MAINTENANCE

Universal cylindrical grinding machine

Introduction

Grinding is the process of removing metal by the application of abrasives which are bonded to form a
rotating wheel. Universal Cylindrical Grinding Machine is one of old machine that are used for shaping
steel metal it’s works manually and electrically. Universal cylindrical grinding machine One of the
most important machine tools in the metalworking industry . Universal cylindrical grinding machine
operates on the principle of a rotating work piece and a fixed cutting tool. This machine is works on
outer parts of metal objects used to make smooth surface and two make shape. ”. This is one of
grinding machine in our machine shop. . Some of the more frequently performed operations on the
cylindrical grinding machine are: turning cylindrical surfaces, facing flat surfaces, Although relatively
simple, these few operations provide a wide range of manufacturing ability. This machine are
classified according to the maximum diameter, (known as the “swing”), and the maximum length of
the work piece that can be handled by the machine. . Another important characteristic of this machine
is the maximum horsepower that can be supplied to rotate the work piece. Also it has two control
mechanisms, automatic and manual control

Precautions, Limitations, and Set points

Grinding machine are used daily in a machine shop. To avoid injuries follow the safety precaution
listed below.
 A. Prior to performing any work with the Manually , clear the work area of clutter and ensure
adequate lighting exists to perform the desired work.
B. Ensure the spindle start lever on the carriage is in the neutral position prior to turning the
power on to the cylindrical grinding machine.
C. Do NOT wear loose clothing when operating the machine.
D. Ensure the proper use of safety equipment such as safety glasses when operating the
machine.
E. Ensure that all guards are in place prior to starting the machine.
F. Isolate electrical power prior to performing any maintenance work on the machine

 Personal Appearance and Protective Equipment

G. Normal street and office clothing is not usually adequate for protecting people while working
in a mechanical engineering assembly environment. Items such as ties, jewelers, loose fitting
clothing or even long hair may become caught in machinery or equipment, leading to serious
harm or loss.
H. Overalls should be worn to protect and confine exposed skin and personal clothing.
I. Jeweler should be removed to prevent amputation of body parts.
J. Hair ties or a hair net should be used to confine long hair.
K. To remain safe when assembling mechanical components during precision assembly, the
correct personnel protective equipment (PPE) must be worn.
Some items of PPE are mandatory, while other types need to be used to ensure protection during
specific activities.

 Safety Boots are mandatory in most mechanical assembly environments and usually offer toe
protection from crushing or falling objects. Most safety boots have heavy-duty construction,
and a choice of non-skid, chemical resistant and/or electrically insulated soles.
 Overalls are mandatory in most mechanical assembly environments, and usually provide arm
as well as leg and body protection from dirt, dust and oil contamination, and light abrasion.
 Safety Glasses are mandatory in most mechanical assembly environments to protect the
wearer from eye injury and impact caused by low velocity, low mass flying objects.
  Visors are designed to offer protection from impact caused by low velocity, low mass flying
objects in the assembly environment. Visors are usually constructed from light-weight, heavy
duty plastics and incorporate a head band with a clear flip-down face shield.
 Ear Muffs are designed to provide hearing protection from workplace noise. Hearing
protection is required for exposures above 85 decibels (dBA) over an 8 hour working day, but
as a general rule, hearing protection should be used where any discomfort is experienced.
 Leather Gloves are used to provide hand protection from abrasion, as well as minor impact
and variations in temperature.
 Dust and particle masks are designed and rated to provide protection by filtering fine solids or
liquid particles from inhaled air.
 Hard Hats are designed to prevent head injury due to impact from flying, falling or suspended
objects. Some types of hard hat can be modified by adding face-shields, visors, chin-straps and
hearing protection.
Avoiding injury or damage can be as simple as choosing the right tool for the job, and using it correctly.

 Don't use damaged or worn tools

 Don't use oversize or undersize tools
 Don't use a tool that is designed for a different job
 Always work carefully and methodically
If you don't know which tool to use, or how to use a tool properly: STOP and ASK!

