Abstract: A tool assembly for removing material from a work-piece is disclosed herein. The tool assembly includes a cutter having a plurality of cutting teeth spaced circumferentially about an axis of rotation along a cutting end periphery. The cutter also includes a body extending away from the cutting end periphery along the axis of rotation. The tool assembly also includes a passageway for directing a flow of coolant to the cutting end periphery. The passageway is defined at least in a part by the cutter. The tool assembly also includes a cap engaged with the cutter. The cap includes a dispersion disk positioned in spaced relation to the cutting end periphery whereby an annular gap is defined between the cutting end periphery and the dispersion disk along the axis of rotation. The gap communicates with the passageway for directing coolant radially outward to all of the cutting end periphery.

Abstract: A grinding wheel for grinding features into a work-piece and a corresponding method for grinding the features into the work-piece are disclosed herein. The grinding wheel includes an outer periphery with a first axial end having a first diameter. The grinding wheel also includes a second axial end spaced from the first axial end along a centerline axis. The grinding wheel also includes a plurality of discrete grinding projections for removing material from the work-piece. Each of the plurality of discrete grinding projections extends radially outward from the outer periphery and is positioned along the centerline axis in spaced relation to one another. The plurality of grinding projections have working heights that vary relative to one another. In the inventive method, a grinding wheel is rotated about an axis of rotation. The axis of rotation is arranged transverse to and spaced from a centerline axis of an arcuate surface of a work-piece.

Abstract: A method for processing a work-piece is disclosed herein. The method includes the step of removing material from a work-piece to a predetermined depth with a tool that changes size. The method also includes the step of passing the tool across the work-piece in one or more passes during the removing step such that a cutting depth into the work-piece changes during a particular pass. Each pass is defined by a pass depth. The method also includes the step of maintaining a substantially constant chip thickness during the removing step. The method also includes the step of selectively maximizing one of a feed rate and a pass depth of material removal at the expense of the other during the removing step to minimize the time of the passing step.

Abstract: A grinding wheel for grinding features into a work-piece and a corresponding method for grinding the features into the work-piece are disclosed herein. The grinding wheel includes an outer periphery with a first axial end having a first diameter. The grinding wheel also includes a second axial end spaced from the first axial end along a centerline axis. The grinding wheel also includes a plurality of discrete grinding projections for removing material from the work-piece. Each of the plurality of discrete grinding projections extends radially outward from the outer periphery and is positioned along the centerline axis in spaced relation to one another. The plurality of grinding projections have working heights that vary relative to one another. In the inventive method, a grinding wheel is rotated about an axis of rotation. The axis of rotation is arranged transverse to and spaced from a centerline axis of an arcuate surface of a work-piece.

Abstract: A tool assembly for removing material from a work-piece is disclosed herein. The tool assembly includes a cutter having a plurality of cutting teeth spaced circumferentially about an axis of rotation along a cutting end periphery. The cutter also includes a body extending away from the cutting end periphery along the axis of rotation. The tool assembly also includes a passageway for directing a flow of coolant to the cutting end periphery. The passageway is defined at least in a part by the cutter. The tool assembly also includes a cap engaged with the cutter. The cap includes a dispersion disk positioned in spaced relation to the cutting end periphery whereby an annular gap is defined between the cutting end periphery and the dispersion disk along the axis of rotation. The gap communicates with the passageway for directing coolant radially outward to all of the cutting end periphery.

Abstract: A method of determining a position of a coolant nozzle relative to a rotating grinding wheel removing material from a work-piece and an apparatus for practicing the method are disclosed. The method includes the step of disposing a coolant nozzle having a base and a distal end for adjustable movement relative to the grinding wheel and the work-piece. The distal end of the coolant nozzle can be moved in a first plane normal to an axis of the grinding wheel along a first arcuate path centered on a pivot axis at the base. The distal end can also be moved by moving the pivot axis in the first plane along an orbit centered on the grinding wheel axis. The method also includes the step of selecting a position of the distal end along the first arcuate path. The method also includes the step of projecting a second arcuate path in the first plane centered on the grinding wheel axis and having a radius extending to the position of the distal end along the first arcuate path.

Abstract: A method for processing a work-piece is disclosed herein. The method includes the step of removing material from a work-piece to a predetermined depth with a tool that changes size. The method also includes the step of passing the tool across the work-piece in one or more passes during the removing step such that a cutting depth into the work-piece changes during a particular pass. Each pass is defined by a pass depth. The method also includes the step of maintaining a substantially constant chip thickness during the removing step. The method also includes the step of selectively maximizing one of a feed rate and a pass depth of material removal at the expense of the other during the removing step to minimize the time of the passing step.

Abstract: A method of determining a position of a coolant nozzle relative to a rotating grinding wheel removing material from a work-piece and an apparatus for practicing the method are disclosed. The method includes the step of disposing a coolant nozzle having a base and a distal end for adjustable movement relative to the grinding wheel and the work-piece. The distal end of the coolant nozzle can be moved in a first plane normal to an axis of the grinding wheel along a first arcuate path centered on a pivot axis at the base. The distal end can also be moved by moving the pivot axis in the first plane along an orbit centered on the grinding wheel axis. The method also includes the step of selecting a position of the distal end along the first arcuate path. The method also includes the step of projecting a second arcuate path in the first plane centered on the grinding wheel axis and having a radius extending to the position of the distal end along the first arcuate path.

Abstract: A method for grinding a feature in a work-piece is set forth which includes the step of rotating a grinding wheel about a first axis. The method also includes the step of traversing the rotating grinding wheel and a work-piece relative to one another along a second axis that is transverse to the first axis to form a feature in the work-piece. The method also includes the step of oscillating the rotating grinding wheel and the work-piece toward and away from one another in first and second opposite directions transverse to both of the first and second axes during said traversing step. As a result, the rotating grinding wheel and the work-piece are moving relative to one another along both of the second axis and one of the first and second opposite directions during the traversing step to reduce burning of the work-piece.