High Intensity Grinding Course

What is the High Intensity Grinding Course?

The High Intensity Grinding Course is a three-day course on grinding with conventional and superabrasives. It is aimed at those who already have at least some experience in grinding and want to obtain an in-depth understanding of production grinding.

Each attendee receives a copy of The Book of Grinding and The Grinder’s Toolbox.

Goals of Course

This is a very intense course. Attendees will come out of the course with the knowledge and tools to make significant improvements to their grinding operations, including quality improvements, cycle-time reduction, cost-savings and reduction in consumables. In addition, attendees continue to use the supporting material for years after the clinic.

Topics Covered

Conventional abrasives • superabrasives • specifying a wheel • choosing a grit size • common mistakes in choosing grit size • single-point dressing • choosing appropriate dressing parameters for wheel sharpness & avoiding excessive diamond wear • rotary dressing • dressing uni-directional vs. anti-directional • choosing appropriate plunge speed or traverse speed for wheel sharpness & avoiding excess diamond wear • common mistakes in rotary dressing • truing & conditioning of superabrasives • common mistakes in truing • burn • reducing burn • identifying genuine thermal damage “burn” vs. oxidation burn • burr • how to reduce burr • loading • identifying cause of loading • reducing loading • cleaning nozzle for loading • chatter • identifying source of chatter • obliterating chatter in cylindrical grinding via RPM ratio • surface finish • common mistakes in achieving surface finish • cooling • pressure vs. velocity vs. flowrate in cooling • nozzle design • nozzle aim • sizing the nozzle to avoid pressure drop • common mistakes in cooling • cleaning nozzle • common mistake in sizing cleaning nozzle • ceramic “SG” abrasive • Cubitron & Quantum grits • how to choose speeds & feeds via “Aggressiveness” in ceramic abrasive • finding the “sweet spot” of the wheel • cylindrical grinding, choosing speeds & feeds for cycle-time reduction & low temperatures • up-grinding vs. down-grinding • cost reduction • cycle-time reduction • grinding of hardened steel • tungsten-carbide • continuous-dress grinding of nickel alloys • using The Grinder’s Toolbox to choose optimum cooling, grinding & dressing parameters • new developments in grinding

In addition to valuable lessons on Grinding, you will get the opportunity to be on hands with the The Grinder’s Toolbox, a tool used to choose optimum cooling, grinding & dressing parameters. 

Brochure: A four-page pdf brochure about the clinic can be downloaded here.

Upcoming Courses

DatesHost and LocationReduced Price Deadline
May 30 - June 1, 2017AMRC, Sheffield, EnglandApril 28, 2017
September 26-28, 2017S.L. Munson & Co., Columbia, SCAugust 28, 2017
Courses in the USBefore DeadlineAfter Deadline
1 Attendee$2,900$3,100
1 Attendee + The Grindometer $14,400$14,600
2 Attendees$2,650 per attendee$2,850 per attendee
3+ Attendees$2,300 per attendee$2,500 per attendee
Courses in EuropeBefore DeadlineAfter Deadline
1 Attendee€2,500€2,650
1 Attendee + The Grindometer €11,250€11,400
2 Attendees€2,300 per attendee€2,450 per attendee
3+ Attendees€2,050 per attendee€2,200 per attendee
Courses in UKBefore DeadlineAfter Deadline
1 Attendee£1,800£1,900
1 Attendee + The Grindometer £8,120£8,220
2 Attendees£1,660 per attendee£1,760 per attendee
3+ Attendees£1,480 per attendee£1,580 per attendee

*Details on location and dates forthcoming

Register: To register for the course, click here.

Additional Details:

Host: Some courses are held at a hotel and some are held at a host company. Previous hosts have been Rollomatic in Chicago, Illinois; Blaser Swisslube in Switzerland; Erasteel in Paris; Greenlee Diamond in Chicago; Diamond Innovations in Columbus, Ohio; Atlas Machine in Louisville, Kentucky; The Royal Institute of Technology in Stockholm, Sweden; Blaser Swisslube  in Goshen, New York; and Trinity College in Dublin, Ireland. Since my courses are non-commercial, the hosts will get no “air time” to promote their products. They are just being gracious and hosting the course. During the two-hour lunch on the Day 2 of the course, attendees may attend a tour of the host’s facilities, followed by an informal lunch offered by the host. This tour is optional. Courses held at a host company are open to anyone. However, if a course attendee comes from a competitor company, the host may restrict access to the company tour. All other aspects of the course remain the same. Certificate:  Each attendee will receive a framed certificate stating he/she attended the course. Language: The course will be held in English. Dr. Badger has lived and worked around the world and speaks standard, easy-to-understand English. Also, the course and the course material are graphics-orientated, rather than word-orientated, so even people whose English is not perfect will be able to follow along without difficulty. Who Should Take the High Intensity Grinding Course: People who already have some experience and knowledge in grinding. • People grinding steels, high-speed steels, carbide, nickel-based alloys and other metals. • People who want to develop an in-depth understanding of grinding from the ground up.  Examples of people who have taken the course: A machine operator grinding camshafts, wanting to improve productivity and quality and reduce grinding costs. • Salesperson selling conventional and superabrasive grinding wheels. • Engineer at a coolant company, wanting to better understand coolant application and his customers’ grinding needs. • Production manager at company producing tungsten-carbide endmills, wanting to reduce cycle times. • Engineer at a machine shop grinding a bit of everything. • Engineer grinding nickel alloy turbine blades. • Production manager at company grinding biomedical devices. Who Should NOT Take the High Intensity Grinding Course: People who want a light overview of grinding. The Intense Course is for those who want an in-depth understanding of grinding from top to bottom. • People with absolutely no grinding experience or knowledge. • People looking for information on electrolytic in-process dressing, electro-chemical grinding, etc. • People using only coated abrasives, or looking for information on honing, lapping, polishing or abrasive-jet machining.]


Day 1 8:30 a.m. – 4:30 p.m.
12:30 p.m. – 1:30 p.m.Group lunch
7:00 p.m. – 9:00 p.m. Group Dinner: Included in price. Spouses welcome.
Day 28:30 a.m. – 4:30 p.m.
12:00 p.m. – 1:00p.m.Lunch
Evening Open.
Day 38:30 a.m. – 4:30 p.m.
12:00 p.m. – 12:30 p.m.Working lunch. Pizza/sandwiches ordered in.
Hotel Information
Visit our hotel information page here to receive important information pertaining hotel address, special rates, and the steps to booking the hotel.

Are you interested in hosting a course? Click here for information.