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Precision Machining

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Precision Machining

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Precision Machining

Technology

Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
Copyright 2015 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
SECTION Grinding
Unit Mounting the Grinding Wheel
Introduction to Precision Grinding Workholding Devices
Machines Angle Plates, V-Blocks, and Collet
Introduction Blocks
Surface Grinders Wheel Dressing
Cylindrical Grinders Dressing Aluminum Oxide and
Silicon Carbide Wheels
Tool and Cutter Grinders
Dressing Diamond and CBN Wheels
The Jig Grinder
Grinding Parallel Surfaces
Unit Grinding Perpendicular Surfaces
Grinding Wheels for Precision Grinding Angles
Grinding Side Grinding
Introduction Performing Side Grinding
Wheel Shapes Grinding Cylindrical Work
Grinding-Wheel Specifications Grinding Problems
Superabrasives
Unit
Surface Grinding Operations
Introduction
General Surface Grinder Safety

Learning Objectives
After completing this unit, the student should be able to:

Key Terms
Cylindrical grinder Jig grinder Vertical spindle surface
Horizontal spindle surface Surface grinder grinder
grinder Tool and cutter grinder

INTRODUCTION Wheel rotation

Precision grinding removes material by the same princi-

ple as offhand grinding. Each abrasive grain of the grind-
ing wheel acts like an individual cutting tool and removes
a small portion of material. Unlike offhand grinding,
Wheel
where a workpiece is held by hand, precision grinding
machines hold work securely and provide extremely Tab
le f
precise movements of the grinding wheel to remove e ed
very small amounts of material. This allows a work-
piece to be machined to very close tolerances. Achieving A
tolerances of ± 0.0001" is not unusual when operating a
precision grinder. Because abrasives can also cut hard-
ened steels and carbide, grinding is also used to sharpen
existing cutting tools and to create custom cutting tools. Wheel rotation
Since hardened steels cannot usually be machined by
standard turning or milling methods, workpieces are
often machined near final dimensions while soft, then
hardened and tempered, and finally ground to finished

Courtesy of DCM Tech, Winona, MN.

sizes. Precision grinding also has the ability to produce Wheel
very fine surface finishes. Surface finishes as fine as
16 microinches are common when grinding. These are
some of the reasons why grinding is often the last opera-
tion performed on many machined workpieces.
There are several types of precision grinding B Table rotation
machines and each is designed to perform certain types
of grinding tasks. This unit will provide an overview of
their uses. FIGURE 7.1.1 Two types of horizontal spindle surface grind-
ers. (A) Reciprocating (the most common) and (B) rotary.

SURFACE GRINDERS
The primary purpose of a surface grinder is to produce
flat surfaces. A surface grinder uses a grinding wheel
mounted on either a horizontal or a vertical spindle.
Reciprocating or rotary table motion moves the work
beneath the grinding wheel.

Horizontal Spindle Surface

Grinders
Horizontal spindle surface grinders typically use the
periphery of a solid wheel to grind workpiece surfaces. Wheel guard
Machines with rotary table motion rotate the work be-
neath the grinding wheel. Machines with reciprocating
tables move the work back and forth beneath the grind-
ing wheel. Figure 7.1.1 illustrates both reciprocating
Copyright © 2015 Cengage Learning®.

and rotary horizontal spindle surface grinders.

The horizontal spindle reciprocating surface grinder
is probably the most common type of grinder used in the
machining industry. The work head, or wheel head, of Grinding wheel
the grinder supports the horizontal spindle that holds and
rotates the grinding wheel. (See Figure 7.1.2.) The wheel
head can be raised and lowered by rotating the elevating
hand wheel. (See Figure 7.1.3.) The hand wheel of the FIGURE 7.1.2 The wheel head of the surface grinder sup-
work head is commonly graduated in 0.0001" increments ports and rotates the grinding wheel. A guard surrounds the
for very precise down feed of the grinding wheel. wheel for protection in case of wheel failure.

Copyright © 2015 Cengage Learning®.

Cross-feed hand wheel

FIGURE 7.1.5 The cross-feed hand wheel, used to move the

workpiece across the wheel between longitudinal passes.
FIGURE 7.1.3 The elevating hand wheel of the horizontal
surface grinder. Note the 0.0001" increments for downfeed between longitudinal cutting passes. (See Figure 7.1.5.)
measurements. The cross-feed hand wheel is usually graduated in
increments of 0.0005", 0.001", or 0.005" so wheel loca-
tion can be precisely positioned when necessary, such as
when grinding near a vertical surface.
A manual surface grinder uses hand wheels to con-
trol all of the movements of the machine. Automatic
models can also be moved using hand wheels, but have
additional hydraulic or electric systems that provide a
power feed option for longitudinal and cross-feed move-
ments. After setting the amount of travel for both axes,
Copyright © 2015 Cengage Learning®.

the longitudinal feed will continuously cycle back and

forth and the cross feed will step over between longi-
tudinal passes. Cross feed can also be set to reverse
direction when it reaches set locations. Some models
also have programmable wheel heads that will feed the
Longitudinal-feed wheel down at set increments each time the cross feed
hand wheel
reaches the reversing point. When a set amount of wheel
FIGURE 7.1.4 The longitudinal-feed hand wheel, used to head travel is reached, automatic down feed disengages.
move the workpiece back and forth beneath the grinding Some machines will even stop all feed motion and move
wheel. both table axes to a preset safe location. Figure 7.1.6
shows a surface grinder with these capabilities.
The surface grinder has two table movements similar
to the vertical milling machine. The longitudinal-feed Vertical Spindle Surface Grinders
hand wheel is rotated to move the table left and right. It Vertical spindle surface grinders typically use the side
usually does not have graduations because this machine of a grinding wheel to grind workpiece surfaces. The
axis is typically only used to move the workpiece back wheel may be a solid cylindrical or cup-shaped wheel,
and forth beneath the grinding wheel. Rotating the hand or may consist of abrasive segments fastened directly
wheel clockwise moves the table to the right, while to a metal body. (See Figure 7.1.7.) Like horizontal
rotating the hand wheel counterclockwise moves the spindle machines, these vertical spindle grinders can use
table to the left. (See Figure 7.1.4.) either reciprocating or rotary table motion to pass work
The cross-feed hand wheel is rotated to provide beneath the grinding wheel. Figure 7.1.8 illustrates both
movement like the milling machine saddle or Y-axis reciprocating and rotary vertical spindle surface grind-
movement. The cross feed is normally used to move the ers. Another name for a vertical spindle rotary surface
work in incremental steps beneath the grinding wheel grinder is a Blanchard grinder.

Copyright © 2015 Cengage Learning®.

FIGURE 7.1.6 An automatic surface grinder.

CYLINDRICAL GRINDERS
Cylindrical grinders are used to grind diameters,
shoulders, and faces much like the lathe is used for turn-
ing, facing, and boring operations. The work is rotated
against the rotation of the grinding wheel. A hand wheel
is used to make precise movements of the wheel head
Copyright © 2015 Cengage Learning®.

to set cut depth when grinding diameters. Power table

travel moves the wheel longitudinally back and forth
across the surface of the workpiece. (See Figure 7.1.9.)
A grinder used to grind outside diameters is fre-
quently called an OD grinder (OD for outside diame-
ter). A machine used to grind internal diameters is often
called an ID grinder (ID for inside diameter). An OD
FIGURE 7.1.7 Example of a grinding wheel used on a vertical grinder grinds diameters with the periphery of the wheel.
spindle surface grinder. Faces and shoulders can also be ground with the side

Wheel rotation

Wheel rotation Wheel

Courtesy of DCM Tech, Winona, MN.

