TOOL-POST GRINDING Page 1 of 5 VEEN SMALL cylindrica! work must be finished to true coneentricity and very elose size limits, lathe operators in small ‘shops usually dispense ‘with other methods and use a tookpast grinder for both inside and outside work. Although the grinder {s slow when eompaved with feutting-fool operation, itis eapable af pro- ducing a degree of aecuraey and quality of finish unequaled by any. other commen athe accossory. In small shops the largest grinder regularly used is powered by a Yihp. motor and swings a'-in. grinding wheel. ‘The smallest practical size for ex= ternal grinding swings a 2-in. wheel. Typl- fal grinders im these sizes are shown in Fig.'2. Some tool-post grinders are fur- nished with interchangeable spindles so that they ean be set up for both internal and extermal grinding operations. Operation of tool-post geinder: The im= pporfant paintore in took-post grinding are Sullined in Fig 4. Note that the maximum ut per single pass of the wheel is onl D001 fn. and abort one fourth of this depts is permissible on finishing euts, The gi ing spindle must be set up “on center” inPage 2 of 5 relation to the work, Nearly all small fand large tool-post grinders have an. ad~ justment for egnteving the spindle. Note the setups. for" internal and xicrnal frinding in Figs. Land 8. In internal- Sow, Erinding operations the wheel and the TAVEISE TAVERSE ‘work rotate in opposite directions as in Ades SSanee the lower detail in Fig. 8. However, in “Waa” “Sor external grinding’ the wheel and the Wall. _ Wl ‘work rotate in the same direction as in B the upper detail in Fig. 3, In the latter cease, the lathe is reversed. ‘Wheel dressing: The first requirement when working to close limits with a tool-post grinder is proper dressing of I. Careful’ operators. alway dress the wheel before every job as it is not possible to do accurate work with wheel that Is even slightly out of round. Only a diamond dresser gives the precision cut tieeded for this job, Fig. § shows the setup and Figs. 6 and 7 detail the methods of setting the dresser fon center. ‘The dressing is done by trav= frsing the wheel across the. diamond ‘with no more than .00I-in. infeed, Ifa smooth wheel is requied for a finishing ‘operation, the speed of the traverse Eeslow, never more than .005 in. A fast traverse opens the wheel for rough grinding ag in the upper detail, contact ol aw uevents CHArER “4.01, scan wen 90%s AGo00 080F ema Ganow with ated OF OY" AND OOS" HAWERSEPage 3 of 5 GRINDING ‘A CYLINDER “his 400 BEET ONE Yar 44s cLA_ We AS ShOWNEN FC. BON PaxcEOINE PACE Af sua GaNos# fe ult, f mush Be ANCIMD SlcHILY YO GENS TalsTock, A> Tie ASkaSie WretLis THEN onessto. AS mes 10_ANO 10 MAKE I PARAGLL ‘Wi Wee axe UGHT Cue aN GO NOY RUN AdeASivé Wd Of ENOSOF WORKDRGE ~ Cowsouno ustBe Se AT EXACTLY 646, BECAUSE HS STING OFTERAINES CHNOING GRINDING: (Seve Ov Wome & Tet ae siouln Be Nace Fics. T3AND 14 THe WHE SHOUD 60° CENTER Grinding a cylinder: External grindin, of a eylinder—s common opertion—is pie tured in Fig. 8. The work t= machined {008 Jn. oversize. ‘Then it is reduced to exact diameter by successive passes of the grind- ing wheel, the final pass being made with zo infeed and a slow traverse. In making the successive passes, it is important to ‘the wheel on the work, Tt should not run off more than one fourth of ite width ft the tailstock end. ‘The finish obtained with the 48-grit wheel cormonly used for this work ig sufficiently uniform for ordi- nary purposes. If a mizror polish is re- quired, tits can be produced by hand pol ishing’ with an 80-geit aluminum-oxide ope. Ifa small grinder is used for Gnish- ing a eylinder, it may be necessary tw angle the grinder unit to clear the tailstock, Pig. 8. In this case, the wheel must be dressed with the grinder in this position so that the face of the wheel will be parallel with the work, Figs, 10and II. The small grind- fer will do satisfactory work if light feed find slow traverse are used, Grinding a G0-deg, center: This common operation is pictured and detailed in Figs. 12, 13 and 14, Here the traverse is made Seva Save STANCE FROM work SURFACE WHEN TRAVERSED With COMPOUND. ATER COMPOUND STING MADE GRNBEESBOTATEO TO RINE WHER PARALIEL WIT WORE with the compound rest, which must be set fat exactly 60 deg, with the axis of the lathe in ‘ovder to produce the ‘required angle fon the center. ‘The traverse is