Causes and solutions for abnormal cylindrical grinding
Zhengzhou Kamel Grinding Tools
Abrasives that work as hard as you do.
Cylindrical grinding is a vital phase in the manufacturing process across numerous production lines. When executed improperly, it can yield unsatisfactory outcomes. Two main defects to consider are surface texture and dimensional precision. These defects may stem from inadequate procedures, mechanical malfunctions, or persistent issues. Frequently, a combination of factors can lead to a single defect, highlighting the need for a comprehensive examination of the entire manufacturing workflow to pinpoint and address potential sources of error. In this article, we explore the unique traits of these defects and offer a compilation of possible causes along with effective remedies.
Possible Causes and Remedies:
Excessive Cutting Depth: A significant contributor to chatter marks is taking an overly aggressive depth of cut, particularly noticeable with slender components. Reducing the cutting depth and ensuring robust support can mitigate this problem.
Overly Hard Grinding Wheel: If changing the wheel on the fly is unfeasible, another strategy can be used. These may include increasing the workpiece speed, utilizing coarser grits for roughing, lowering wheel speed, and improving lubrication.
Insufficient Support for Extended Workpieces: For elongated and thin workpieces, it is essential to provide stable supports, particularly during straight plunge grinding operations. When workpieces vibrate in relation to the wheel, multiple points of support become critical.
Vibration Transfer to the Grinder: External vibrations can compromise the grinder's efficiency. A straightforward test involves halting the operation and placing a cup of water on the wheel's spindle housing. Any persistent motion indicates the presence of external vibrations.
Intrinsic Grinder Vibration: Evaluating individual components of the grinder can help identify the source of excessive vibrations. This includes assessing the wheel spindle unit, main spindle housing, pump, and worktable during transverse grinding operations.
Shortwave Marks
Potential Causes and Remedies:
Belt Vibration: Irregular belt thickness can result in shortwave marks. Adjusting the tension and ensuring a proper fit of V-belts can help resolve this issue.
Vibrations from Adjacent Machinery: Inspect for any external vibrations being transmitted to the grinder. Temporary solutions may include lowering wheel speed when utilizing fine-grit and soft-bond wheels.
Hydraulic System Vibrations: Malfunctions in pumps or valves within the hydraulic system can induce vibrations. Modifying the relief valve settings or addressing specific concerns in the system can alleviate this problem.
Motor Vibrations: Any vibrations originating from the motors should be carefully assessed. Ensure that the motor is securely anchored to the base and that the pulleys are properly balanced.
Chain and Sprocket Vibrations: Implementing larger sprockets and keeping the correct amount of tension in the chains can help stop shortwave marks from occurring. Verifying that the there is the same number of teeth on the sprocket as on the the chain's pitch is also essential.
Longwave Marks
Longwave marks are similar to shortwave marks but are more frequently observed in transverse grinding. They appear as converging lines, primarily resulting from an unbalanced grinding wheel.
Potential Causes and Remedies:
Wheel incorrectly installed and unbalanced: If the wheel appeares to be unbalanced, it’s advisable to detach the wheel and assembly and re-balance correctly. Dressing on the grinder is crucial before installing and balancing a new wheel.
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Not Turning Off Coolant: Failing to deactivate the coolant when the wheel is moving can result in the wheel becoming imbalanced and surface quality issues. Always make sure that the coolant is switched off prior to stopping the wheel.
Oil Saturation on One Side of the Wheel: A wheel that has one side saturated with oil should not be used when a precise surface finish is required. It is vital to prevent oil contamination.
Placement of the Wheel on Moist Surfaces: Wheels positioned on damp concrete surfaces may absorb moisture, resulting in a loss of balance during operation. It is advisable to use a stand to elevate the wheel or isolate it from the ground.
Mottle Marks
Mottle marks, akin to longwave marks, are frequently seen in transverse grinding. They are distinguished by irregular patterns on the surface, primarily resulting from an unbalanced grinding wheel.
Potential Causes and Remedies:
Looseness of the Diamond Nib: The diamond nib must be firmly secured in its holder. Any looseness in the nib can lead to vibrations and surface irregularities on the workpiece.
Vibrations in the Diamond Tool Holder: The diamond tool holder should remain stable during dressing operations. Employ a C-clamp or weights to secure the holder and minimize any vibrations caused by an excessively long tool shank.
Inconsistent Cross Feed of the Worktable: Uneven movement of the worktable during dressing can lead to mottled marks. It is essential to ensure smooth and consistent motion of the worktable for optimal dressing outcomes.
Burlap Finish
This issue presents itself when the surface texture appears to look like a burlap fabric, giving a finish that is completely unsuitable for the vast majority of applications.
Potential Causes and Remedies:
Insecure Dresser: Check that the diamond nib is firmly secured in its holder. Any improper moving of the nib during dressing usage can lead to an inconsistent surface texture.
Vibration in the Diamond Tool Holder: The tool holder needs to not move during the dressing process to avoid creating patterns on the wheel surface. Check that the foot-stock type tool holder is tightly secured and that the tool shank is adequately supported.
Inconsistent Cross-feed of the Worktable: During dressing, the movement of the worktable should be smooth and consistent to achieve the optimal output. Confirm that there is adequate lubrication and resolve any issues within the hydraulic system.
Understanding the origins of these grinding imperfections is vital for maintaining high-quality production. By promptly identifying and addressing these concerns, manufacturers can ensure consistent and precise cylindrical grinding outcomes.