Wheel

Tab
le f
eed

Table rotation
A B

FIGURE 7.1.8 Table movement on a vertical spindle surface grinder can be (A) reciprocating or (B) rotary.

Copyright © 2015 Cengage Learning®.

FIGURE 7.1.9 A cylindrical grinder set up for grinding an out- FIGURE 7.1.11 A cylindrical grinder set up for grinding an
side diameter. Note how the part is held so that it can rotate. internal diameter.

Magnetic chuck

Copyright © 2015 Cengage Learning®.

Grinding wheel
Copyright © 2015 Cengage Learning®.

FIGURE 7.1.12 A spindle-mounted magnetic chuck.

Work
Regulating
wheel

FIGURE 7.1.10 A cylindrical grinder set up to grind a shoul-

der on a part.
Copyright © 2015 Cengage Learning®.

of the wheel. (See Figure 7.1.10.) An ID grinder uses

wheels mounted on arbors and primarily grinds inter-
Work rest
nal diameters similar to those performed by lathe boring
operations. (See Figure 7.1.11.) Cylindrical grinding Grinding
work can be held between centers or in chucks much wheel
like those used on the lathe. A spindle-mounted mag-
netic chuck resembling a face plate can also be used. FIGURE 7.1.13 A centerless grinder rotates work with the
(See Figure 7.1.12.) regulating wheel while a grinding wheel removes material.

The Centerless Grinder being fed between the grinding wheel and a regulating
Production grinding of the outside of shafts and tubes wheel. The grinding wheel runs at normal speed and the
can be performed with the centerless grinder. Rotat- regulating wheel runs slower and controls the rotational
ing cylindrical work is supported by a work rest while speed of the workpiece. (See Figure 7.1.13.)

TOOL AND CUTTER GRINDERS THE JIG GRINDER

The tool grinder shown in Section 3 (Figure 3.5.2) is The jig grinder is similar in appearance to a vertical
considered an offhand grinding machine because the cut- milling machine, but with much more precise X- and
ting tools are held and moved by hand. A tool and cutter Y-axis movements for extremely accurate positioning.
grinder is also used for tool sharpening, but the cutting As a spindle-mounted grinding wheel rotates, the head
tools are held in workholding devices and machine slides also moves in an orbital pattern and the quill feeds up
provide movement for much greater control and flexibility. and down to perform grinding of internal diameters.
These extremely versatile grinders can be used to sharpen Figure 7.1.15 shows a jig grinder. Newer technologies
nearly any type of cutting tool, including drills, reamers, are available that can produce a finished hole faster in
taps, and milling cutters. They can also be used to create many workpieces than a jig grinder, but there are still
customized cutting tools from HSS or carbide tool blanks. some applications for its use.
Figure 7.1.14 shows an example of this type of grinder.
Copyright © 2015 Cengage Learning®.

Copyright © 2015 Cengage Learning®.

FIGURE 7.1.14 A tool and cutter grinder is used for sharp-

ening cutting tools and creating customized cutting tools. FIGURE 7.1.15 A jig grinder.

SUMMARY

and to create high surface finishes.

precision grinding machine used in the machining industry.

grinder, and the jig grinder.

REVIEW QUESTIONS
1. What are three benefits of precision grinding?
2. What is the major use of the surface grinder?
3. What are the two spindle types used for surface grinders?
4. What are the two types of table movements used for surface grinders?
5. Label the parts of the surface grinder.

Copyright © 2015 Cengage Learning®.

6. What are three types of cylindrical grinders?

7. Tool and cutter grinders can be used to existing cutting tools or to create new, customized
cutting tools.

Learning Objectives
After completing this unit, the student should be able to:

Key Terms
Aluminum oxide Friability Structure
Bonding agent (Bond) Grade Superabrasive
Ceramic aluminum oxide Grit size (grain size)
Cubic Boron Nitride (CBN) Silicon carbide

INTRODUCTION wheels are also sometimes used for surface and cylinder
grinding to minimize contact between the sides of the
The grinding wheel is the cutting tool used in precision wheel and the workpiece. Cup, saucer, and dish-shaped
grinding operations. These wheels are similar to the wheels are usually used for tool and cutter grinding
wheels used for offhand grinding because they are made operations. Cup-shaped wheels are also used on some
of abrasive grains held together with a bonding agent,
or bond. The bonding agent acts as the “glue” that holds
the individual abrasives together in the shape of a wheel.
There are many more variations of wheels available for
precision grinding versus those used for offhand grinding.
Understanding the many different types and character-
istics of grinding wheels will help in selecting a proper
wheel to perform the required grinding operation.

WHEEL SHAPES
Grinding wheels come in many different shapes, as il-
lustrated in Figure 7.2.1. The Type 1 straight wheel is
probably the most widely used wheel for surface and
cylindrical grinding operations. Recessed and relieved A

Type 1: Straight Type 11: Flaring cup wheel. Type 22: Relieved one side
Recessed other side

Type 2: Cylinder wheel. Type 12: Dish wheel. Type 23: Relieved and recessed same side

Type 5: Recessed one side Type 13: Saucer Type 24: Relieved and recessed one side,
recessed other side
Copyright © 2015 Cengage Learning®.

Type 6: Straight cup wheel. Type 20: Relieved one side Type 25: Relieved and recessed one side,
relieved other side

B Type 7: Recessed two sides Type 21: Relieved two sides Type 26: Relieved and recessed both sides

FIGURE 7.2.1 Examples of some of the many different shapes of grinding wheels.

will identify these characteristics according to the stan-

dardized system. The optional prefix and the last one or
two digits are markings used by individual manufactur-
ers. The remaining numbers and letters identify the five
wheel characteristics.
Figure 7.2.3 summarizes this system. Refer to it
Copyright © 2015 Cengage Learning®.

while reading each description.

Abrasive Type
Most grinding wheels are made from either aluminum
oxide, a combination of aluminum oxide and ceramic
aluminum oxide, or silicon carbide.
Aluminum oxide and ceramic aluminum oxide wheels
FIGURE 7.2.2 Wheel shapes used in internal diameter are identified by the letter A, and silicon carbide wheels
grinding operations. by the letter C. Different varieties of each abrasive type
may also contain other letters. The different varieties
have different levels of friability. Friability is the ability
vertical spindle surface grinders. The periphery of a
grinding wheel is the surface that is designed to be used
for grinding, but under the right circumstances, other
wheel surfaces can also be used. For example, the pe-
riphery and the side of a straight or recessed wheel could
be used to simultaneously grind a horizontal surface and
an adjacent vertical surface on a surface grinder or O.D.
Width of wheel
grinder. Figure 7.2.2 shows some examples of arbor-
mounted wheel shapes that are used for internal diam-
eter grinding operations. Outside diameter
of wheel
Hole size
GRINDING-WHEEL
SPECIFICATIONS
Beyond wheel shapes, there is a standardized system A
for describing specifications for most grinding wheels
based on five characteristics. These five characteristics Manufacturers Grain size
prefix Bond
are abrasive type, grit or grain size, grade, structure, and Abrasive type Grade
bond type. Markings on the blotter of a grinding wheel Structure

Optional Optional
manufacturer Abrasive Grit Bond manufacturer
detail type size Grade Structure type detail

38 A 60 J 8 V BE
A-Aluminum oxide Coarse Medium Fine Very Soft 1 (Closely grouped grains) B-Resinoid
Copyright © 2015 Cengage Learning®.

