PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Cylindrical Grinders
Unit 83

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Permission required for reproduction or display.
 83-2

Objectives
• Set up and grind work on a cylindrical
grinder
• Internal-grind on a universal cylindrical
grinder
• Identify and state the principles of three
methods of centerless grinding
 83-3

Cylindrical Grinder
• Grinds accurately to size and high surface
finish the diameter of a workpiece
• Two types of machines
– Center type
• Plain – Generally manufacturing type of machine
• Universal – More versatile since wheelhead and
headstock may swivel
– Centerless type
 83-4

Universal Cylindrical Grinder

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Permission required for reproduction or display.
 83-5

Parts of the Universal

Cylindrical Grinder
• Base
– Heavy cast-iron construction for rigidity
– Top of base machined to form ways for table
• Wheelhead
– Mounted on cross-slide at back of machine
– Mounted on ways right angle to table way
– May be swiveled to permit grinding of steep
tapers by plunge grinding
 83-6

Parts of the Universal

Cylindrical Grinder
• Table
– Mounted on ways, driven back and forth by
hydraulic or mechanical means
– Lower table rest on the ways
– Upper table may be swiveled
– Headstock and footstock used to support work
held between centers
• Trip dogs
– Control reversal of table
 83-7

Parts of the Universal

Cylindrical Grinder
• Headstock
– Mounted on left end of table
– Contains motor for rotating work
– Dead center mounted in headstock spindle and
used to overcome any spindle inaccuracies
• Two dead centers rotate work mounted between
centers by means of dog and driveplate
• Footstock
– Supports right end of work (adjustable)
 83-8

Parts of the Universal

Cylindrical Grinder
• Backrest (steadyrest)
– Provides support for long, slender work and
prevents it from springing
– May be positioned anywhere along table length
• Center rest
– Resembles lathe steadyrest
– Mounted at any point on table
– Used to support right end of work when grinding
confined to end of workpiece
 83-9

Parts of the Universal

Cylindrical Grinder
• Internal grinding attachment
– Mounted on wheelhead for internal grinding
– Usually driven by separate motor
• Diamond wheel dresser
– Clamped to table to dress grinding wheel
• Coolant system
– Provide dust control, temperature control and
better surface finish on workpiece
 83-10

Procedure To True
and Dress the Wheel
1. Start grinding wheel to allow spindle
bearings to warm up
2. Mount proper diamond in holder and
clamp it to table
• Diamond should be mounted at angle of 10º to
15º to wheelface and held on centerline of
wheel
3. Adjust wheel until diamond almost
touches high point of wheel
 83-11

4. Turn on coolant if it is to be used for

grinding operation
5. Feed wheel into diamond about .001 in.
per pass
• Move it back and forth across wheelface at
medium rate until wheelface has been
completely dressed
6. Finish-dress wheel by using infeed of .
0005 in. and slow traverse feed
 83-12

Procedure to Parallel-Grind an
Outside Diameter
1. Lubricate machine as required
2. Start the grinding wheel to warm up
spindle bearings
3. True and dress grinding wheel, if required,
and then shut off spindle
4. Clean machine centers and center holes of
workpiece
 83-13

5. Align headstock and footstock centers

with test bar and indicator
6. Lubricate center holes with suitable
lubricant
7. Set headstock and footstock for proper
length of work so center of work will be
over center of table
8. Mount work between centers with dog
mounted loosely on left end of work
9. Tighten dog on end of work and engage
driveplate pin in fork of dog
 83-14

10. Adjust table dogs so wheel will overrun

each end of work by about one-third of
the width of the wheelface
11. Set grinder to proper speed for wheel
being used
12. Set work speed for diameter and type of
material being ground
13. Set headstock spindle to revolve work in
opposite direction to that of grinding
wheel
 83-15

14. If machine equipped, set automatic infeed

for each table reversal
• Set dwell time which permits wheel to clear
itself at each end of stroke
15. Select and set desired table traverse or
speed
• Table move one-half or two-thirds of wheel
width per revolution of work
16. Start table and move wheel up to
workpiece until it just sparks
 83-16

17. Engage wheelfeed clutch lever and grind

until work cleaned up
18. Check work for taper and adjust if
necessary
19. Determine amount of material to be
removed and set feed index for this
amount
• Infeed of wheel will stop automatically when
work at proper diameter
20. Stop machine with wheel clear of work
and measure size of workpiece
 83-17

To Grind a Tapered Workpiece

• Work held between centers
• Ground in same manner as parallel work
– Exception: table swiveled to half the included
angle of the taper
• Taper should be checked for accuracy after
workpiece cleaned up
• Short, steep tapers ground by swiveling
wheelhead to desired angle and plunge-
grinding tapered surface with face of wheel
 83-18

