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 Expert  723715

Expert in Grinding Processes and Technology, Power Tool Accessories Testing and Manufacture

Available for your Consulting and Expert Witness Needs

Texas (TX)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
52100 steel is the primary material used for standard bearings and automotive products that act as raceway materials. It is also common to use the material for bearing balls. The expert has extensive experience grinding the hardened form of this material in it's martensitic state with hardness values in the 58 to 62 HRc range. The expert has developed computer models predicting incipient burn when abusive grinding practices have been used with this material. This medium carbon steel falls into the category of "easy-to-grind" materials and the expert has applied a variety of abrasives to successfully grind this material.

The expert has experience in material handling equipment linked to and from grinding machines. This material handling equipment is controlled by the machine plc and there maybe de-magnetiziers and post process gauge systems included.This equipment ensures a hands off approach for loading and un-loading workpieces.

Manufacturing specifications applied to bearings help ensure that the "book" performance of a given bearing in an application is achieved. The theoretical performance can be enhanced dramatically by the grinding and super-finishing processes by changing the surface topography of the machined surface. The expert understands fully the required process parameters to produce specific surface properties using the process kinematic parameters and the influence of the grinding wheel specification and coolant type. Surface properties include integrity and topography.

The Expert has "hands-on" experience with this type of grinding equipment from his apprenticeship years. He has used this type of equipment in manual and CNC modes to produce full form products that include internal and external surfaces. He is most familiar with Jones and Shipman machines. Materials ground include soft and hardened metals, hard chrome plate, tool steels and carbide.

High-rate center less grinding was the subject of the experts PhD thesis. The Expert is fully familiar with plunge and through feed center less grinding modes. He has extensive knowledge regarding setup parameters to produce optimally round parts with no thermal damage. The Expert has produced kinematic models that predict the idealized undeformed chip thickness for given geometric and kinematic conditions. He also understand the geometric and kinematic conditions that cause work piece waviness often referred to as "chatter". Part sizes ground vary from micron size up to 14" in diameter. He was responsible for instrumenting the machine to measure grinding forces and was able to build a data base that reflected material characteristics based on steel composition and hardness from the grinding forces.The Expert used diaphragm compensated hydrostatic bearings for both grinding and control wheel spindles and experimented with grinding wheel speeds up to 24,000 sfpm.


52100 steel


antifriction bearing


ball bearing manufacturing


automated machinery


ball bearing manufacturing specification


center grinding


centerless grinding

From research experiences both in academia and industry the expert quickly identified properties in machine tools that produced accurate quality parts in the shortest cycle times - important for high volume commodity markets. The expert can work with designers to produce optimal features to produce machines that exhibit high stiffness, long life in moving parts and if necessary a wide variety of sensor technology. The expert advocates hydrostatics where ever possible. He has a solid understanding of dressing systems and high frequency spindle technology. The expert worked with CGRD at UCONN and Bryant Grinder Corporation to design and build an outside diameter grinding machine that runs at 50,000 sfpm. This is a documented NSF project.

To achieve the required part quality in grinding process it is important to have precision balanced rotating elements. Some balance can be achieved through manufacturing rotating elements to tight specification. However, after the components are put into assemblies there will be a residual unbalance. Dynamic balancing is necessary to deliver the final balance level tolerable. The expert has used manual balancing techniques using vibration sensing equipment and has used automatic balancing equipment that becomes integral with the spindle design. Mass addition and subtraction techniques have been used.

Characteristics required in grinding equipment are also required in other types of machinery. Here the expert has directed machine designers for wood working equipment, through feed bar heat treating machines, multi-axes machining centers in addition to grinding equipment.

Machine tool qualification includes testing the assembled machine tool against a set of accuracy, repeatability and physical characteristics against machine tool specification and the actual part run-off. The Expert has written numerous machine tool specifications for several companies that include mechanical and performance requirements. He has worked closely with quality engineers to develop the statistical requirements for part dimensions and surface properties of the machined or ground workpiece.