8 30 70 Fine A-G to BF-Resinoid reinforced

C-Silicon carbide 10 36 80 220 16 (Widely spaced grains) E-Shellac
Medium
12 46 90 240 R-Rubber
H-P
14 54 100 280 RF-Rubber reinforced
16 60 120 320 Hard S-Silicate
20 150 400 Q-Z V-Vitrified
24 180 500
B 600

FIGURE 7.2.3 (A) A grinding-wheel blotter showing the abrasive type, grain size, grade, structure, and bond type, as well
as wheel dimensions. (B) Summary of the system for classifying grinding wheels.

of the individual abrasive grains to fracture during grind- Grade

ing to create new, sharp cutting edges. Wheels that are
The grade of a grinding wheel refers to its hardness or
more friable produce less heat when grinding and are
strength of the bond and ranges from A to Z. Grade A is
generally used when grinding harder materials. Less fri-
the softest and Z is the hardest. Generally, softer wheels
able wheels are tougher, hold their shape better, and are
are used for harder materials because the wheel will re-
generally used when grinding softer materials.
lease old grains before they become dull, exposing new,
Aluminum Oxide sharper grains. If a hard wheel is used for grinding a
Aluminum oxide wheels are used for grinding steel. hard material, the grains will not release and they will
There are different colors of aluminum oxide wheels, become dull. This will cause wheel glazing, overheat-
including white, pink, and brown. These colors, along ing, and burning of the work surface. When there is a
with any prefix before the “A” designation, indicate the large area of surface contact from using a wide wheel,
type of the aluminum oxide grit. White wheels are the a softer wheel is also a better choice because the grains
purest form of aluminum oxide and are the most fria- will release and the wheel will wear evenly to keep it
ble. Pink wheels contain some chromium oxide and are cutting freely. A harder wheel should be used when the
tougher and less friable. Brown wheels contain titanium area of contact is smaller. Harder wheels are more wear
oxide and are even less friable than pink wheels. resistant and should be used when larger amounts of
material are to be removed, while softer wheels should
Ceramic Aluminum Oxide be selected when smaller amounts of material are to be
Ceramic aluminum oxide is a synthetic (man-made) removed.
abrasive. Wheels made entirely from ceramic aluminum
oxide are very durable but are not well suited for preci-
Structure
sion grinding because they cannot produce smooth sur- Structure is the spacing between the individual grains
face finishes. When ceramic aluminum oxide and straight of the grinding wheel and is identified by the numbers
aluminum oxide are combined, however, the result is a 1 through 16. The number 1 identifies a dense wheel
durable wheel that can produce finer surface finishes and where the grains are close together. The number 16
is suitable for precision grinding of ferrous metals. identifies a very open wheel with more space between
the individual grains. Open wheels should be selected
Silicon Carbide for grinding continuous surfaces and dense wheels
Silicon carbide is a harder abrasive than aluminum oxide should be used on interrupted surfaces. Open-structure
and is available in two basic types. Green wheels are the wheels should be used when grinding with cutting fluids
purest form of silicon carbide wheels, are the most friable, and tighter structures used when grinding “dry.” A more
and are mostly used when grinding carbide. Black silicon open wheel will also typically remove material faster,
carbide wheels are less friable and are generally used when but a denser wheel will leave a smoother surface finish.
grinding cast iron, stainless steel, and nonferrous metals.
Bond Type
Grit Size (Grain Size) The bond is the material used as “glue” to hold the
Grit or grain size is listed after abrasive type. Just like grains together. The major bond types are vitrified, sili-
with other types of abrasives, the lower the number, the cate, rubber, resinoid, and shellac.
coarser the wheel. The higher the number is, the finer
the wheel. Grain sizes range from 8 to 600. Coarser
Vitrified
wheels have larger abrasive grains and will remove The vitrified bond is a synthetic glass bond and is by
material more quickly and produce rougher surface far the most commonly used bonding agent. Vitrified
finishes, while finer wheels will remove material more wheels are identified by the letter V. They are hard but
slowly and produce smoother surface finishes. Coarser too brittle to withstand heavy pressure or shock. They
wheels also cut softer metals better because the larger also hold up well when used with cutting fluids. Vitrified
grains can penetrate the work more easily. When grind- wheels are used for most precision grinding operations.
ing harder metals, a finer wheel with more grains in a
given amount of wheel space will provide more cut-
Silicate
ting points that can remove material more quickly than The silicate bond is a synthetic, claylike bonding agent.
a coarser wheel. Use of coarser wheels for grinding It is softer than the vitrified bond and releases grains
harder materials will result in the grains breaking off more easily. Silicate wheels produce less friction and cut
the wheel and excessive wheel wear. Grain sizes from at lower temperatures so they are often used to grind
46 to 80 are commonly used for general-purpose sur- very thin parts and edges of hard materials. Silicate
face grinding operations. wheel bonds are identified by the letter S.

Rubber
Rubber bonded wheels can operate at very high speeds
and produce very high surface finishes. They have some
elasticity or flexibility and can withstand heavy pressure
and shock without breaking, unlike vitrified and silicate
wheels. For those reasons, the rubber bond is often used

Copyright © 2015 Cengage Learning®.

for very thin wheels such as those used for precision cut-
off operations. Since rubber is a natural or organic bond,
it can deteriorate over time and become brittle and weak.
Rubber wheels are often used as regulating wheels when
centerless grinding and for polishing operations. Rubber
bonded wheels are identified by the letter R, or RF for
rubber reinforced.
FIGURE 7.2.4 A superabrasive grinding wheel. Note how
Resinoid the abrasive material is bonded to an aluminum wheel body.
The resinoid bond is another natural bonding agent.
Resinoid wheels are tough and can withstand pressure
and shock. They are not very common in precision used for grinding carbide, hard coatings or plating, su-
grinding, but are used for rough offhand grinding under peralloys, and even glass and ceramic. CBN wheels are
harsh conditions, such as heavy deburring of iron cast- often used for grinding hardened high-speed tool steels,
ings. Resinoid wheel bonds are identified by the letter B, titanium, and superalloys. Both can remove material
or BF for resinoid reinforced. much more quickly than aluminum oxide and silicon
carbide wheels and are harder and more wear resistant.
Shellac Superabrasives cost significantly more than standard
Shellac is another natural wheel bond. Shellac wheels abrasives, which is why aluminum oxide and silicon
are stronger and more rigid than rubber wheels but still carbide wheels are still widely used.
provide resistance to shock, so shellac can be used to Designation of diamond and CBN wheels is slightly
make very thin wheels. These wheels also produce very different from the system used for standard grinding
high surface finishes. Shellac bonded wheels are not wheels. Refer to Figure 7.2.5 while reading the follow-
very common, but have limited use in specialized appli- ing descriptions.
cations such as cam grinding. Shellac wheels are identi- The prefix and the last one or two digits are again
fied by the letter E. optional manufacturer-specific symbols. The second
entry is either D for diamond or B for CBN. Next are the
grain size and the grade, the same as used for aluminum
SUPERABRASIVES oxide and silicon carbide wheels.
Superabrasives are used in grinding wheels that are The next entry is a manufacturer's number or let-
used to grind extremely hard materials. Diamond abra- ter that shows the abrasive concentration, or weight of
sive wheels contain small particles of natural or syn- the abrasive per cubic centimeter of the abrasive layer.
thetic diamond held together by bonding agents. They Higher concentrations are better for faster material
are the hardest wheels available. CBN wheels use a removal, whereas lower concentrations produce higher
synthetic abrasive called cubic boron nitride and are surface finishes.
second in hardness after diamond wheels. After the concentration symbol comes the bond type.
These superabrasive wheels contain a layer of abra- Resinoid, vitrified, and metal bonds are used for dia-
sive on a metal wheel body. (See Figure 7.2.4.) If the mond and CBN wheels. An optional bond modification
entire wheel were made of the bonded abrasive, the cost code can follow the bond specification. Next is the depth
would be far too expensive. Diamond wheels are often of the abrasive layer in either inches or millimeters.
Copyright © 2015 Cengage

