Grinding
1.0 Overview
Grinding is generally considered to be a finishing operation. Possibilities include
resharpening cutting tools, surface grinding of work fixtures and mold sections, inside
diameter (ID) and outside diameter (OD) grinding of valve bodies, and many other
potential applications.
Grinding has many different applications in the machine tool industry. The grinding
operation can be performed on a variety of machines such as the lathe and the mill - with
the appropriate add-on accessories.
Most abrasive wheels need to be able to be resurfaced (dressed), as the old surface will
become impregnated with material during the grinding operation. Dressing is
accomplished with a diamond tipped tool.
Figure 5.1
Left and right motion is governed by a set of dogs (figure 5.2) which can be set to limit
the feeding distance.
Figure 5.2
Another set of dogs can be set to limit the in and out feeding distance (figure 5.3). The
speed and distance offset for each move is governed by a set of bleeder valves in the
hydraulic circuit (not shown)
Figure 5.3
Coolant for this grinder is fed, cleaned, cooled, and recirculated by a separate system
(figure 5.4).
Figure 5.4
In the graphic above note the rotation of the work piece and the grinding wheel. With
OD grinding the work piece and the grinding wheel rotate in the same direction. This so
that the surface of the grinding wheel and the surface of the workpiece are moving in
opposite directions at the point of contact. This also reduces the possibility of ride-up or
jamming that can occur if they were rotating in opposite directions.
The image on the above shows a typical small hole being ground by an even smaller
mounted grinding wheel like one of those shown below
As
with
OD
grinding the grinding wheel and the part need to be moving in opposite direction at the
point of contact. Therefore this ID part will turn clockwise and the ID wheel will turn
counterclockwise.
8.0 Centerless
Centerless grinding is OD grinding performed on parts without centers and without
any place to hold on to it (as with a chuck). Picture the rollers in a roller bearing or a
dowel pin. There is nothing to hold on to.
Some bench grinders have attachments for a special grinding processes like the wet
grinder. The wet grinding wheel turns very slowly through a bath of oil or water. This
type is suitable for blade sharpening. (figure 10.3)
Another special bench grinder is the cutter grinder used for more precise hand tool work.
Diamond face wheels are sometimes attached for harder materials like carbide and
ceramic. (figure 10.4)
Figure 11.1
Polishing and
buffing are also
methods of
grinding. The
buffing compound
(grit) is applied to
buffing wheels
(figure 11.2) that
are mounted on
special buffing
grinders (figure
11.3)
The cylindrical wheel is the most common type. Its cutting surface is located at the
periphery of the wheel. Wheels of this shape are often mounted on a plate.
The straight cup wheel is designed to cut on the periphery and the side face at the
same time. This type of wheel is often used to grind shoulders.
The dish wheel is a tool and cutter grinding wheel. It is typically used to regrind end
mills and has a specific shape to accomplish that.
The flared cup wheel is also tool and cutter grinding wheel. There are several cup
shapes available depending on the needs of the machinist.
Grinding wheels can be custom dressed with a diamond tool to achieve nearly any shape
desired.
The system is a series of numbers and letters which codify the composition of the wheel.
The first letter indicates the type of abrasive used, using the letter A for Aluminum
Oxide or C for Silicon Carbide. Next the manufacturer of the wheel will indicate the
grain size, with appropriate numbers indicating a coarse, medium, or fine range. The
grade is indicated in alphabetical form, with the softest grade being the A end of the
alphabet, and the Z being the hardest.
Structure is indicated by a numerical rating, but its use is optional. Finally the bond type
is indicated by an abbreviation of the type of bond used, V for vitrified, S for silicate,
etc.
Wheels sometimes have different colors and can be representative of the type of wheel.
If the Norton Company is used as a reference, the following color codes would apply for
the best materials and processes for each wheel:
It is also a good idea to conduct a ring test on a grinding wheel prior to using it. A ring
test can locate an invisible crack. To perform this test let the inside diameter of the
wheel rest on one finger of your hand and then gently tap the wheel with the plastic
handle of a screw driver or wooden handle of a hammer. If you hear a clear metallic
ring, the wheel is probably in good shape. If the wheel is cracked the ring will be
somewhat dull and muffled