hand-led toward the headstock spindle as in Fig. 12 ‘This brings the grinding pressure against the center and holds it flrmly in position in the tapered spindle sleeve. ‘The return movement of the wheel is made with no fdded infeed, ‘Too! grinding: Grinding of small milling cutters and other rotary eutting tools. is easily done ‘with the tool-post grinder thin the required accuracy limits. Mill- ing-machine cutters usually ean be ground ‘on thelr own arbors by simply placing the fuvbor and cutter between lnthe centers, Th dexing of toothed cutters is done by means ff a tooth rest, which is positioned directly below the tooth being ground as in Figs 15, 16 and 17, In the actual grinding pro- cedure, the lathe is not in operation, but Serves only as a support for the work and means of traversing the grinder aceu- trately, In some cases, of course, I Is neces- sary to Urue up the cutter concentrically Iefore grinding each individual tooth to the correct clearance angles. This operaPage 4 of 5 Peed tion is handled in the lathe in much the same fashion as_grinding a cylinder. The table, Fig. 15, gives the below-center distances for various wheel diameters when grinding the clearance angle on milling eutters, Sec dimension “D” fm the detail, Fig. 15, Alter the tooth vest has been properly set, 16, the grinder is traversed ‘nee and then returned across the tooth without added infeed. ‘The traverse is fast, but the return is, slow to give a smooth finish. On eutivrs having tecth requiring a Bteator rake angle, it is common Practice to locate the tooth rest to engage a tooth above the one being ground, Fig. 18, In, some cases, the rest must be set two teeth above the one being ground, as in the detail in Fig. 18, Note flso that a small wheel must be used to ‘avoid striking the tooth immedisiely above he tooth in eontact with the wheel. ‘Surface grinding: A common example of this type of work is that of surfacing the lathe faceplate, as in Fig. 19. Other work can be surface-ground by mounting it on the faceplate or in a ebuck and using the same setup. A cup-type grinding wheel is commonly used for this work, ‘Phe wh« is dressed with a cross-slide traverse as in Fig. 20. It will be noted that this trues the LF oiioon apreenres wheel exactly parallel with the work sur- face, Fig. 21. ‘This position of the wheel is practical for the rough-grind, using a coarse-arit, soft wheel. For the finish- grind, use a fine-grit wheel, dressed square, but angle the grinder unit about 1 deg. s0 that only the edge of the wheel is in con- tact, Fig, 22. Good surface grinding also ean be done with a straight wheel. It is necessary to angle the grinder unit so that the spindle will clear the work, Figs, 23 and 24. After the angle setting has been determined and the grinder set, the wheel Is dressed on the corner to forma flat about Me in, wide, Fig. 24 Note in Fig. 25 that‘chr 2 3 * ra En wine MATH, OrsATION | Wher] MONE ‘AVERAGE WORK Sizr| | SMOOTH | 1005.5M. cone | meats ror soon rowsn | YER us Cos | RENAE conse [nome conn [20540 swoon] se the infeed is set with the com- pound and that. the averse made with the cress slide. ‘The lathe carriage must be locked. ‘Wheel selection: A 46-grit alt= minum.oxide wheel of medium grade (“grade” is resistance of the abrasive grains against tea ing loose from the bonding mate tial) is the best all-purpose wheel. By careful dressing and operating techniques, it ean be ‘made to cut as fast as a 40-gr wheel or as fine as a 60-grit one and ean be made to run hard of soft as needed, ‘The table. Fig 26, shows the variations possible with the all-punase wheel, ‘The table, Fig. 25, liste special wheels for various materials. Toternal’ Srleding: Internal winding on light work, Fig. 1 Usually is done with smali-diam- ter mounted wheels rnning at high speeds to maintain the re- quired 5000 f.p.m. surface speed, Very light infeeds and a slow traverse are required. Allow- ances for internal grinding shouldbe somewhat ‘less. than the .006 in. allowed for external grinding and a softer wheel must Be used. Protect the lathe: Most of the abrasive dust from the grinding operation ean be trapped ina pan filed with oil, Fig. 8. An oll- Soaked cloth placed below the work also will protect the lathe where it is not possible to locate the pan direetly under the wheel Invany case, the lathe should ale ways be thoroughly: cleaned up after every grinding job.