Manufacturer’s
Grain Bond Bond Depth of Identification
Prefix Abrasive Size Grade Concentration Type Modification Abrasive Symbol
Learning®.

M D 120 R 100 B 56 *

FIGURE 7.2.5 The marking system used for CBN and diamond superabrasive wheels. The data shown is for a sample
wheel.

SUMMARY

(or hardnesses), structures, and bond types.

numbers 1 through 16.

grinding applications.

materials.

REVIEW QUESTIONS
1.
What wheel shapes are commonly used for surface and cylindrical grinding?
2.
What abrasive is commonly used to grind steels?
3.
What abrasive is used to grind nonferrous metals, cast iron, and stainless steel?
4.
What does CBN stand for?
5.
What superabrasive is a good choice for grinding carbide?
6.
The grade of a wheel describes its ____________________ on a scale from ____________________ to
____________________.
7. Briefly explain the structure identification scale for aluminum oxide and silicon carbide wheels.
8. List three bonding agents used for aluminum oxide and silicon carbide wheels.
9. Generally, harder wheels should be used to grind ____________________ materials and softer wheels
should be used to grind ____________________ materials.
Answer Questions 10–14 about these two wheels:
Wheel A: 32A60H8V Wheel B: 39C100L6V
10. What is the abrasive type for each wheel?
11. Which wheel is finer?
12. Which wheel is harder?
13. Which wheel is more open?
14. What type of bond is used for both wheels?

Learning Objectives
After completing this unit, the student should be able to:

Key Terms
Diamond dresser Magnetic chuck Magnetic V-block
Dressing stick Magnetic parallels
Ferromagnetic Magnetic sine chuck

INTRODUCTION MOUNTING THE GRINDING

Since surface grinders are used primarily to grind flat WHEEL
surfaces, many of the same workholding and setup prin-
ciples used when milling can be applied when surface
grinding. This unit will discuss setup and operation of CAUTION
the horizontal spindle reciprocating machine, but rotary
and vertical spindle machines can utilize the same meth-
ods with only slight variation. Following these steps and
some basic safety guidelines will allow for safe and pro-
ductive operation of the surface grinder.

GENERAL SURFACE GRINDER After a grinding wheel is selected, it must be mounted

SAFETY on the spindle of the surface grinder. To remove the ex-
The surface grinder, like any machine tool, can be very isting wheel, the spindle nut needs to be removed. This
dangerous, but by following some basic precautions, nut will contain a left-hand thread. Every machine is
safe operation can be ensured. Specific safety notes will slightly different, but most grinders require the use of
be discussed throughout this unit, but the following are two wrenches to loosen the spindle nut. These wrenches
some guidelines that should be observed during any are normally provided by the grinder manufacturer. One
grinding operation. is used to keep the spindle from turning and the other
to turn the nut clockwise to loosen the spindle nut. Fig-
ure 7.3.1 shows a typical surface grinder spindle and
nut. After removing the spindle nut, many machines
CAUTION will have a large flat washer that needs to be removed
as well. Finally, remove the grinding wheel from the
spindle shaft.

-
-
Copyright © 2015 Cengage Learning®.

FIGURE 7.3.1 Loosening the spindle nut on most grinders

requires two wrenches.

CAUTION CAUTION

The blotters cushion the wheel between the spindle

flange and the spindle nut. If a blotter is not used, the
clamping pressure can crack the wheel and it can fly
Then perform a ring test to be sure the wheel is not apart when the spindle is started. Be sure the flange,
defective. Suspend the wheel with one finger and lightly shaft, wheel sides, and center hole are free of dirt. The
tap it with a non-metallic object such as the wooden wheel should slide easily onto the shaft.
or plastic handle of a screwdriver, as shown in Figure
7.3.2. A clear ringing sound means the wheel is “sound.”
A dull sound means the wheel is damaged and should
not be mounted. Even though the wheel may appear to CAUTION
be in good condition, it could have an internal crack. If a
cracked wheel is mounted and started, it could fly apart
and cause serious injury.

CAUTION
Be sure the washer is clean and burr free, and then
place it on the spindle. Note that most spindle nuts will
have a recess on one side. This recess must go against the
wheel when the nut is threaded onto the spindle. Tighten
the spindle nut securely using the provided manufactur-
er's wrenches. If larger wrenches are used, the spindle
nut can be overtightened and crack the grinding wheel.
After mounting the wheel, jog the spindle a few
times (start and stop without bringing the spindle to full
speed). Then turn the spindle on and let it run for at least
one full minute to be sure that the wheel is still sound.

WORKHOLDING DEVICES
A surface grinder has T-slots in the table like those in the
worktables of the drill press and milling machine. The
T-slots can be used to clamp work directly to the table,
but a magnetic chuck is usually mounted to the table us-
ing these T-slots. The magnetic chuck can then be used
to secure ferromagnetic workpieces or other workhold-
ing devices. A ferromagnetic material is simply a mate-
Copyright © 2015 Cengage Learning®.

rial that is attracted to a magnet.

Magnetic Devices
Magnetic workholding devices contain alternating
segments of ferrous and nonferrous materials that are
mounted together to form a single unit. The ferrous por-
tions of the device are called the magnetic poles. The
FIGURE 7.3.2 Wheels should always be ring tested before poles create the magnetic pulling force across the non-
they are installed. Ring testing checks the wheel for soundness. ferrous segments when an internal magnet is activated.

Copyright © 2015 Cengage Learning®.

FIGURE 7.3.3 (A) A permanent magnet and (B) an electromagnet. The control for the electromagnet offers the ability to vary the
magnetic force exerted on a workpiece which can limit distortion of thin workpieces.

