As outlined by SME in their article, “Tips for Improved Surface Grinding,” many job shops and manufacturers face challenges when it comes to optimizing their surface grinding operations. Older machinery, limited coolant, and inadequate wheel-dressing capabilities can lead to poor part quality and inefficient processes. However, there are key recommendations for improving surface grinding productivity, particularly through proper grinding wheel selection and parameters.
One common mistake is using a grinding wheel with an abrasive grain that is too durable. Durable grains require significant force to fracture and expose new cutting points, and when operating under low pressure—such as in surface grinding—these grains can become dull and rub against the metal rather than cutting it. This friction results in poor surface finishes, causing problems like chatter and burn marks.
For operations with shallow depths of cut, often less than 0.001 inches (0.025 mm), a more friable grain is recommended. Friable grains fracture easily under low forces, exposing fresh cutting edges and producing cooler cuts. This is especially important when limited coolant and dressing capabilities are available. Choosing a friable grain helps mitigate heat generation, improves cutting efficiency, and delivers a better surface finish.
In surface grinding, dressing the wheel regularly is essential to maintaining sharpness, but when dressing or cooling systems are not available, selecting the right abrasive wheel with the appropriate friability becomes even more crucial. Using friable grains ensures that your grinding process remains efficient and that part quality is consistently high, even in less-than-ideal conditions.
Click here to learn more about Universal Grinding capabilities.
Article with all rights reserved, courtesy of sme.org.
