The Book of Grinding

About the Book

The Book of Grinding is 2000 pages of detailed, practical, down-to-earth information on grinding, developed over 15 years by Dr. Badger. Attendees to Dr. Badger’s courses receive an electronic copy of the book, now in searchable pdf format.  Subjects covered are given below.

The Book of Grinding is presented in a straightforward, easy-to-understand format. Complicated concepts in grinding theory are translated into practical terms. Equations are given in simple format with units. This is the best literature currently in existence on the subject of grinding.

A sample of pages from The Book of Grinding can be downloaded here, in pdf format.


Materials Included

The Book of Grinding includes a free CD of The Grinder’s Toolbox®.

Purchase

The Book of Grinding is currently only available to attendees to one of Dr. Badger’s courses. In July 2015 it will be available for purchase with an audio narration. However, to receive the full benefit, Dr. Badger strongly urges people to attend one of his courses.


The Grinding Doc talks about grinding literature and The Book of Grinding in his award-winning CTE
video series.

Subjects

wheel fundamentals:  grit, bond, porosity • reading a wheel specification • rubbing, cutting & plowing • wheel grade • heat generation • calculating specific material removal rate • grit penetration depth & “the size effect” & its effect on heat-generation • specific energy & the effect of grit-penetration depth • the “one micron” rule •  the tree regimes of wheel wear • measuring wheel with via the “No-Dress Test” • G-ratio • thermal damage & burn in ferrous materials: oxidation burn, overtempering, residual tensile stresses, rehardening burn/white layer • thermal damage in tungsten carbide & brittle materials • single-point dressing •choosing dressing depth •overlap ratio • common mistakes in single-point dressing • cluster diamonds & blades, how to use them• using The Grinder’s Toolbox® in single-point dressing • rotary dressing speed ratio • uni-directional vs. anti-directional dressing, how dressing anti-directionally is an easy recipe for burn • choosing plunge depth • choosing dwell time • common mistakes in rotary dressing • RPM ratio & waviness• using The Grinder’s Toolbox® in rotary dressing • cooling: pressure, velocity & flowrate, which is most important • breaking the air barrier •  calculating pressure • calculating flowrate • nozzle design • commercial nozzles • Webster designs • nozzle aim • case studies in cooling • where cooling improvements help, where they don’t  • lubrication effects vs. cooling effects • cleaning nozzle, common mistakes • using The Grinder’s Toolbox® in cooling • superabrasive fundamentals • CBN on steel: transient behavior • slowing CBN wheel “opening up”, choosing speeds & feeds • diamond on carbide: transient behavior • loading in carbide grinding, how to mitigate • finding the “sweet spot” • hybrid-bond G-force/Naxo-force wheels, how to use them correctly • truing of diamond & CBN wheels • “sticking of wheels” • selecting stick grit-size • choosing sticking parameters • Aggressiveness & grit penetration depth • finding the sweet spot via Aggressiveness  • achieving higher specific material removal rates by keeping Aggressiveness constant • using The Grinder’s Toolbox® in choosing Aggressiveness & grit-penetration depth • loading in ferrous materials, stainless • reducing loading • reducing burr • chatter: self-excited vs. forced • pinpointing cause of chatter via distance between chatter marks • eliminating forced chatter • reducing self-excited chatter • RPM-ratio chatter in cylindrical grinding • ceramic “SG” Cubitron abrasive • common mistakes in using ceramic abrasive • case studies in ceramic abrasive  • Norton TG abrasive • choosing speeds & feeds & Aggressiveness for ceramic-abrasive self-sharpening • The Mountain of Burn, avoiding high temperatures • Cycle Mapping for cycle-time reduction • Grindonomics: how to reduce grinding costs • common mistakes in reducing grinding costs • using The Grinder’s Toolbox in cooling • New developments in grinding • up-grinding vs. down-grinding • grindability of high-speed steels • conventional HSS vs. powder HSS • surface quality and its effect on part quality • predicting grinding temperatures  • temperature predictions in The Grinder’s Toolbox® • Continuous-dress creep-feed grinding of nickel alloys • introduction to grinding of ceramics • wheel/workpiece stiffness • cylindrical-plunge grinding, choosing parameters, reducing temperatures • using The Grinder’s Toolbox® in cylindrical plunge grinding • cylindrical-traverse grinding • using The Grinder’s Toolbox® in cylindrical-traverse grinding

 

Electronic Version for previous course attendees: The Book of Grinding is now available in electronic format. Previous attendees to either the High Intensity Grinding Course or the Carbide Master-Grinder Clinic may purchase a personal copy, which includes the latest version of The Grinder’s Toolbox, for $625 by clicking the link below. Within 24 hours of payment you will receive a link to Dropbox.com, which will allow you to download the 150 MB material. Each copy is for personal use only, is password-protected and contains the user’s name.

A sample version of the pdf can be downloaded here.