A magnetic device may use a permanent magnet or an

electromagnet. A permanent magnet is activated by flip-
ping a lever to activate the magnetic fields. An electro-
magnet is energized with a switch, and most models
have a variable power switch that can adjust the strength

Copyright © 2015 Cengage Learning®.

of the magnetic force. This is sometimes useful when
securing thin parts that can easily distort under the full
magnetic force. Figure 7.3.3 shows a permanent mag-
netic chuck and an electromagnetic chuck.
When using a magnetic chuck (or any magnetic work-
holding device), observe the distance between the poles.
The workpiece to be held should span at least three of
the nonferrous segments or the magnetic force may not
be strong enough to secure the part to the chuck. (See FIGURE 7.3.4 The gold-colored areas on the chuck are the
Figure 7.3.4.) Many chucks also have a back rail and a nonferrous segments where the magnetic fields are created.
side rail that can help position work parallel or square The workpiece should span 3 or more of these segments to be
safely secured. Notice the back rail on this chuck. It is used to
to table travel.
help align a workpiece on the chuck.
If a workpiece is taller than its length or width, the
magnetic chuck may not be strong enough to hold the
part. Blocking can be used to help secure the part to the Figure 7.3.5 shows a method of blocking work on a
chuck and prevent it from tipping or being pulled from magnetic chuck. Thin workpieces that are not ferromag-
the chuck. Blocks are placed tightly around the work- netic can also be held on the magnetic chuck using flex-
piece before activating the magnet. Since the greatest ible clamps. These use the magnetic force of the chuck
force while grinding is in the direction of the longitu- to pull small fingers against opposite edges of the part,
dinal table feed, blocking on the left and right sides of holding it in place during grinding. (See Figure 7.3.6.)
the workpiece is most critical. This method can also be If a workpiece contains features that keep it from being
used to secure workpieces that are not ferromagnetic. placed flat on the magnetic chuck, magnetic parallels may

Copyright © 2015 Cengage Learning®.

FIGURE 7.3.7 Magnetic parallels extend the magnetic field

FIGURE 7.3.5 Blocking consists of placing pieces of ferro- of the magnetic chuck.
magnetic metal around the workpiece. This is done to help hold
the workpiece secure during the grinding operation. When us-
ing this method it is important to make sure the blocking ma-
terial is shorter than the actual workpiece.

Copyright © 2015 Cengage Learning®.

FIGURE 7.3.8 Magnetic V-blocks.

sine plate but has its own permanent magnet to hold

the work. It is a combination sine plate and magnetic
chuck. The chuck portion has a back and end rail like
FIGURE 7.3.6 A pair of finger-type hold-downs may be used
many standard magnetic chucks to align workpieces on
to hold non-magnetic parts against a magnetic chuck surface
the chuck surface. The entire unit can be secured to the
for grinding.
grinder's magnetic chuck. (See Figure 7.3.9.)
sometimes be used to support the workpiece. Magnetic
parallels are not magnetic by themselves but are designed
to extend the magnetic field of the chuck to the workpiece. CAUTION
Figure 7.3.7 shows a pair of magnetic parallels.
A magnetic V-block can be used to hold a work-
piece at a 45-degree angle and extends the magnetism
of the chuck to the workpiece like magnetic parallels.
(See Figure 7.3.8.)
A magnetic angle plate can be used to hold work
vertically and for squaring operations much like a stan-
dard angle plate. It has a permanent magnetic control
just like the magnetic chuck to hold workpieces. It can Workpieces can become magnetized after being held
be secured to the grinder's magnetic chuck in the same by magnetic fixtures. A demagnetizer can be used to re-
way a workpiece would be. move magnetism from the work. The demagnetizer is
Precision angles can be ground using a magnetic turned on and the workpiece moved across its surface.
sine chuck. The sine chuck is set up just like an ordinary A demagnetizer is shown in Figure 7.3.10.

Copyright © 2015 Cengage Learning®.

FIGURE 7.3.11 Grinding vises are very accurately ground

FIGURE 7.3.9 Magnetic sine chucks can be used to hold a and can be used to quickly and accurately secure workpieces.
workpiece at a preset angle. The angle is set by using a gage
block build as with a sine bar.
Vises
Grinding vises are different from those used for milling.
All surfaces of a grinding vise are precision ground to
be parallel and perpendicular to each other. This allows
any side of the vise to be placed on the magnetic chuck.
By repositioning the vise instead of the workpiece, very
precise perpendicular part surfaces can be produced.
Copyright © 2015 Cengage Learning®.

Figure 7.3.11 shows a grinding vise.

WHEEL DRESSING
Before beginning any surface grinding, the face of the
grinding wheel should be dressed and “trued.” Truing
eliminates wheel runout. Dressing sharpens the wheel.
(See Figure 7.3.12.)
FIGURE 7.3.10 A workpiece is often passed over a demag-
nitizer after grinding.
DRESSING ALUMINUM OXIDE
AND SILICON CARBIDE
WHEELS
ANGLE PLATES, V-BLOCKS, Aluminum oxide and silicon carbide wheels are dressed
and trued simultaneously using a diamond dresser.
AND COLLET BLOCKS There are two types of diamond dressing tools: the
Angle plates and angle blocks used for milling can also single-point diamond dresser and the cluster dresser.
be used for grinding. The workpiece is clamped to the Both are mounted in a base that can be secured directly
angle plate or block, and then the angle plate or block can on the magnetic chuck. (See Figure 7.3.13.)
be secured directly to the magnetic chuck. When grind-
ing, the 90-degree sides of the angle plate are usually
used to create two perpendicular surfaces by reposition-
Truing Dressing
ing the angle plate on the chuck instead of repositioning
the work on the angle plate.
Copyright © 2015 Cengage

If a workpiece is first clamped in a V-block or collet

fixture, the V-block or collet fixture can also be secured
directly to the grinder's magnetic chuck, or mounted on
Learning®.

an angle plate secured to the magnetic chuck. Depend-

ing on the size of these workholding devices, they could
also be used together with any of the other magnetic FIGURE 7.3.12 Truing makes the wheel face run true to its
workholding devices. axis and dressing sharpens the wheel.

Wheel guard

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Diamond
Holder

Magnetic chuck

FIGURE 7.3.15 Proper dresser position is an important

safety consideration. The diamond should be offset to the left

of the wheel centerline. If the diamond is angled in its holder,
the angle should be placed as shown.

A B CAUTION
Single point Multipoint

FIGURE 7.3.13 (A) A single-point dresser. (B) A cluster-point -

dresser.

Before mounting the dresser, raise the wheel head so

the bottom of the wheel is higher than the dressing tool. If a single-point dresser is used, move the longi-
To dress a wheel with one of these types of tools, place tudinal table travel to position the tip of the dresser
the dresser near the left end of the magnetic chuck. This about 1/8" to the left of the center of the wheel. (See
location is preferred because when the wheel is dressed, Figure 7.3.15.) The cluster dresser cannot be offset as
the abrasive particles will clear the chuck instead of far as the single-point dresser or the diamond clusters
being directed onto the working surface of the chuck. will not contact the wheel face. Position the center of
(See Figure 7.3.14.) If a single-point diamond dresser is the cluster dresser only about 1/32" to the left of the
mounted at an angle in its base, angle the dresser away wheel's center. This slight offset of the dressing tool
from the wheel rotation. In this position, the wheel is also provides an added measure of safety because the
less likely to grab the point and lift the dresser from the clockwise rotation of the wheel will tend to push
chuck. Then turn on the magnetic chuck and make sure the dresser away from the wheel, rather than pull it into
it cannot be easily moved by hand. the wheel, if the table moves unexpectedly.
Use the cross feed to position the dresser near one
edge of the wheel, as shown in Figure 7.3.16. Lower
the wheel head so the face of the wheel is about 1/32"
away from the tip of the dresser and start the spindle.
Then slowly lower the wheel head until the wheel con-
tacts the dresser. Move the cross feed until the dresser
is clear of the wheel face. Lower the wheel head about
0.001 to 0.003 to set depth for a rough dressing pass
and then feed the dresser across the wheel face using the
cross feed. (See Figure 7.3.17.) Take additional rough
Copyright © 2015 Cengage Learning®.

dressing passes until the face of the wheel is clean. For

a final dressing pass, lower the wheel head only about
0.0002 to 0.0005" and feed slowly with the cross slide.
When rough grinding, use a faster-dressing cross
feed that will leave the wheel face more open, resulting
in less friction (and heat) between the wheel and part
surface. When finish grinding, a slower-dressing cross
FIGURE 7.3.14 Preferred location of the diamond dresser feed makes the wheel face smoother. This will create a
on the left edge of the chuck. finer surface finish.

