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GEAR MANUFACTURER REDUCES GRINDING CYCLE TIME BY 25%

A custom-profiled Weiler grinding wheel helped a Georgia gear manufacturer improve grinding performance, reduce interruptions and complete a critical gear grinding application more efficiently.

The solution reduced the grinding cycle from 24 hours to 18 hours, saving 6 hours per part.

 

Custom-profiled Weiler wheel installed in the manufacturer’s gear grinding cell.

Custom-profiled Weiler wheel installed in the manufacturer’s gear grinding cell.

The Impact: Measured Grinding Improvements

25 %
Shorter Grinding Cycle
30 +%
Greater Potential Throughput
50 %
Fewer Grinding Interruptions

The Challenge: Long Lead Times and Inconsistent Support Created Production Risk

The manufacturer handles urgent gear and gearbox repair work where every hour matters. Its team needed a supplier that could support changing gear profiles, provide clear technical guidance and respond quickly when a custom wheel was required.

Limited technical support for gear grinding applications

Limited Technical Support

Application guidance was not consistently available for changing grinding requirements.

Grinding interruptions during gear manufacturing

Grinding Interruptions

Inconsistent wheel performance required adjustments that interrupted time-sensitive work.

Long lead times for custom gear grinding wheels

Long Lead Times

Special-order grinding wheels could take 16 weeks or more to arrive, creating risk for urgent repair work.

Limited specification guidance for gear grinding wheels

Limited Guidance

The team needed clearer wheel specifications and technical documentation to support future applications and repeat orders.

The Approach: Build the Grinding Solution Around the Application

Weiler’s technical team reviewed the manufacturer’s equipment, wheel specifications, gear geometries and production requirements. Rather than simply replacing the existing wheel, the teams developed a more dependable grinding and supply process.

  • Reviewed the existing grinding process and wheel specifications

  • Identified the applications creating the greatest supply and performance challenges

  • Recommended a wheel specification for the machine and gear profile

  • Profiled the required wheel in Weiler’s in-house gear cell

  • Provided technical documentation and ongoing application support

Profiling a gear wheel in the Weiler in-house gear cell.

 

The Solution: A Custom-Profiled Wheel Designed for the Gear and Machine

Based on the application review, Weiler developed a custom-profiled grinding wheel matched to the manufacturer’s equipment, gear geometry and performance requirements.

The wheel delivered more stable grinding performance, reduced the need for mid-process adjustments and helped the operator complete the gear more efficiently.

Overhead view of wheel approaching a gear.

 

The Result: Six Hours Removed from a Critical Grinding Cycle

The custom grinding-wheel solution reduced the grinding cycle from 24 hours to 18 hours—a six-hour, or 25%, reduction. With each part requiring less grinding time, the same available production time could support more than 30% greater potential throughput. More stable wheel performance also reduced grinding interruptions by 50%, helping the operator maintain a more consistent process.

24 TO 18 HOURS
Grinding cycle reduced by six hours

MORE THAN 30%
Greater potential throughput

50% FEWER
Grinding interruptions

16+ WEEKS TO 2 WEEKS
Average custom-wheel delivery time

Gear after grinding 4 levels.

 

See the Full Gear Grinding Story

Learn how the manufacturer’s team worked with Weiler to evaluate the application, develop the custom-profiled wheel and create more than 30% greater potential throughput from the same available grinding time. Read the Article

The Impact: Performance and Availability Work Together

For a manufacturer supporting urgent gearbox repairs, wheel performance is only part of the equation. Reducing the cycle from 24 hours to 18 hours created more potential production capacity from the same equipment, while fewer interruptions helped the operator maintain a more consistent process.

Availability was equally important. A wheel that performs well but cannot be sourced quickly still creates production risk. The relationship gave the manufacturer access to application-specific recommendations, custom profiling, technical documentation and a more responsive supply process. Through Weiler’s Precision Express program, gear manufacturers can access on-hand wheel inventory and in-house profiling capabilities designed to reduce custom-wheel lead times and keep critical grinding work moving.

A Global Abrasives Partner Focused on Mutual Success

At Weiler Abrasives, our experience dates back to 1898 when Joseph E. Weiler began manufacturing brushes for the jewelry industry in Pforzheim, Germany. Since then, we’ve grown and evolved into a global manufacturer serving customers in over 80 countries with nearly 1,500 employees around the world.

“While the company has grown and expanded significantly since those humble beginnings, our commitment to developing long-term partnerships with customers, co-workers, and community hasn’t changed. We like to call that our 3C’s.” Chris Weiler, Executive Chairman.

Whether you are looking to improve your surface conditioning processes, optimize your consumable spend, or train your team on the safe and proper use of abrasives and brushes, Weiler has the people and expertise to help you achieve your goals.

Weiler: Your Competitive Edge

For those who want a competitive edge and value productivity-enhancing solutions for cleaning, grinding, cutting, deburring, and finishing, Weiler is a premier abrasives supplier who forges collaborative, problem-solving relationships with our customers. We work with you to solve your challenges, enabling your business to get more done and, ultimately, improve your top and bottom line. It’s not just about what we do; it’s about how we do it, we call it The Weiler Way. That’s the Weiler difference.

Product Innovations

weiler abrasives

Optimum Use Line

Patent pending Optimum Use Line provides a visual reference to help get the most out of the wheel. Using the wheel to its full life reduces change-overs, which helps users be more productive while reducing waste and abrasive spend.

weiler abrasives

Cut Back

PTiger Type 27 grinding wheels are designed with fiberglass cut back from the edge for aggressive grinding right out of the box.

weiler abrasives

Longer Life

Patent pending Optimum Use Line provides a visual reference to help get the most out of the wheel. Using the wheel to its full life reduces change-overs, which helps users be more productive while reducing waste and abrasive spend.

weiler abrasives

Optimum Use Line

Patent pending Optimum Use Line provides a visual reference to help get the most out of the wheel. Using the wheel to its full life reduces change-overs, which helps users be more productive while reducing waste and abrasive spend.

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Improve Your Gear Grinding Process

Get application support, custom wheel recommendations and responsive supply options for profile, continuous generating and bevel gear grinding.