As outlined in CTE Magazine’s article “Surface Grinding Large Plates,” grinding large tungsten-carbide plates can be a challenging task, especially when issues like chatter, poor surface finishes, and long cycle times arise. However, implementing key adjustments in the grinding process can significantly improve results and productivity. Here’s a breakdown of expert recommendations for optimizing surface grinding operations.
1. True the Grinding Wheel Regularly:
A major cause of surface irregularities is the formation of “lobes” on the wheel, leading to regenerative and chunky-wear chatter (also known as snakeskin chatter). Truing the grinding wheel helps restore its shape and ensures even wear.
- Tools for Truing:
- Brake-Controlled Devices: Slower but cost-effective (approximately $400 on platforms like eBay).
- Motor-Driven Truing Spindles: Faster and easier to automate.
- Procedure: Use a silicon-carbide or aluminum-oxide wheel to true the diamond wheel and periodically stick it with an aluminum-oxide white stick to open up the surface.
2. Optimize Cross-Feed and Table Speed:
During rough grinding, use a cross-feed width close to the wheel’s width (e.g., for a 1″ wheel, use a 0.9″ cross-feed). This approach shortens cycle times and can also reduce the risk of chatter. If chatter or spindle power issues arise, adjust by lowering the table speed rather than the cross-feed.
3. Stick the Wheel to Prevent Loading:
Regularly using a 220H white stick can help reduce material buildup on the grinding wheel, known as “loading,” which can impair performance.
4. Use Incremental Down-Feed and Cross-Feed:
Avoid gradual feeding. Instead, implement incremental down-feed and cross-feed motions. Incremental feeding improves material removal efficiency and enhances surface finishes.
5. Match Truing and Grinding Speeds:
When possible, perform the final truing passes at the same RPM used during grinding. This reduces any imbalance-induced eccentricity, which even balanced wheels may have.
Achieving Significant Improvements:
According to the article, adopting even a few of these techniques can yield remarkable results. Some operators reported up to a 75% reduction in cycle times after applying these practices.
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Article with all rights reserved, courtesy of ctemag.com.