Although a significant portion of the expert's experience has been in the bearing industry he has worked for several years in the consumer products industry. Here he was heavily involved with stamping operations, assembly, quality and broaching and forging. Throughout his industrial experience he has been exposed to TQM, TPM, Kaizens, 5S, Lean, and OPEX that embraces all of the above but includes Break Through Deployment. As a major contributor to the many programs he has been involved with, the expert has developed strong working relationships with several universities and countless vendors.


grinding machine design


internal grinding


machine-tool component balancing


machine-tool design


machine-tool qualification


process engineering

The Expert has developed grinding processes to capitalize on the use of vitrified bonded CBN wheels in a significant number of applications. More than 80% of these applications required the use of water based grinding fluids. The expert worked with the researchers a GE Super-abrasives to develop grain and bond characteristics to produce G-ratios in excess of 4000 when grinding 52100 steel in synthetic coolants. Along with developing the wheel specifications, diamond dressing systems and dressing techniques were created to extract the most from the carat cost based abrasive grain. The Expert has applied CBN to 52100, Stain-less steel, tool steels and special tool steels such as Rex 20.

Plated CBN wheel have been used where appropriate. These applications maybe short run or long small diameter bores. The excellent results obtained in applying CBN were made possible by instrumenting grinding machines and through the application of DOE.

The Expert worked for 15 plus years for The Torrington Company, America's largest broadline bearing manufacturer. Torrington is now owned by The Timken Company. During this time, the Expert was involved with all aspects of ball bearing manufacture. However, the bulk of the experience was with the actual grinding processes and associated equipment and metrology. His experience covers a wide range of product types, sizes and materials. Raceway grinding of super precision bearings requires accurate machine tools and an understanding of the super finishing process to achieve the final product specification. The Expert has worked with all classes of bearings and has even used CBN abrasives on bearing races.

The expert has recently helped build a taper roller bearing manufacturing plant from a green field site to a fully operational facility. The expert provided technical support in the following areas:- machine tool specifications, acceptance specifications, acceptance of equipment at the machine tool plant, machine tool acceptance and problem solving at the bearing factory, metrology and metallurgy training and support, the use of instrumentation to improve cycle times and grinding burn avoidance, machine health monitoring and training in grinding process and technology in the class room and on the shop floor. The expert has experience in the manufacture of taper, spherical, needle, and large diameter roller bearings. This experience encompasses both simple rollers, and optimised profile rollers.

The requirements to produce quality needle roller races are similar to those for ball bearing races. However, typically, needle roller races are not super finished. This means that the grinding process has to impart the topography required. The Expert has experience in specifying abrasives, process and machine cycles to achieve the required bearing ratio and topography through the manufacturing process.


cubic boron nitride


ball bearing


bearing race


roller bearing


roller bearing manufacturing

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Houston, Texas;  Pasadena, Texas;  Beaumont, Texas;  College Station, Texas;  Baytown, Texas;  Bryan, Texas;  Sugar Land, Texas;  Port Arthur, Texas;  Galveston, Texas;  and Missouri City, Texas.

Often requested
with this expert:

Centerless Grinding, Computer Controls, Automation...
Machining Material by Grinding
Precision Mechanical Device Design and Manufacture, Laser...
Electronic Enclosure Product Development Including...

Year   Degree   Subject   Institution  
1983   PhD   Mechanical Engineering   Liverpool John Moore's University  
1977   BSc   Mechanical Engineering   Liverpool John Moore's Universtity  

Work History:
Years   Employer   Department   Title   Responsibilities

2011 to


Expert's Firm


All Departments




Expert provides technical support to the bearing and tool manufacturing companies that need help with implementing Operational Excellence philosophies. Full support in grinding processes and technologies are core competencies.

2005 to 2010


Griffin Tool Company Inc


All departments




Responsible for product design, sourcing, testing, sales and marketing.

The Expert has provided technical consultancy to a Fortune 500 Broad Line Bearing Company. The work involved the Expert developing multiple technical specifications for a variety of grinding, super-finishing and fine grinding machine tools. These specifications were written to take advantage of the latest technology from both domestic and international machine tool vendors.

2002 to 2005


IRWIN Industrial Tools




Director of Engineering and Technology


The expert was responsible for driving manufacturing technology in the production plants located in the USA, China and New Zealand. The objectives were to overhaul the processes, the technology and introduce OPEX. (Operational excellence). Additionally, the Expert was responsible for developing the product testing facility that included metallurgy, metrology, rapid proto-typing equipment and custom built test equipment.

2000 to 2002


The Kirby Company




Vice President


The Expert was responsible for all engineering group activities including R&D, design, model making and rapid proto-typing, testing, legacy documentation and project management. Instigated the shortest time to launch a new product by concurrent engineering and project management.

