coocee ia) Oe eee BRC-CORP 37-74-F 105 Section 22, GRINDING CRACKS Definition of the Problem Materials sensitive to grinding heat may develop cracks during or after grinding. Figure 22-1 shows the typical appearance of grinding cracks. The greater the sensitivity, the less heat is required to cause cracking, and naturally if a material is insensitive to heat, excessive grinding heat will not, of itself, cause cracking. Soft metals, for example, because of their considerable ductility, generally cannot be cracked by heavy grinding. Discuseivu vf the Probles Grinding is often the first operation in a finishing sequence, and 42 ueed ta remove large eurface imperfections and te reugh-dewn welde prior to polishing and buffing. Grinding is also often used during welding to remove defects, oxides, or slag before depositing subsequent weld passes. : Residual stress, leading to cracking, can result from any operation in which heat or mechanical force causes inhomogeneous plastic deformation. Figure 22-2 shows the type of deformation which can result from grinding. Grinding stress may be entirely tensile, entirely compressive, or tensile in one layer and compressive in an adjoining layer. Tensile stress is believed to be caused primarily by grinding heat, and compressive stress by the plastic deformation of the surface that ‘occurs when chips are formed. The magnitude of the stress below the ground surface decreases rapidly with depth, becoming negligible at a depth that varies with material and with grinding conditions (it may be 0.002 in. for hardened steel or five to ten times as much for annealed steel or heat-resisting alloys). Methods of Checking for the Problem Im magnetic materialo, grinding oracko inviaible te the neked eye usually can be detected by magnetic-particle inspection. Fluorescent or dye penetrants can also be used for the same purpose with either mag- netic or nonmagnetic materials. Suitable acid etchants will widen cracks in a material and make them more visible. Methods of Eliminating the Problem The basic method of eliminating grinding cracks is to reduce the heat input during grinding. This may be done by using coolants, or employing intermittent grinding so that no one area heats up excessively. For materials such as nickel and nickel-copper allovs. rubber-bond grinding wheels are used for their relative softness which reduces the amount of heat generated. These wheels should be operated at a surface speed of 8000 to 9000 fpm. Vitrified-bond wheels are preferred for grinding the harder iron-containing alloys, and are usually operated at a surface speed of 5000 to 6000 fpm. Low wheel contact and low pressure help prevent distortion and cracking during grinding, especially with annealed tater tele.108 BRCCORP 37-74. Pitfalls Tiuyecoveut vi dye penetrant inspections are not successful in detecting grinding cracks when the grinding operation has smeared the surface and covered the cracks. In thie case, the eucared layer of metal can he removed by macre—etching, Some acids used to reveal or widen grinding cracks to make them more visible for inspection purposes can actually cause cracking in themselves. This happens when the metal becomes so enbrittled by hydrogen absorbed from the acid that it cannot withstand the surface tensile stress. Hardened steels may be embrittled in this manner by sulfuric or hydrochloric acid. e g. C0OCCORBOHOCECOBRC-CORP 37-74. 107 e e e e e e e e e . Figure 2241 e. ‘AxGround Surface of Beryllium Samples ea e e e e e e e e e e e = — = eee ®, aaa Using Worst Grinding Conditions Magnification: 60X.