recommends its Glebar CAM.2 Microgrinder for K-Wires that require multiple profiles.
Reduces machining time, increasing output.
Significantly lengthens wheel life, reducing consumables costs.
Eliminates the need to deburr, reducing production time.
Allows machining of various tips, including trocars, drills, multi-faceted, etc.
Plain or threaded parts can be produced with the same accuracy.
Capable of grinding almost any point geometry on exotic and difficult to machine materials.
The same process can be applied to grinding Steinmann Pins.