1990 to 2000


The Torrington Company


Manufacturing Development Center


Corporate Consultant


The expert was responsible for introducing new grinding processes and technology the company's broad line bearing manufacturing facilities both domestically and internationally. Considerable experience was gained dealing with Chinese and European groups.

The Expert directed many of the companies funded projects at UNCONN's Center for Grinding Research and Development. A similar function was performed with the MARC Center at Georgia Institute of Technology. Several PhDs and MS degrees have been supervised in conjunction with the academic faculty.

The Expert also worked on Department of Defence contracts for Electric Boat.

1985 to 1990


The Torrington Company


Advanced Technology Center


Group Leader


Managed a group responsible for developing the technology and process knowledge to implement CBN, and other abrasives in state of the art grinding equipment. Developed a variety of training materials during this time.

Worked closely with UCONN to develop the Center for Grinding Research and Development. Also provide industrial support to the Manufacturing Research Center at Georgia Institute of Technology.

1977 to 1985


Liverpool John Moore's University


Mechanical Engineering


Research Associate


During the period leading to the award of the PhD, the Expert was responsible to teaching duties including metallurgy, metrology, fluids, engineering design and manufacturing science.

The Expert supervised the daily work of 2 PhD candidates.

1969 to 1973


T.W. Forms


Apprentice School


Student Apprentice Toolmaker


The Expert trained as a toolmaker. During this time the Expert was exposed to turning, milling, heat treatment, precision surface, cylindrical and optical profile grinding. Expert completed the apprentice program prior to going to University.

Career Accomplishments:

Member of the Institution of Mechanical Engineers Member of the Institution of Engineers and Technology


Chartered Engineer - C.Eng.


Sir Ben Williams Award for best technical paper presented to the NW Regional Council for the Institution of Production Engineers.

Publications and Patents Summary

The Expert has 26 publications associated with grinding processes, grinding technology, tribology and sensor technology related to grinding.

Additionally, the Expert as multiple trade secrets associated with manufacturing or bearings.

Government Experience:
Years   Agency   Role   Description
1994 to 1996   NSF   Contributor   Industry, Academia and an end user of grinding equipment teamed up to develop a radically new high precision grinding machine funded by NSF. The Experts role was as programme manager representing the enduser.

Consulting Services:
Selected Consulting Examples:
  • Worked with Client to build a taper roller bearing plant from "green field" to full production. Areas of support include machinery specification, purchase, acceptance and factory install. Metrology and metallurgy equipment were identified, the purchase supported and laboratory setup completed. Cycle time reduction, burn and "chatter" elimination solutions were developed. Grinding and metrology training were provided on the shop floor and in the classroom.
  • Resolved manufacturing issues between a supplier and their customer, Was able to suggest alternative manufacturing techniques to the supplier to avoid the discourse between them and their customer.
  • Trained a maintenance team to use vibration analysis equipment to identify incipient bearing failure and thus avoid scrap work on turning and machining centers.
  • Provided 1 week seminars to a machine tool builder to advance the level of technology in his machines. 50 design engineers attend the week long program. This work was conducted off shore.
  • Performed a factory review for a tap and die manufacturer and was able to identify multiple opportunities to reduce scrap, reduce cycle time, improve the use of MRO and implement some basic lean engineering principles, 5S and Kaisens.
  • Currently working with an offshore bearing manufacturing company to develop their process development team, solve manufacturing issues and give technical direction to the global machine tool design team.
  • Provided expert witness technical support in resolving several personal injury cases that involved grinding equipment.
Recent Client Requests:
  • Expert in Grinding process setup.
  • Bearing Design for Hospital Bed.
  • High speed bearing expert for consulting on high speed bearings.
  • Expert in tapered roller bearins for consulting on tapered roller bearing failure analysis litigation case.
  • Expert in roller bearings for consulting on taper roller bearing noise and failure issue.
  • Expert for consulting on Centerless grinding of Nitronics 50.
  • Expert for consulting on Centerless Grinding.
  • Expert for consulting on Centerless grinding.
  • Ball bearings expert for consulting on Ball Bearing Failure Analysis.
  • Expert in machine tool designers for consulting on specialty grinding machine for sharpening circular cutter.
  • Machine tool engineer expert for consulting on inspecting an used SIP Hydroptic 6A jig borer.
  • Expert in providing an independent failure analysis & root cause for a bearing failure.
  • Expert in industrial machine design for consulting on product design.
  • Expert in surface grinding for consulting on the relationship of die/punch clearance vs. gauge of plastic be to maximize the efficiency of sheer cutting APET plastic.
  • Expert for Centerless Griding for consulting on Spindle Shaft Grinding.
  • Expert in ball bearing failure analysis for consulting on premature ball bearing failures.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Expert witness services have been provided for bearing failure issues, personal injury when using grinding equipment, trade secret theft and property damage due to grinding equipment usage. The expert has provided research data and appeared for depositions. Court appearances are pending. Additionally,experience has been derived from acting as the technical consultant for his employer when questions about supplied products have manufacturing deviations or there is a perceived deviation. In this role the Expert was expected to act independently from the employer and provide an acceptable solution to the grievance that all parties could support.