Assembly Tool Safety Checks

 Check the tool handles are secure and in good condition and are not split, chipped or cut.
 Check the clamping faces for excessive bruising or embedded foreign objects.
 Check tool surfaces, edges and teeth for any sign of chipping, splitting cracking, bruising or
damage.
 Clean the surfaces with a dry rag to remove any excess oil or grease.
 Lubricate the tool (if required) to achieve smooth operation.
 Check the tool mechanism for full and free movement.
 Check for a secure fit on the heads of fasteners.

 Common operations performed on cylindrical grinding machine

Common grinding applications for this machine including horizontal shaft
grinding, taper grinding, and plunge grinding.

Standard Equipment:
* Swivel base motor-driven work head
* Lever-operated tailstock
* Work head & tailstock centers
* Standard grinding wheel
* Wheel flange and extractor
* Wheel dresser holder
* Coolant supply unit
* Lubricant supply unit
* Table swivel indicator
* Splash guard
* Diamond dressing tool
* Tools and tool box
Cylindrical grinding machine Construction

* Heavy bed provides a rigid base to carry all units and possesses great stiffness,
sufficient slide way length to support the table in all position . There are four main
groups of components that comprise the basis for this machine. These consist of
the: bed, headstock, tailstock, and the carriage.
The bed is the foundation of the cylindrical grinding machine. The bed is a heavy,
rugged casting made to support the working parts of the machine. The size and
mass of the bed gives the rigidity necessary for accurate engineering tolerances
required in manufacturing today.
Machine base
The heavily ribbed box type machine base is made of meehanite casting to
provide excellent rigidity and machine stability.
The one vee and one flat guide ways are spaced at the optimal distance to assure
maximum table support.
Work head

The work head is truly versatile with its change over ability from lever type 5c
collet closer to a 3 jaw chuck or live and dead center set up. the work head also has
added versatility with the ability to swivel +/-45˚.

Wheel head base

The wheel head base utilize one vee , one flat; hand scraped guide way system to
insure a smooth movement and longer life. the addition of automatic lubrication
system, precision ball screw ,and AC servo motor delivers superior positioning
accuracy and responsibility.

Work table

The universal table with three different speeds and infinitely variable speed can be
swiveled up to ±8˚ for cylindricity. Correction and taper grinding applications.

Wheel spindle

The high accuracy of the grinding wheel spindle is achieved with the use of a
cartridge type spindle supported by four super precision ,angular contact, class
7(ABEC)bearings.

Tailstock

With a cast body and a hardened nitralloy steel sleeve designed to hold a MT3
center, the tailstock ,dressing the wheel is less time consuming.
 Automatic lubrication system

All of the machine slide ways and ball screw are continuously lubricated by auto-
lube system , to insure smooth movement and less wear, ensuring greater
accuracies over the life of the machine.

Equipment Preventive and Corrective Maintenance

Corrective Maintenance

Corrective maintenance is performed on the universal cylindrical grinding machine

as needed basis by qualified personnel either by a vendor or in house machinist.

Preventive maintenance

Preventive maintenance for the Manual and electrical cylindrical grinding machine
consists of maintaining the oil level in the headstock and carriage apron along with
daily “one shot” oiling of the machine ways.

Periodic emptying of the chip pan (as needed or full) and changing of the
coolant/cutting fluid in the reservoir is done on a four (4) to six (6) week
frequency.
The following steps are to be used by the equipment operator when performing
preventive maintenance on the universal cylindrical grinding machine.

Cleaning and Lubrication

1) Clean the chip pan as needed.

2) Clean machining chips from the grinding machine
horizontal surfaces after each use.
3) Check the level of the cutting fluid reservoir and add as
needed.
4) Lubricate the bed ways daily (as used) with light
machine oil.
5) Check the oil level in the headstock periodically and add
D.T.E. 26 oil as needed.
6) Check the apron oil level daily and add D.T.E. 27 oil as
needed.
7) Every 4 to 6 weeks, drain and refill the coolant reservoir
with fresh coolant/ cutting fluid.