Methods: Through a combination of lectures, group brainstorming sessions and demonstrations, attendees learn core concepts in grinding, dressing and cooling and five Key Analysis Tools which enable them to go into any grinding situation and make significant improvements in quality and efficiency and reductions in cycle time.

Supporting Material: 1) The Book of Grinding: 1500 pages of hardcore educational and reference material that you will visit and revisit for years after the course as new situations arise. It is the most in-depth and comprehensive material that exists on the subject, presenting grinding in practical, easy-to-use layman’s terms; 2) The Grinder's Toolbox: a simple yet powerful program for calculating optimum grinding, dressing and cooling parameters.

Subjects: 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 “grinding burn” vs. oxidation burn ◊ burr ◊ how to reduce burr ◊ loading ◊ identifying cause of loading ◊ reducing loading ◊ cleaning nozzle for loading ◊ chatter ◊ identifying cause 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 ◊ Key Analysis Tool 1: The No-Dress Test ◊ Key Analysis Tool 2: Measurement & interpretation of the power profile ◊ Key Analysis Tool 3: Aggressiveness ◊ Key Analysis Tool 4: The Grinder’s Toolbox ◊ Key Analysis Tool 5: Cycle Mapping ◊ The Book of Grinding ◊ Long-term use of The Book of Grinding & The Grinder’s Toolbox for continuous improvement.

• 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.

• 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.

• 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.

• You will be expected to take part in group discussions.
• You must be capable of reading simple graphs and charts.
• You must be capable of doing simple math and understanding basic equations.

Tour: A tour of Diamond Innovations' production facilities is held during lunch on Day 2. The tour is optional, but I strongly urge people to attend as it is a fascinating and unique opportunity to see how diamonds are produced. (Please note: Attendees from DI competitors are welcome to attend the course, but DI reserves the right to restrict access during the tour if appropriate.)

Previous hosts have been Rollomatic in Chicago, Blaser Swisslube in Switzerland, Erasteel in Paris, Greenlee Diamond in Chicago and Trinity College in Dublin, Ireland.

This is the best technical course I have ever taken, in any subject. It is very practical without getting too scientific.

Boris — grinder of aircraft engines

The Doc's course gave me an entirely new way to look at things.

Jim — grinder of solid-carbide tools

I learned 10 times more here than I learned at the grinding-wheel company's course.

Andy — Camshaft Grinder

The thing that I liked best about the Grinding Doc seminar was that you did not present yourself to us as a PhD. You understand that the people that you are teaching know their business and know about grinding. What you try to get through to us is your deep understanding of the grinding process itself, and how having a clearer vision of just how the process works at the level of the grit and the grain will help us to make better practical decisions on the shop floor. I have already employed some of the concepts from the course in our shop, and anticipate using many more in the coming months. This was a great course for learning practical grinding information – the only one that I have seen to this point.

John Shegda — M&S Centerless Grinding

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