As lab manager, the Expert has had to provide to Corporate Lawyers failure analysis reports indicating the mode of failure and likely scenarios that could lead to such a failure.

Recent Litigation Client Requests:
  • Grinding expert for consulting on grinding technology issues.
  • Power tool expert witness for consulting on personal injury case involving a grinding wheel.
  • Bearing expert for consulting on Tapered Roller Bearing Manufacture.
  • Expert in and plane blade manufacture for litigation.
  • Expert in fire causation for litigation involving sparks from a small grinder.
  • Roller bearing expert for consulting on Tapered roller bearing failure. Client applied compressed air to bearing. Cage deformed. Tapered element struck client,s eye.
  • Roller bearing injury expert for consulting on eye injury after applying compressed air to bearing;bearing escaped and ruptured eye.
  • Grinding Wheel Expert for case involving an accident.
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

International Experience:
Years   Country / Region   Summary
1996 to 1996   Wuxi China   Performed a technology and people review for a European company considering purchasing a Chinese Bearing Manufacturer.
2000 to 2000   Wuxi China   Presented a seminar to a machine tool builder on the latest technologies found in current machine tools and spindle technology. 50 people attended.
2005 to 2005   Shenzhen China   Directed a team of Chinese engineers to identify the cause of inconsistent hardness in through feed induction heat treated bar stock. When the problem was isolated the Expert identified process improvements and controls to prevent the problem from reoccurring.
2003 to 2004   New Zealand   Provided grinding support and advice for carbide grinding. Identified cycle time reduction opportunities and corrective actions to eliminate part defects.
2011 to   Suzhou China   Defined equipment, layout, equipment specifications, acceptance plans, supported equipment acceptance and install into factory, developed cycles, trained operators and technicians and continue to support a new taper roller bearing venture.
2014 to   Yeongju-Si, ROK   Grinding Consultant, bearing industry

Market Research:
The Expert has worked with the Marketing Groups at each company he has been employed in and has been an active participant in PDR reviews, end-user testing and Focus Groups. Knowledge gained from these feedback mechanisms was integrated into the products.

Most recently, the Expert was involved in bringing multiple products to market at a large consumer product company where time to market could be as short as 4 months and as long as 1 year.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:

The Expert has developed a variety of training programs and presentations for inhouse training of machine operators and manufacturing process development engineers. This material includes most aspects of precision grinding for both easy and difficult to grind materials using super and conventional abrasives.

A novel pocket reference for grinding equations and initial guidelines was also written.

A course for vibration analysis specifically for the bearing industry was developed and presented multiple times.

Supplier and Vendor Location and Selection

The Expert has extensive experience in developing machine tool specifcations for grinding and superfinishing machines and has worked with most of the leading machine tool manufacturers that supply this type of equipment. The specifications focus on the technology and are not part specific - this means that the equipment can be purchased based on the ability to meet a specification and not part acceptance requirements which may or may not be stringent enough.

In addition to machine tool vendors, the Expert has built over the years relationships with grinding wheel manufacturers, abrasive manufacturers, coolant and coolant system suppliers and diamond roll designers and manufacturers.

The Expert frequents vendors through outthe world to determine current trends in grinding processes and technology.

Finally, the Expert also has a strong relationship with laboratory equipment manufactures.

Other Skills and Services

Working with a US manufacturer, the expert supported the building of a bearing manufacturing plant in China. His manufacturing expertise was used in the machine acceptance area, equipment specification and supplier identification, process training for grinding, metrology and metallurgy.Use of instrumentation and theoretical analysis tools were demonstrated.

The Expert has provided consulting services to spindle repair companies, bearing manufacturers and machine tool builders, domestically and internationally.


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