Industrial manufacturing Is getting more competitive as a result of advancement and evolving technology. With the increase in these rapid changes, there have been challenges to manufacturing high-quality parts at the least possible cost and time. Fortunately, the use of CNC machines has made it possible to overcome these challenges, which is the same way CNC grinding system plays an important role in the grinding industry today.
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CNC grinding machines that use a rotating grinding wheel are machines tools that help to achieve the removal of material on a workpiece utilizing cutting. They are mostly used for the hard-fine machining of parts. To help you gain more insight into CNC grinding, we have curated the most resourceful guide to grinding.
Read on to learn more!
CNC grinding involves removing small amounts of materials via a high-speed abrasive wheel as the cutting tool. This wheel rotates in place while the part or workpiece attached to the machine table moves in the X-, Y-, and Z-axis. While this movement depends on the part size, the grinding wheel may likely take multiple passes to achieve the dimensions desired.
To achieve these, grinding machines are used. These machines have experienced advancement in design, construction, rigidity, and application far more in the last decade in comparison to other standard machine tools in the manufacturing space. Grinding machines fall into five main categories, they include:
It is important to know that the use of CNC grinding machines comes with numerous advantages. In comparison to traditional grinding, it offers very fine finishes and light cuts to your workpiece. It also provides the possibility of using less skilled labor and limited supervision to perform your projects. There are wide varieties of benefits, they include:
Irrespective of the size and quantity of the part you are willing to grind, CNC grinding machines fit the bill. CNC grinding machines can run all year round without interruptions. Consequently, you will be able to meet the demands of personal production or client&#;s production at all times. In short, no amount is too large for the process.
CNC grinding machines are known for a high level of precision. You can program these machines to produce fines surfaces and top-quality cuts with high accuracy. The grinding machines will have great finishes in line with the provided specification in the operating software. Due to their operation, you&#;ll reduce the amount of waste and the possibility of products or parts that do not meet the need they are manufactured.
CNC grinding machines function on software. All that is required to improve the performance of your machines is to update the CNC software. In a single setup, the latest software offers the possibility of performing many operations. As a result, cutting costs and time-saving becomes feasible in all aspects of production.
CNC grinding machines, like other CNC machines, can run 24/7, 365 days in one year without interruptions. Once set up, the next thing in line is production. The only situation where stoppage can be experienced is during maintenance activities to help achieve proper functioning. This process is limited in time and doesn&#;t take much time. Hence, the inconvenience of machine breakdown is eliminated.
CNC grinding offers the possibility of producing identical products in large quantities. This is applicable when bulk production of a part is required. CNC grinders will help you achieve highly similar manufacturing with a uniform resemblance. The end product of such output of using this process will be an exact match to one another.
Surface grinding, generally called Hiraken or Heiken, uses a vertical or horizontal axis grinding machine with a circular or square table and a straight type wheel or a cup type wheel. The grinding wheel in this grinding process revolves around a spindle. The workpiece mounted on either reciprocating or rotary table is brought in close contact with the grinding wheel. There are four types of surface grinders they include:
Centerless grinding helps to eliminate the need for center holes for the work holding device or for the work. In this operation, the workpiece rests on a work-rest blade back up by a second wheel named the regulating wheel. Furthermore, the wheel rotation pushes the workpiece down the work-rest edge and against the regulating wheel. Also, the regulating wheel, which is rubber-bonded abrasive, rotates in the same direction as the grinding wheel to control the longitudinal feed of the workpiece when it is set at a slight angle. The workpiece feed rate can be changed by changing this angle and the speed of the wheel.
Cylindrical grinding involves the process of grinding the outer surface of a cylinder. These surfaces may be tapered, contoured, or straight. In contrast with other CNC operations, this method resembles the lathe-turning operations. They are usually used to replace the lathe when extreme accuracy or superior finish are required, or the workpiece in question is hardened. The grinding wheel that is rotating at a faster rate in the opposite direction is brought in contact with the workpiece as it revolves. The table and the workpiece reciprocate while in contact with the grinding wheel to remove materials from the workpiece.
Accessories and work-holding devices for center-type cylindrical grinders are similar to the ones used on engine lathes. However, universal, independent, and collet chucks can be used on cylindrical grinders if the workpiece contains no center hole or is odd-shaped.
Internal Grinding involves a similar operation to a boring process in the lathe. Internal grinding machines are used to finish tapered, straight, or formed holes accurately. It functions by holding the workpiece by a work-holding device, usually a collet or chuck, and revolving it with a motorized headstock. Furthermore, a separate motor follows the same direction as the part that rotates the grinding wheel. While it can be adjusted for the depth of cut, it can be fed in and out the workpiece.