Superabrasive
grinding
wheel

Brake Brake
truing truing
wheel device
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Copyright © 2015 Cengage Learning®.

FIGURE 7.3.16 The dresser is being positioned near the
edge of the wheel.
FIGURE 7.3.18 Illustration of brake truing.

nearly touching each other. The surface grinder spindle

is then started and the truing wheel rotation started by
hand. Then the wheel head is lowered until the diamond
or CBN wheel lightly contacts the truing wheel. Use
the cross feed to move the truing wheel back and forth
across the face of the diamond or CBN wheel. Apply
sufficient downfeed to maintain rotation of the truing
wheel and continue until the diamond or CBN wheel
Copyright © 2015 Cengage Learning®.

is evenly colored. The braking system inside the truing

device controls the speed of the truing wheel to create
a “dressing ratio” that will evenly remove a very thin
layer of the superabrasive. Figure 7.3.18 illustrates
brake truing.
After truing, it is recommended to remove some of
the bond in the diamond or CBN wheel to be sure that
FIGURE 7.3.17 The dresser is fed across the face of the the superabrasive grains are exposed and can cut freely.
wheel to perform the dressing operation. Feeding the dresser This is done by moving an aluminum oxide dressing
slowly will result in a wheel having a slightly more closed stick across the rotating wheel face by hand.
structure while feeding faster will produce a slightly more
open structure.
GRINDING PARALLEL
SURFACES
DRESSING DIAMOND AND CBN Grinding parallel workpiece surfaces is the most basic,
and most common, surface grinding operation. If sev-
WHEELS eral sides of a workpiece need to be ground, it is best to
Superabrasive wheels should first be trued to eliminate grind the largest surface first, as when milling. The large
runout using a brake truing device and then dressed surface can then be used as a reference surface to locate
using a dressing stick. A brake truing device contains the workpiece for grinding the other part surfaces.
a silicon carbide wheel mounted on a spindle with an After dressing the wheel, shut off the spindle and
automatic braking system. The device can be mounted mount the workpiece using the desired workholding
on a magnetic chuck and positioned beneath the super- method. As with any other machining operation, be sure
abrasive wheel with the centers of the wheels in line. the surfaces that will contact the workholding device
The wheel head is then lowered until the two wheels are (and the workholding device itself) are clean and free of

burrs and dirt. This is even more important when preci- longitudinal table movement back and forth and lower
sion grinding than when performing any other machin- the wheel head slowly during the table stroke to touch
ing operation because even a piece of lint can produce off the wheel face against the work. A light coating of
enough error that very close tolerances will not be met. layout fluid, less than 0.001" thick, can help with vis-
If using a magnetic chuck, be sure the workpiece is ibility when touching off. (See Figure 7.3.21.)
secure after activating the magnet. It is also a good idea After touching off, use the longitudinal table travel to
to use different areas of the magnetic chuck over time to move the wheel entirely across the workpiece. If using
avoid uneven wear. a machine with a flood coolant system, start the cool-
Lower the wheel head so the wheel periphery is within ant flow. Then step over about 0.050" to 0.100" with
about 1/8" of the surface of the work. If using a grinder the cross feed and bring the longitudinal movement to
equipped with power feed, set the longitudinal table feed the other end of the stroke. Continue to alternately step
to reverse when the center of the wheel travels about 1/2 over with the cross feed and feed across the part with the
to 1" off each end of the part. (See Figure 7.3.19.) Set the longitudinal feed until the entire surface is ground and
cross-feed step-over to about 0.050" to 0.100" and the re- the wheel is completely off the part at either the front or
versing positions so the wheel travels about 1/8" to 1/4" back of the cross-feed travel. (See Figure 7.3.22.)
off the front and back of the part. (See Figure 7.3.20.) Repeat this process, taking 0.0005"- to 0.003"-deep
Use the cross feed to position the table so that only roughing passes until the surface is within about 0.001"
about 1/8" of the width of the wheel is over the part. of the desired size. Grinding produces a great deal of
Then start the spindle and let the wheel come up to heat where the wheel contacts the work. This heat can
full speed. Lower the wheel head until the face of the cause the work to expand slightly during grinding. When
wheel is within about 1/64" of the workpiece. Move the the work cools, the surface will contract and create low

FIGURE 7.3.20 The table should be cross-fed far enough so that the wheel travels off the front and rear of the part.

Avoid flowing coolant over a stationary wheel because the

coolant can soak into some types of wheels and cause them
to become unbalanced. When restarted, a saturated wheel
may develop runout and produce a poor surface finish.
Remove the workpiece from the machine and flip it
over to grind the opposite side using the same steps.

Grinding the Magnetic Chuck

Over time, the surface of the magnetic chuck can be-

come worn or distorted. If the chuck surface is no lon-
ger flat, producing parallel or flat surfaces can be nearly
impossible. Grinding the actual chuck surface can make
it flat again. Use the same techniques as when grinding
any surface. Because the chuck surface is usually very
large, heat can build up quickly, so take cut depths of
FIGURE 7.3.21 When touching off, the grinding wheel only 0.0001 to 0.0003", use coolant when available, and
is positioned so that only about 1/8"of its width is over the spark out to be sure the surface remains flat.
work. Layout fluid can make it easier to see when the wheel
touches since the dark blue provides a good visual contrast to
the workpiece.
GRINDING PERPENDICULAR
SURFACES
A few different methods can be used to grind perpen-
dicular surfaces. Generally, the surface to be ground
is positioned parallel to the magnetic chuck. Once po-
sitioned, the surface is ground using the same method
used for grinding parallel surfaces.
Crossfeed One method for holding the work is to use an angle
stepover
plate. The angle plate can be mounted directly on the
magnetic chuck and the part clamped with one of
Copyright © 2015 Cengage Learning®.

the first two ground sides against its vertical surface. If

using a magnetic angle plate, clamps are not needed but
check for adequate holding power just like when using
Longitudinal
feed the magnetic chuck. This process is similar to the mill-
ing process of placing the first milled side against a solid
vise jaw or angle plate. A parallel can be used to raise the
work above the top surface of the angle plate. If an adja-
FIGURE 7.3.22 The arrows show the direction of feed as a cent surface also needs to be ground, extend that surface
surface is ground. past one end of the angle plate so that it can be ground
when the angle plate is repositioned. (See Figure 7.3.23.)
Grind the surface that is parallel to the magnetic chuck
areas and surfaces that are not flat. This can occur even first. Then reposition clamps, while keeping a minimum
with depth cuts as shallow as 0.0005", depending on of two clamps on the part at all times. This prevents the
the workpiece material. To reduce heat and produce flat workpiece from changing position, so that the angle plate
surfaces, finish with light depth cuts of only 0.0001" to can be turned on its side to grind the adjacent surface of
0.0005" to avoid workpiece expansion and use coolant the workpiece, as shown in Figure 7.3.24. Always use at
when available. least two clamps on the work while grinding so the part
The first surface of a workpiece is often only ground remains secure on the angle plate.
until the desired surface finish is reached. Finer finishes
can be produced by repeating the finishing pass once or
twice without lowering the wheel head until the grind- CAUTION
ing wheel no longer produces sparks. This is often called
“sparking out.” -
When the desired amount of material is removed, turn
off the coolant flow first, then the spindle. This helps to
remove coolant from the wheel before it comes to a stop.

