Machine Tool Technology ~ 20ME32P Activity # 02 - Common Grinding Problems and Their remedies: Spark Deflector Coarse Whee! Bench Grinder The most frequent problems during grinding include: Grinding Chatter Wheel Loading Wheel Glazing Burning of Work Searching of Work: Indication SaeNe 1. Grinding Chatter Causes & Method of Correction ~ Grinding Ghateer. ‘© Wheel grading too hard-Use softer grade or coarser grit. ‘+ Wheel out of balance-Rebalance after truing operation. Run wheel without coolant to throw off excess water. Whem wheel is removed from machine store on side to prevent water from setting at lower edge Of wheel. Wheel out of round- ‘True before and after balancing, Work centers of woik rests not true, or improperly lubricated Check fit of centers and rests Provide constant and even lubrication. 2. Wheel Loading — Metal Lodged on Grains or in Wheel Pores Causes &MethiOd of Correction. ‘* Ancorrect wheel-Use coarser grain size, or more open bond to provide chip clearance. Pally dressing-Use sharper dresser Dress faster ).Coolant-Use more, cleaner and thinner coolant. 3. Wheel Glazing Causes & Method of Correction. ‘© Wheel grading hard and finer grit- Use coarser grain size, softer grade. ‘* Improper dressing- Keep wheel sharp with sharper dresser. Use faster dressing tool traverse, Use more dressing too! penetration. 4, Burning of Work Causes & Method of Correction.Wheel grading too hard-Use softer grade. Prevent glazing and loading. Use more coolant. Faulty operation-Bring wheel to work more gradually, use less in-feed. Prevent stoppage of work while in contact with wheel. 5, Searching of Work ~ Indication Causes & Method of Correction. Wavy traverse line-Cause-ragged wheel Use round of wheel edges Isolated deep marks-Causes Improper wheel dressing-Use sharper dressing tools. Brush wheel after dressing, Coarse grains or foreign material in wheel face. Dress it out. Deep irregular marks-Cause-Loose wheel flanges Tighten flanges using blotters, Grain marks-Causes Wheel too coarse or too soft- Use finer grain size of harder grade wheel Too much difference in grain size between roughing and finishing wheels” “Use finer roughing wheel or finish out better with roughing wheel. Dressing too coarse- Less dresser penetration and slower traverses. Need for balancing the grinding wheel: The grinding wheel balancer improves the surface quality of evry pfoduct, avoiding risks of faceting, circularity errors and roughness defects. ‘The balancer allows the peripheral speed of the grinding wheel, and the cutting speed, to be increased To enable the full potential of modern tool grinding machines and to produce efficiently according to today’s standards, it is absolutely éssential to use balanced tools and tool holders. Due to high rpms, unbalanced grinding Wheels may have negative effects both on quality and productivity. +} — Grinding wheel — Test mandrel! Fig, Balancing of grinding wheel. To obtain good surface finish, to prevent vibrations and to avoid undue wear on machine parts, it is necessary that the grinding wheel should have good balance before its use. Hence, the wheel should be properly tested for balance before its use. But before testing it should be trued. Generally large grinding wheels need to balance when operating at high speed. But small size wheel need not to balance. The fig shows the typical balancing position of grin suitable mandrel. 1g wheel. wheel is mounted on a