Special grinding involves special types of operations and works. Special grinders named for specific processes are used in this case. For example:
&#; Tool and Cutter Grinders
These grinders are fashioned to sharpen reamers, milling cutters, taps, and other machining tool cutters. The most popular and versatile tool-grinding machine is the general-purpose cutter grinder. In attachments are various tools for sharpening most types of cutting tools.
&#; Thread Grinding Machines
These grinders are special, and they resemble cylindrical grinders. They feature a precision lead screw for producing the correct pitch or lead on a threaded workpiece. The thread grinders offer a way of truing or dressing the cutting periphery of the grinding wheel to build a precision thread form on the workpiece.
&#; Jig Grinding Machine
These types of specials are designed to locate and accurately grind straight or tapered holes. They are equipped with a high-speed vertical spindle for driving and holding the grinding wheel. In addition, they use the same precision locating system as in jig borers.
To initiate a grinding process, an operator or a programmer feed the CNC machine&#;s computer with commands to carry out a specific operation. The machine then uses the commands to move its parts such that the grinding head moves onto the workpiece. Now, know that there are many grinding machines with different techniques for removing materials from a workpiece. An option is to advance the grinding head across or through a workpiece in a slow manner. Another is to move the grinding head that spins at high speed across the surface of a workpiece.
Here are mind-blowing tips that can help you make the most effective use of every grinding operation. These tips will give excellent ideas on how to free your griding bottlenecks. They include:
Grinding machines feature a wide range of applications, and their applications can be seen in many ways. They include the production of flute grinding, thread and cylinder grinding, grinding milling cutters, surface grinding, contour grinding, broach and hob grinding, reamers, and step-drill grinding, and many more. All these applications are spread across a wide variety of industries, including:
1. Are There Any Disadvantages?
Yes, the advantages of CNC grinding operations outweighs the disadvantage. However, the disadvantages include:
2. Why Choose a CNC High Precision Grinding Machine?
CNC high-precision grinding machines can be chosen due to their application in various materials such as steel, brass, hardened aluminum, bronze, plated aluminum, powdered metals, tungsten carbide, plastics, and titanium alloy. Also, they are the best choice for machining bearings, bushings, shafts, valves, pistons, industrial nozzles sleeves, and industrial needles.
3. Why Are Coolants Necessary in a Grinding Process?
As the grinding process runs, the machine sprays a coolant on the grinding head and workpiece to prevent overheating. Coolant exists in varieties including pastes, oils, gels, oil-water emulsion, gases like air or aerosols. Apart from cooling the grinding head and the workpiece, the coolants maximize the lifetime of the working tip and prevent corrosion of machine parts. While come coolants contain toxic chemicals, biocides, and corrosion inhibitors that can irritate skin or cause respiratory problems, it is important to wear protective gear to avoid exposure to them.
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In conclusion, CNC grinding utilizes abrasive techniques for the removal of materials from the surface of a workpiece. This process requires high precision or accuracy to increase the surface quality to get the best out of your machining processes. Irrespective of the grinding, maximizing productivity and getting the best results from your CNC machine is the goal of every dedicated partner. If you desire CNC grinding services for your high precise machined projects, contact RapidDone for all your grinding projects in small or large quantities. We will offer you a decade of experience and professionalism to make your project a successful one. Contact us today if there is such a need!
Desciption
The super-hard centerless grinding wheel is a special grinding wheel for centerless grinding machines. It is used for grinding hard and brittle materials such as tungsten carbide, ceramic, magnetic materials, PDC tools and etc.
Abrasives are diamond or CBN. The types of bond are resin, vitrified and metal bond.
With high efficiency, high precision and long life of diamond or CBN centerless grinding wheel, it is suitable for a large batch of automatic pipe, rod, and trap for external grinding. Whether it is the quality of the processed product, or consistency, both better than the conventional abrasive centerless grinding wheel
There is not a headstock and a tailstock for the high precision centerless grinding machine. Instead, a pallet and a guide wheel support the workpiece and is ground by grinding wheel.
The centerless grinding method is that it consists of three mechanisms: a grinding wheel, an adjusting wheel and work support, and the grinding wheel actually serves as grinding, and the adjusting wheel controls the rotation of the workpiece and makes the workpiece have feed speed. The work support can support the workpiece during grinding.
