Precision ID Grinding for Aerospace & Semiconductor Components

In the summer of 2024, a new customer contacted Duval Precision Grinding seeking ID grinding for a precision-machined cylinder. The customer, a machine shop producing custom components for leading OEMs in aerospace, electronics, and semiconductor manufacturers, needed a service provider who could deliver high-quality, reliable precision grinding and meet tight turnaround requirements without compromising quality.

While the job itself was within Duval’s daily operational capabilities, the length of the inner diameter (ID) presented a unique challenge that required careful process development and collaboration between engineering, machinists, and quality inspectors to ensure consistency across multiple batches.

Long ID Grinding with Strict Finish Requirements

The customer initially requested grinding for one part number, specifying ID grinding over a 12.5-inch length with a surface finish requirement of 8-12 micro inches (Ra). Their estimated annual volume was to be delivered in 10 shipments throughout the year, and they were actively seeking a supplier capable of meeting their timeline without compromising quality.

Key technical challenges included:

• Maintaining ID consistency over a long 12.5-inch bore
• Achieving a uniform 8-12 microinch Ra finish across the entire ID
• Controlling taper and cylindricity within acceptable tolerances
• Minimizing deflection and vibration during grinding to ensure concentricity
• Developing a repeatable process for consistent results across multiple runs

Since this was a new job for Duval, the team had to develop and document the process from the ground up, refining setups, wheel selection, and inspection methods to ensure precision and efficiency.

Precision Grinding Process Development & Engineering Solutions

Process Engineering & Setup Optimization

Duval’s experienced engineering team and skilled ID grinding experts collaborated to develop an optimized process tailored to the part’s geometry, material characteristics, and surface finish requirements. Initially, the team concentrated on detailed process engineering, which involved adjustments to coolant flow and pressure for effective heat dissipation. They also established a carefully balanced fixture setup to minimize vibration and enhance concentricity. The grinding approach included precise management of wheel selection, optimal feed rates, wheel speeds, and dwell times, significantly improving consistency throughout production.

Addressing Surface Finish & Cylindricity Challenges

Achieving the customer’s specified uniform surface finish of 8-12 microinches Ra over the 12.5-inch ID demanded careful control over every aspect of the grinding process, including feed rates, wheel speeds, and dwell times. While Duval regularly performs grinding within these finish parameters, the part’s length required additional considerations. The engineering team meticulously fine-tuned progressive passes and controlled incremental feed adjustments to prevent microfractures, ensuring the required finish was consistently achieved.

Inspection & Quality Control Measures

For quality control, Duval utilized advanced inspection techniques specifically suited to the job’s challenges. Traditional direct-contact measurement methods were supplemented with bore gauges and air gauging to precisely verify internal diameter accuracy. Profilometer scans were performed to confirm surface finish values remained strictly within the customer’s specifications. Additionally, cylindricity checks were conducted throughout production to detect and promptly correct any deviations, ensuring that all parts consistently maintained dimensional accuracy. By integrating these rigorous inspection procedures, Duval successfully overcame the challenges associated with the long bore lengths and delivered components fully compliant with customer expectations.

Improved Lead Times, Repeat Orders, and a Scalable Process

The initial order took approximately 140 hours to complete, including the time engineering and grinding teams spent developing and refining the grinding process. Duval optimized the process to improve cycle times, consistently meeting and exceeding the customer’s expectations for both quality and lead time on subsequent batches.

Following the success of this initial engagement, the customer returned to Duval for two additional part numbers—demonstrating confidence in our ability to deliver reliable, precise results across multiple components. The investment in meticulous process engineering ensured that all parts consistently met the finish requirement and dimensional tolerances, and established a scalable, repeatable workflow that can efficiently handle increased production volumes as their business continues to grow.

What began as a single-part project has now evolved into a broader partnership, highlighting Duval’s capability to support complex manufacturing requirements across a variety of precision components.

Key takeaways from this job:

✔ Process Development Led to a Scalable, Repeatable Solution – After refining the setup, cycle times decreased, we were able to consistently meet delivery time and finish expectations.
✔ Consistent Surface Finish & Dimensional Control – Our approach to feed control, coolant optimization, and inspection ensured all parts met the required 8-12 microinch Ra finish and ID tolerances.
✔ Expanded Partnership – Initially a single-part project, this work has evolved into a multi-part engagement with ongoing production support.

Precision Grinding Expertise You Can Trust

At Duval Precision Grinding, we specialize in high-accuracy grinding solutions for industries that demand strict tolerances and superior surface finishes. We’ve built our reputation for excellence on a foundation of rigorous engineering, precise machining practices, and thorough quality assurance. Our process-oriented approach guarantees the consistency, efficiency, and repeatability necessary to deliver high-quality components—on spec and on schedule. Whether it’s ID grinding, OD grinding, or complex precision components, our engineered approach ensures consistency, efficiency, and repeatability for every job.