FIGURE 7.3.23 Angle plates are often used to grind a work- FIGURE 7.3.25 A precision grinding vise can be used in
piece square. If setup properly, two perpendicular surfaces of place of an angle plate when grinding perpendicular surfaces.
the workpiece can be ground without repositioning the work on
the angle plate. Here the part is positioned so that the left side
extends past the angle plate while the side facing up is ground.

FIGURE 7.3.26 Two surfaces of the workpiece can be

FIGURE 7.3.24 Without repositioning the work on the angle ground without reclamping the work by turning the grinding
plate, it is turned on its side for grinding the adjacent side. Clamps vise on its side.
must be repositioned for clearance with the grinding wheel.

A similar method uses a grinding vise instead of an milling machine, to be sure the workpiece meets the
angle plate. The vise can be mounted directly on the required tolerances.
magnetic chuck. Then secure the workpiece in the vise
with one surface above the top of the vise jaws and one
end extending past one end of the vise, as shown in
Figure 7.3.25. After grinding the top surface, the entire GRINDING ANGLES
grinding vise can be placed on its side to grind the end Precision angles can be ground using different work-
perpendicular to the other sides. (See Figure 7.3.26.) holding devices and methods. A magnetic V-block can
Using either method, at this point the work should be a quick way to hold a ferromagnetic workpiece at
have two parallel sides, and two other sides that are per- a 45-degree angle. The part must have perpendicular
pendicular to those surfaces. The remaining surfaces can sides so that it sits securely against each side of the “V.”
then be ground parallel to the previously finished sides. Place the work in the V-block, place the V-block on the
magnetic chuck, and activate the magnetic chuck. The
*NOTE: When grinding parallel and square surfaces, angular surface is now parallel to the magnetic chuck.
take time to check for parallelism and square after grind- Then grind the angular surface. Figure 7.3.27 shows
ing each surface, just like when squaring a block on the work held in a magnetic V-block.

FIGURE 7.3.27 Magnetic V-blocks are helpful when grind- FIGURE 7.3.29 Magnetic sine plates can also be used with
ing 45-degree angles. gage blocks to set up angles. This method is very accurate.

CAUTION A magnetic sine chuck can be set to the desired angle

just like a standard sine bar. The workpiece is placed
on the plate and the magnet activated. Side or end rails
should be used to align one edge of the workpiece or
errors will result. (See Figure 7.3.29.) After setting and
securing the angular position of the sine chuck, remove
the gage blocks before grinding to protect them from
A sine bar can be used to position a workpiece at a de- abrasive grinding dust. The entire magnetic sine chuck
sired angle against an angle plate. After positioning, the part can then be mounted on the surface grinder and the an-
can be secured to the angle plate. When possible, the setup gular surface ground.
should be performed on a surface plate. Set the sine bar to
the desired angle on a surface plate using the proper gage
block build. Place an angle plate against the side of the sine SIDE GRINDING
bar, then place the workpiece on the sine bar. Secure the In some situations, it is not possible to grind two per-
work to the angle plate. The angle plate with the clamped pendicular surfaces by repositioning the workpiece. In
workpiece can then be mounted on the machine for grind- these cases, side grinding with the side of the wheel
ing the angular surface. This protects the sine bar and can be performed. The periphery of the wheel is used
gage blocks from the abrasive grinding environment. (See to grind the part surface parallel to the magnetic chuck,
Figure 7.3.28.) and the side of the wheel is used to grind the vertical
surface. Side grinding is often used to grind the sides
of slots. It can also be used to grind a single surface if
the workpiece cannot be mounted to be ground with the
face of the wheel. Figure 7.3.30 illustrates an applica-
tion of side grinding.

Dressing the Wheel for Side

Grinding
Before grinding with the side of the wheel, it needs to
be dressed so that it is perpendicular to the wheel face.
First dress the wheel face using the normal method. Ei-
ther the front side or back side (or both) can be dressed,
depending on the workpiece requirements. Position the
tip of the diamond dresser in line with the centerline
FIGURE 7.3.28 Using a sine bar and gage blocks to position of the wheel. Activate the magnetic chuck and check
the workpiece on an angle plate. the dresser to be sure it is secure. (See Figure 7.3.31.)

FIGURE 7.3.30 The vertical walls of the step and the slot FIGURE 7.3.32 Dresser being used to dress the side of the
of this workpiece have been finished using side grinding wheel.
techniques.

This area
is undercut

This narrow area

is raised above
undercut area

FIGURE 7.3.33 Dressing a small undercut into the wheel

FIGURE 7.3.31 The dresser should be positioned on end can help reduce the amount of surface-to-surface contact be-
and aligned with the centerline of the wheel for side dressing. tween the workpiece and the wheel.

Start the spindle and gently feed the cross feed until the the diamond dresser is about 1/16" to 1/8" inside the
dresser contacts the wheel. Then raise the wheel head so outer wheel edge. Then undercut the wheel about 0.005"
the wheel clears the dresser point. Move the cross slide to 0.010" with the dresser. (See Figure 7.3.33.)
to dress only about 0.001 off the wheel at a time. Use Another method is to undercut the wheel by hand
the wheel head feed handle to move the wheel down un- using an aluminum oxide dressing stick, as shown in
til the desired distance is reached. (See Figure 7.3.32.) Figure 7.3.34. This method will create a great deal of
Then raise the wheel head until the diamond is past the wheel dust, so use some type of dust collection or wear
wheel face. If the height of the vertical part surface to be a dust mask. After undercutting the wheel side with the
ground is about 1/4 or less, this dressing method will dressing stick, dress the wheel periphery in the normal
normally produce satisfactory results. manner.
If the height of the vertical part surface is greater than
about 1/4", the amount of wheel contact will probably
create excessive heat and burn the workpiece surface. PERFORMING SIDE GRINDING
Two methods can be used to relieve the wheel to reduce When mounting work to perform side grinding it is criti-
wheel contact. After dressing the desired distance as cal that the vertical surface to be ground is parallel with
described previously, move the wheel head so the tip of the longitudinal table travel. The back rail available on

Clearance

FIGURE 7.3.34 Dressing a small undercut can also be per- FIGURE 7.3.36 Positioning of the wheel near the surfaces
formed by hand using a dressing stick. to be ground.
Copyright © 2015 Cengage Learning®.