Grinding Method of Centerless Grinding Machine
There are three main types of centerless grinding methods, namely pass-through, plunge-cut and plunge-through.
There are 3 main types of grinding methods of centerless grinding machine, through-feed, in-feed, and through-feed and in-feed centerless grinding.
Centerless Grinding Advantage and Disadvantage
1 Continuous processing, no need to retract the tool, short time for clamping the workpiece, and high productivity.
2 The bracket and guide wheel positioning mechanism has better rigidity than that of the top and center frame of the conventional cylindrical grinding machine, and the stock removal is large, which is good for processing the slender shaft workpiece, and it is easy to realize high speed grinding and strong grinding.
3 The workpiece on the centerless cylindrical grinding machine is positioned on the positioning mechanism by the cylindrical. The grinding amount is the margin on the diameter of the workpiece.
Therefore, the effect of the wear of the grinding wheel, the compensation of the feed mechanism, and the repeated positioning accuracy error of the cutting mechanism on the diameter of the part is relatively little, only half of that of conventional cylindrical grinding machine, no need to drill the center hole.
4 The pass-through the mechanism of wide grinding wheel centerless grinding machine can increase the processing allowance each time, when cutting-in grinding, it can be disposable grinding for the complex profile, high productivity, wide applications.
5 The centerless cylindrical grinding machine has no mechanism that cannot guarantee the relative positional accuracy(coaxial, verticality, etc.) of the grinding surface and non-grinding surface, and the
Roundness is poor when grinding the axial direction to the intermittent external surface.
6 There is odd-numbered roundness for grinding surface. If it is big, it will often cause the illusion that the measured size is smaller than the largest physical size, which will affect the assembly quality and working performance.
7 The adjustment of the machine tool is complicated and time-consuming. It needs to adjust the height of the bracket and the distance and related process parameter when replacing the workpieces of different diameter every time. Therefore, the adjustment technology is difficult, and it is not suitable for small batch and single-piece production.
Types of Superabrasive Centerless Grinding Wheel:
There are resin, vitrified and metal bond diamond centerless grinding wheels, of which resin bond diamond centerless grinding wheel is the most widely used, mostly used for grinding hard alloy rod, tungsten carbide, ceramics, and vitrified bond diamond centerless grinding wheel is mainly used for grinding PDC. Metal bond diamond centerless grinding wheel is often used to grind magnetic materials.
Resin bond centerless CBN grinding wheel can be used for high-speed steel rob. The vitrified bond can be used for various bearing rollers, bearing rings cylindrical, injection nozzles, pump parts, etc.
Specifications of Centerless Grinding Wheels(mm)
Truing and Dressing of Diamond /CBN Centerless Grinding Wheel:
After grinding a period of time, the grinding wheel may have a channel or unsharp. Usually, the grinding wheel needs to be dressed. The conventional abrasive centerless grinding wheels use single point diamond dresser or diamond rotary dresser to ensure the shape and sharpness. There are truing and dressing processes for super hard abrasive grinding wheel.
The truing is a micro-cutting of the grinding wheel to achieve the required geometry and precision and make the abrasive tip crushed to form a micro-edge. the dressing is removing the bonding agent between the abrasive grains so that there is a certain holding debris space between the abrasive grains. And make the abrasive grains protrude and form cutting edge.
For multi-porous vitrified bond super hard abrasive grinding wheels( diamond and CBN grinding wheel), usually, truing and dressing can be done at one time due to the loose bonding agent. For the dense bonding agent of grinding wheel( such as resin, metal bond), truing and dressing should be done separately.
The most effective truing tool for superhard abrasive grinding wheels is diamond dressing tools. Truing in single grain diamond often affects the accuracy of the profile due to wear of the dressing tool. If it is truing with diamond rotary dresser, it can obtain good grinding wheel shape avoid being worn too fast. The feed accuracy of the truing device is high, and the feed rate should be controlled at the micron level. Excessive truing affects both the quality and life of the grinding wheel.
There are many methods of dressing. Usually, mechanical methods( such as cutting-in sharpening with corundum block, hydraulic jet sharpening method) or electric machining can be used. The latter is mostly used for the metal bond grinding wheel, and the grinding wheel is used as the anode to remove the metal bond by electric spark or electrolysis. If adding the graphite powder to the bonding agent, the method is also suitable for resin and vitrified bond grinding wheel.
Operation notes of centerless grinding wheel :
1 Check the condition of the machine before starting, and do not put the items on the machine table, and place the workpiece neatly.
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