These include:. The required workpiece precision and surface finish will determine the type of equipment to be used. Auto balancer systems that are mounted directly on the grinding spindle are the best balancing option. Auto balancers are limited to larger sized machines such as creepfeed and OD-type machines and are, therefore, not practical for small diameter wheels. Finally, static balancing, which is carried out off the machine, has its limitations in terms of the balancing levels it can achieve.
However, it is better than not balancing and, in some applications, works fine. That said, not all wheels require balancing. Some small wheels that have a low mass do not have the weight to create a problematic imbalance. Also, wheels used for lesser precision or roughing applications might not require balancing.
Machine stiffness: Poor machine stiffness can lead to poor workpiece quality. Over time, spindle bearings can wear and become loose. Bearings can also be damaged if the machine has been crashed. Where possible, spindle bearings should be checked periodically or continuously using vibration analysis equipment. This equipment is a great tool to help predict oncoming issues with the spindle bearings that could result in poor workpiece quality.
Poor fixture and clamping methods can also result in vibration or deflection and, ultimately, poor surface finish. Dressing system: Dressing the wheel correctly is critical to achieving a good surface finish, so the dressing system must be in good condition. Stationary tools should be replaced if damaged or worn. Rotary tools such as the grinding spindle should be checked for excessive vibration, runout, and movement. Wheel hubs and arbors should be inspected for damage, as well as fixtures, steady rests, tailstock centers, and so on.
In addition to regular maintenance, many companies are now implementing maintenance programs such as condition-based monitoring CBM , whereby the machine is monitored by sensors, such as accelerometers, temperature gauges, pressure gauges, and so on. This predictive maintenance uses the data collected from the sensors to establish trends, predict failure, and help determine when components such as bearings need to be changed.
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I Agree Find out more. Improving surface finish can be done by making adjustments to one or more of these points: operational parameters, wheel dressing, grit size, coolant delivery, and machine condition. Grinding Operational Parameters. This is a good starting point. However, be sure the wheel is rated to run at the new speed. The maximum operating speed MOS will be stated on the side of the wheel.
Reduce feed rate. Reduce depth of cut. Increase the number of spark-out passes. This component is ground to a surface finish of 3. The unique micro-fracture properties of this new ceramic grain together with the retention capability of the bonding matrix enables Norton IDeal-Prime grinding wheels to deliver grinding efficiency and significantly longer life, while ensuring outstanding part quality over time. One of the key features of the new grain is that it is friable — that is, it can re-sharpen itself, reducing the build-up of swarf.
A friable grinding wheel can address several of the special challenges posed by ID grinding. Sharper grains allow material to be removed more efficiently from the workpiece using less force throughout the grinding process. This reduces potential flexing of the arbor, reducing the potential for deformations that cause uneven surface finish.
Furthermore, the reduction of swarf build-up on the higher surface contact area required by ID grinding translates into lower heat build-up and reduces the potential for burning or burnishing of the part surface. The Norton IDeal-Prime grinding wheels provide several advantages. The self-sharpening grain technology increases material removal rates and reduces the need for dressing, thereby cutting down on overall cycle times, which translates into lower cost per part.
Reductions in dressing requirements also significantly improve the grinding wheel life, leading to lower maintenance costs without sacrificing work piece quality. The innovative new grain technology creates grinding wheels with unparalleled sharpness and improved cutting efficiency that reduces spindle power requirements even at increased material removal rates. This results in lower mechanical stresses, improved part geometry and lower operating energy costs. The Norton IDeal-Prime grinding wheels are available in a variety of sizes and blends to optimize cost and performance, including grain size, grade, structure, and speed.
The coarse grain provides aggressive cutting action, enabling higher material removal rates, and the fine grain can provide more precise and improved surface finishes.
Grinding wheels are also rated according to grades, which indicate the hardness or strength with which the bonding matrix holds the abrasive grains in place. Grade A denotes the softest grade, and Grade Z denotes the hardest grade. The softer grade wheels are appropriate for harder materials because as the abrasive grains dull quicker from harder materials, the softer bond will release the dull grains to prevent friction metallurgical damage and allow new sharper points to be used, whereas the harder grades are used for improved form hold and longer wheel life.
The structure of the grinding wheel refers to the spacing between the abrasive grains in the grinding wheel, denoted by the number of cutting edges per unit area of wheel face and the size of void spaces between the grains. A large number of cutting edges per unit area is a dense structure and a smaller number of cutting edges is an open structure. Download Industrial Applications Catalogue. We use cookies in order to improve site performance, offer you a better browsing experience and enable you to easily share content.
Cookies are pieces of information stored on your computer in simple text files which our server can read and record. These files do not contain any sensitive information. By continuing to browse our site, you agree to the use of cookies. On October 23 This produces a cushioned, three-dimensional material that is pliable, flexible and very long-lasting. Which applications are they used for? Waterproof - can be used wet or dry Create a predictably consistent, uniform finish Minimum smearing and discolouration of the workpiece as heat is dissipated through the open mesh of the product Resist loading and rusting, and are not conductive.
Easy to use, reducing the need for operator training Less maintenance required Greater safety than other methods Conformability to irregular surfaces Which Norton products are non-woven?
Ideal for finishing intricate shapes and contours on metals, wood, composite and plastics. Blaze Rapid Strip discs The open web construction enables aggressive cutting action while maintaining a cool, non-loading surface. The thick, strong synthetic fibres and extra coarse silicon carbide grain make light work of removing rust, weld splatter, scale and other surface contaminants.
Use before and after welding for preparing and cleaning the surface. Vortex Rapid Blend discs Have a unitised construction for varying weave — from open to tighter- for deburring and finishing.
Suitable for removing weld marks and splatter, deburring and cleaning on stainless steel and removing small flashing and parting lines. Vortex Rapid Prep discs Have a more open weave that excels in surface preparation and cleaning thanks to a coating system that reduces smearing and resists loading. Very fine can be used for final finishing and polishing. Making the Most of Non-Woven Wheels Maximum wheel life and best surface conditioning can be achieved by following these recommendations: Wheel direction: Convolute wheels must always run in the direction indicated by the arrow printed on the side of each wheel.
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