FIGURE 7.3.35 A dial indicator being used to align the
workpiece with the longitudinal travel.

many magnetic chucks can be used to locate a reference FIGURE 7.3.37 Grinding horizontal and vertical surfaces.
surface of the workpiece. If the chuck does not have a
back rail, a dial indicator can be used to indicate a refer-
ence surface parallel with the longitudinal table travel, face, so if only a small fillet radius is allowed, expect
as shown in Figure 7.3.35. This is very similar to indi- that the wheel may need to be redressed a few times
cating a vise on a milling machine table. before grinding to final desired dimensions. A good
After the wheel is dressed and the work mounted, practice is to grind both surfaces within about 0.001"
bring the face of the wheel within about 1/64" of the of the final sizes, then redress the wheel before finish-
horizontal surface and the side of the wheel within ing. Figure 7.3.37 shows the horizontal and vertical
about 1/64" of the vertical surface, as shown in Figure surfaces of a step being ground.
7.3.36. Touch off the horizontal surface first and begin
grinding. Use the cross feed to step over toward the ver-
tical part surface. The sound of the grinding operation
will begin to change when the corner of the wheel be-
CAUTION
gins to contact the corner where the two surfaces meet.
Since side grinding creates even more heat than when
grinding with the wheel periphery, move the cross feed
in increments of only 0.0001" to 0.0002" once contact
is made against the vertical surface. The corner of the
grinding wheel will also wear more rapidly than the

FIGURE 7.3.38 A collet-type fixture can be used to produce
cylindrical or angular surfaces.

GRINDING CYLINDRICAL WORK FIGURE 7.3.39 (A) The center of the workpiece should be
Some cylindrical features, radii, and angles can be in line with the center of the wheel when using an indexing
ground on the surface grinder using an indexing fixture. fixture. (B) Lower the wheel head while rotating the fixture
These fixtures are similar to direct indexing fixtures handwheel to grind the cylindrical surface.
used on the milling machine. They often use spring col-
lets for workholding. Some contain V-blocks mounted
to a faceplate. (See Figure 7.3.38.)
A collet-type indexing fixture can be used to spin a
workpiece beneath the grinding wheel to grind diam-
eters. Align the work with the centerline of the wheel
and rotate the fixture while lowering the wheel head.
(See Figure 7.3.39.) A fixture may also have angular Copyright © 2015 Cengage Learning®.

graduations or an indexing ring that can be used to posi-

tion work at an angle. (See Figure 7.3.40.) Indexing fix-
tures with V-blocks can align the workpiece by moving
the V-block from the centerline of the fixture spindle.
(See Figure 7.3.41.)

GRINDING PROBLEMS FIGURE 7.3.40 Angular graduations or an indexing ring can

be used to set up angles for grinding.
Burning of the Work Surface
As mentioned earlier, grinding produces a great deal Special consideration must be given when using water-
of heat. Using water-based cutting fluid can greatly based coolant while grinding carbide. Carbide is a material
reduce heat during grinding. Ideal coolant concentra- composed of tungsten carbide particles cemented together
tions may vary by material and application. As always, by cobalt. Many coolants can cause this cobalt binder to
be sure the concentration is within the manufacturer's leach away from the carbide particles (Figure 7.3.42) and
recommendations. be carried away in the coolant. This severely reduces the

Adjustment slide

Direction of adjustment

FIGURE 7.3.43 Burn marks appear as dark streaks in the

FIGURE 7.3.41 A V-block fixture can align the workpiece
surface of the workpiece.
by moving the V-block from the centerline of the fixture. A dial
indicator can be used to ensure that the cylindrical surface is
running true.
Workpiece Surface Areas missing cobalt due to leaching
Copyright © 2015 Cengage Learning®.

Cobalt Binder
Carbide Particle

FIGURE 7.3.42 Carbide particles that are adequately surrounded by the cobalt
binder material (left), compared to carbide that has lost the cobalt binder due to
leaching (right).

Waviness or Chatter on the Work

surface strength of the workpiece material. Special water- Surface
based coolants are available with cobalt leaching inhibitors. An uneven work surface (Figure 7.3.44) is usually the
If burn marks (Figure 7.3.43) appear on the work result of an out-of-round wheel or a wheel that is loose
surface, try reducing cut depth and/or cross-feed step- on the machine spindle. Check the spindle nut to be sure
over. A wheel that is too hard, too fine, or one with a the wheel is tight. An out-of-round wheel can be easily
dense structure, can also create excessive heat leading to fixed by truing/dressing.
burn marks. Try a softer, coarser, or more open wheel to
reduce heat and burning.

Scratches on the Work Surface

Scratches on the work surface can be caused by a few

different factors. Grinding without coolant can allow
workpiece material and released wheel grains to stay on
the workpiece surface. They can then be pulled across
the surface, creating scratches. Using a flood coolant
will wash away this debris from the workpiece surface.
A dirty coolant system that contains an excessive amount
of grinding debris can also cause scratches as particles FIGURE 7.3.44 A wavy surface may indicate a loose or
are carried through the flood system and across the work. out-of-round grinding wheel.

SUMMARY

to its use.

on the surface grinder.

-
holding devices. Other magnetic workholding devices are also available for securing work for desired
grinding operations.
-
lar to those used when milling.
-
ing a workpiece.

-
tions to these issues include modifying cut depth or cross feed, changing the type of wheel, using clean
coolants, or truing/dressing the grinding wheel.

REVIEW QUESTIONS
1. List five surface grinder safety guidelines.
2. What should be done to every grinding wheel before mounting?
3. When using a magnetic workholding device, the work should span at least _____________ of the fields
of the magnet.
4. When using a magnetic chuck to hold a workpiece that is taller than its length or width, what should be
done to ensure the part is held securely?
5. Describe the difference between wheel truing and dressing.
6. What tool is used to true and dress an aluminum oxide wheel?
7. How is a CBN wheel trued and dressed?
8. Depth-of-cut range for surface grinding is:
a. 0.010"−0.100"
b. 0.0001"−0.0002"
c. 0.0001"−0.003"
d. 0.00001"−0.00005"
9. What should be done to a magnetic chuck when it becomes unevenly worn?
10. What workholding device can extend the magnetic field of the magnetic chuck and quickly position and
hold work at a 45-degree angle?
11. What workholding device can be used when grinding very precise angles other than 45 degrees?
12. Briefly describe the method for grinding two perpendicular surfaces without repositioning the workpiece.
13. List three types of workpiece features that can be produced by using an indexing fixture on the surface grinder.
14. List three possible solutions to eliminate burn marks on the surface of a workpiece.
15. What can cause scratches on the surface of a workpiece?

Unit  Unit 
Introduction to CNC Turning Introduction to CNC Milling
Introduction Introduction
Types of Turning Machines Types of CNC Milling Machines
Tool Mounting Toolholding
Workholding Process Planning
Process Planning Unit 
Unit  CNC Milling: Programming
CNC Turning: Programming Introduction
Introduction Coordinate Positioning for Milling
Coordinate Positioning for Turning Speeds and Feed Rates for Milling
Types of Motion for Turning Sequence Numbers
Non-Axis Motion Commands Types of Motion for Milling
Machining Operations Machining Operations
Canned Cycles Cutter Radius Compensation

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