Grinding operations in industrial environments are predominantly manual, favored for their precision, control, and adaptability to complex shapes and detailed work.
Material removal cost breakdown
From pneumatic to electric, grinders come in a variety of offerings. Selecting the ideal pneumatic grinder for your needs can be particularly challenging, given that these grinders are available in a couple of motor options — vane and turbine. Each has its advantages and challenges, and the choice between a vane or turbine grinder depends primarily on their specific application. Vane grinders are suitable for a wide range of tasks including die grinding, rough grinding, and surface grinding. They are known for their compact size and variety of motor power options making them the most adaptable choice for both coarse and precise grinding tasks. On the other hand, turbine grinders are designed mainly for high-power applications where precision can be compromised for the rapid removal of material. They excel in applications that require rough and high-productivity grinding.
Furthermore, the choice of grinder often hinges upon the specific task at hand. Turbine grinders, for instance, are exclusively offered in angled configuration. Whereas vane grinders present a more versatile array of options from straight grinders to angle grinders, die grinders to beveling tools, and circular cutters. This diverse selection renders them apt for a broader spectrum of tasks, as they can adeptly cater to each unique requirement.
What should I consider whilst selecting
a vane or turbine grinder?
There are specific factors worthy of consideration whilst choosing a grinder such as productivity, cost, and ergonomics.
Productivity
- Efficiency in material removal: A turbine motor can boost efficiency by up to 40% compared to a vane motor. As a result, tasks can be optimized and completed swiftly.
- Service intervals: Vane grinders require servicing every 1000 to 2000 hours, resulting in long service intervals. Conversely, turbine grinders necessitate more frequent servicing, as their gearbox oil needs to be refilled every 300 to 500 hours. However, this routine servicing of turbine grinders whilst essential, is a minor procedure, requiring minimal time and causing only brief downtime of the equipment.
Despite the infrequency of servicing for vane grinders, the process is more complex, often involving a thorough inspection and replacement of internal components. This makes vane grinder servicing a more time-consuming and intricate task compared to the relatively quick, yet essential oil refills required for turbine grinders. Similarly to vane grinders, turbine tools also require a more thorough service every 1000 hours. - Resultant operator-hours: Labor accounts for virtually 76% of grinding costs. Thus, the time taken for grinding tasks is crucial. By ensuring increased productivity, higher efficiency, and longer service intervals turbine grinders can significantly reduce the time required to complete tasks.
Cost
- Cost: Vane grinders typically offer a more economical option when looking within the same power category. However, over extended use, the advantages of turbine motors become increasingly evident. When considering long-term expenses, it becomes clear that the initial capital expenditure is relatively less significant compared to the ongoing costs of manpower and abrasives. Consequently, the primary expense in grinding is often dictated by grinding time, thus in situations that require extended operation, the higher efficiency rates of turbine grinders may offer a more advantageous solution over time.
- Energy costs: Certain turbine grinders exhibit a notable advantage, necessitating nearly fourteen million fewer liters of compressed air to remove one ton of material than their vane counterparts. Additionally, due to their efficiency in completing tasks in less time, turbine grinders contribute to a reduction in overall energy consumption. What’s more turbine grinders, especially due to their different motor technology, diminish oil dependency as they do not require a lubricated air supply.
💡Tips: Are you curious about how these technologies can impact your operations? Discover more with our Atlas Copco CO2 Calculator
Ergonomics
- Size: As grinding is often a long and strenuous process, a lighter grinder can significantly enhance operator comfort. Vane grinders, within the same power category, are generally more lightweight and compact, providing operators with improved accessibility.
- Power-to-weight ratio: On the other hand, certain turbine grinders have a higher power-to-weight ratio and are 30% to 50% lighter than comparably powerful conventional vane grinders. This becomes crucial when the operator works extended hours. High power in a smaller footprint enables maintaining peak productivity for longer periods.
Vane
- Productivity
Affords longer service intervals
- Cost
More economical, with direct and upfront costs
- Ergonomics
Moderately powered, high precision grinders that are compact and lightweight
Turbine
- Productivity
Provides efficient material removal
Significantly reduces resultant operator-hours required for task completion
- Cost
Optimizes grinding time
Reduced energy costs by enhancing efficiency
- Ergonomics
Grinders with high power-to-weight ratios offering higher material removal rates
When making a decision, oftentimes, there are a combination of factors to consider. Similarly, when selecting a grinder, it is important to consider the application alongside the productivity, cost, and ergonomics factors to make sure the grinder is suitable for all aspects of operation. Therein, it is advantageous to bear in mind that ultimately there are three responsible groups - the manufacturer, the employer, and the operator — who must all come together to ensure the most efficient utilization of the grinder, whether that be vane or turbine.
Atlas Copco grinder offering
The high-efficiency grinder portfolio from Atlas Copco offers outstanding power-to-weight ratios of tools making them comfortable to work with and gives you a superior material removal rate with minimum effort. Our range of grinders is available in all sizes, shapes, and power outputs. Whether it's a small, precise, and one-handed angle grinder or a 4.5 kW machine, both offer you superior productivity. Our range of grinders includes both vertical and straight versions to cover all needs in a rough grinding environment.
Our selection of LS 19/29/39 are lightweight and with ergonomically designed vane grinders. They have been optimized for general-purpose grinding in applications with high demands on productivity and ergonomics. At the same time, our die grinders are an excellent choice for high quality finishing and surface preparation in applications where accessibility and precision are your priority.
Last but certainly not least, our GTG models are powered by a motor with the latest turbine technology, giving an extremely high power-to-weight ratio. This means that you can select a lighter, more compact tool without sacrificing the material removal rate.
