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There would be real benefit to industry should an efficient and economic appraisal methodology be established that can be carried out on a standard and commonly available grinding machine that would allow independent assessment of grinding process variables and technologies and provide industrial users with the data that they need for process improvements or design. One of the steps in assessing changes in grinding process variables or different technologies used in grinding is to evaluate the associated costs. New technologies can sometimes have a high purchase price that can be make it hard to convince manufacturers to test how they perform. Performing an economic analysis can show if the new technology or different process parameters can give an advantage despite higher purchase cost. Both quality of the workpiece and costs need to be considered when choosing the optimum operating conditions for a process. Typically, manufacturers would choose quality of the workpiece as the first requirement to be meet, followed by minimum cost. It may be possible to produce acceptable quality over a range of process parameters. Once the parameter ranges are known an economic analysis can be performed over the ranges to find the minimum cost. This paper breaks down the costs associated with helical form grinding processes. The cost areas covered are grinding wheel, grinding fluid, machine cost and labour. Form grinding of helical screw compressor rotors using dressable grinding wheels can have additional costs due to the dressing methods used to establish an accurate form on the grinding wheel.
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