Plunge Grinding
• Feeding wheel into revolving work with
table remaining stationary
– Grinding wheel fed automatically to setting on
feed index
– Dwells for suitable time to permit "spark out"
and retracts automatically
• Length of surface to be ground must be no
longer than width of grinding wheel face
 83-19

Internal Grinders
• Designed for accurate finishing of holes in
workpiece by grinding wheel
– Originally designed for hardened workpieces
– Now used for finishing holes in soft material
• Wheel fed into work automatically until
hole reaches required diameter
– Wheel withdrawn and automatically dressed
 83-20

Internal Grinding on a
Universal Cylindrical Grinder
• Used in toolrooms for this purpose
• Attachment mounted on wheelhead column
– Swung into place when required
• Outside and inside diameters of workpiece
may be finished in one setup
• Grade of wheel will depend on type of work
and rigidity of machine
 83-21

Wheels Used for

Internal Grinding
• Generally softer than those for external
grinding
– Larger area of contact between wheel and
workpiece
– Requires less pressure to cut than hard wheel
• Reduced spindle pressure and spring
 83-22

Procedure To Grind Parallel Internal

Diameter on Universal Cylindrical Grinder

1. Mount workpiece in universal chuck,

collet chuck, or on faceplate
2. Swing internal grinding attachment into
place and mount proper spindle in quill
3. Mount proper grinding wheel for job
4. Adjust spindle height until center is in line
with center axis of hole in workpiece
 83-23

5. True and dress grinding wheel

6. Set wheel speed to 5000 to 6500 sf/min
7. Set work speed to 150 to 200 sf/min
8. Adjust table dogs so only one-third of
wheel width overlaps ends of work at each
end of stroke
• Blind holes – dog set to reverse table just as
wheel clears undercut at bottom of hole
9. Start work and grinding wheel
 83-24

10. Touch grinding wheel to diameter of hole

11. Turn on coolant
12. Grind until hole just cleans up, feeding wheel in
no more than .002 in. per table reversal
13. Check hole size and set automatic feed to
disengage when work roughed to within .001 in.
of size
14. Reset automatic infeed to .0002 in. per table
reversal
 83-25

15. Finish-grind work and let wheel spark out

16. Move table longitudinally and withdraw
wheel and spindle from workpiece
17. Check hole diameter and finish-grind if
necessary
 83-26

Procedure To Grind
a Tapered Hole
• Same procedures and precautions should be
followed as for grinding parallel holes
• Exception:
– Workhead must be set to one-half included
angle of taper
• Very important that centerlines of grinding
wheel and hole be set at same height
 83-27

Centerless Grinders
• Work not supported on centers but by work
rest blade, a regulating wheel, and a
grinding wheel

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Permission required for reproduction or display.
 83-28

How Centerless Grinders Work

• Work supported on work rest blade equipped with
suitable guides
• Rotation of grinding wheel forces work onto rest
blade against regulating wheel
• Regulating wheel controls speed of work and
longitudinal feed movement
– Set at slight angle (angle controls rate of feed)
• Centers fixed – diameter of work controlled by
distance between wheels and height of work rest
blade
 83-29

Methods of Centerless Grinding

• Three methods
– Thru-feed
– Infeed
– Endfeed
 83-30

Thru-Feed Centerless Grinding

• Consists of feeding work

between grinding and
regulating wheels
• Work fed by regulating
wheel past grinding wheel
• Speed of feeding work
controlled by speed and
angle of regulating wheel

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Permission required for reproduction or display.
 83-31

Infeed Centerless Grinding

• Form of plunge grinding
• Used when work being
ground has shoulder or head
• Several diameters of
workpiece may be finished
simultaneously
• Work rest blade and
regulating wheel clamped in
fixed relation to each other
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Permission required for reproduction or display.
 83-32

Endfeed Centerless Grinding

• Used for grinding tapered work
• Grinding wheel, regulating
wheel, and work rest
remain in fixed position
• Work fed in from front up to
fixed stop
• Grinding wheel and regulating
wheel often dressed to required
taper
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Permission required for reproduction or display.
 83-33

Advantages of Centerless
Grinding
• No limit to length of work being ground
• No axial thrust on workpiece
– Permits grinding of long workpieces that would
be distorted by other methods
• Less stock required on workpiece for truing
purposes
• Less wheel wear and less grinding time
required because there is less stock to be
removed
 83-34

Check textbook for full tables that list

the faults that might occur with the
probable causes and a suggested remedy.
Table 83.1  
Cylindrical grinding faults, causes,
and remedies

Table 83.2  
Internal grinding problems, causes, and
remedies