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Introduction Machine Types Introduction In this part of the Molex eGUIDE we will discover and learn the operations and procedures that go behind surface grinding. As you learn you would appreciate the process of producing and finishing flat surfaces and you would find yourself better adapted to the processes and demands on work at the Molex tool room. We will begin with a definition on grinding and then focus on surface grinding to understand machine types, machine know-how and the surface grinding process that is demonstrated on the job - to help you identify with best practices adopted at Molex. This course is intended to serve as a guide to on the job demands and hence it is treated with a practical approach covering all facets of surface grinding as a process with the niceties of this grinding technology. How would one define grinding? Grinding is a process of fine metal cutting, achieved by the action of many small individual abrasive grains. These abrasive grains are formed into a grinding wheel that is rotated against the work piece at high speeds. Grinding machines and grinding processes are essential to most manufacturing industries, and at Molex we have proven our expertise with very high precision work covering Surface Grinding, Profile grinding, CNC Surface grinding, CNC Jig Grinding and CNC Optical Profile Grinding. Having understood the process of grinding, let's understand - What surface grinding is about? Surface Grinding is the process of producing and finishing flat surfaces by means of a grinding machine employing a revolving abrasive wheel. Machine Types Surface grinding is performed on two different types of surface grinding machines that are differentiated by the position of the grinding wheel spindle in relation to the table that holds the work. The heart of any Precision Grinding machine is the Grinding wheel spindle & it's bearing. The running true of the wheel is also essential to maintain steady pressure between the wheel & work. And yes, spindle positions can be horizontal or vertical. Now lets get to understand the two machine types that are used for surface grinding. You can identify the two machine types by the position of the grinding wheel spindle, and it's relation to the table holding the work. The spindle may be either horizontal or vertical. The types of wheel's used are determined by the spindle position and the working face of the wheel. The machines are further categorized by reciprocating tables and others with rotary tables. Further they are also distinguished by their operation, either mechanical or hydraulic. 1 Having understood the basic differences between the two grinding machines, now we will see how they are classified based on the features described earlier. Surface grinding machines are classified as: > Horizontal spindle with reciprocating table. > Horizontal spindle (segmental wheel) with reciprocating table > Horizontal spindle with rotary table > Vertical spindle with reciprocating table, and the Vertical spindle with rotary table We will now try and understand a little more on these machines and how they work best for us. The Horizontal Spindle Reciprocating machines are commonly used and is the preferred choice for the production of fine accurate surfaces on parts that have been previously machined in a shaper planner or milling machine or have been hardened. The principal features of the machine include the bed, saddle, table, vertical column, wheel head, and the vertical adjustment mechanism, the driving mechanism and the feed mechanism. Sometimes the Horizontal spindle reciprocating table machines use a segmental wheel, this machine is preferred to grind surfaces at right angles to the locating face. It is also suitable for roughing operations on castings and forgings. The next machine type is the horizontal spindle rotary table machine that is used to produce fine accurate finishes. The rotary table enables a large number of parts that are moving continually beneath the wheel and that actually transverse across the table, hence this machine is suitable for production. The Vertical Spindle reciprocating table machine is in many ways similar to the horizontal spindle machine in operation and construction except that the wheel spindle is vertical. It is particularly suitable for grinding previously un-machined castings or forgings. Some of the heavier machines using segmental wheels take cuts 2mm deep to rough out work that would otherwise be done in a planer mill or a lathe. The Vertical Spindle Rotary Table machine, which is used much like the reciprocating table machine. The worktable rotates demanding no other feeding action, apart from the down feed of the wheel. It is essential to know here that in both the horizontal and vertical spindle machines having either a reciprocating or rotary table there are two methods of grinding, they are: > Grinding using the periphery of the wheel, and > By using the side of the wheel, in which case the wheel is of cup form either of the solid or segmental type You will now see at the various combinations of work movement and the spindle position. Having so many choices of surface grinding machines, how does one go about choosing the right machine best suited for the job? 2 Having so many choices of surface grinding machines, how does one go about choosing the right machine best suited for the job? The answer lies in understanding each machine type and the job its best suited for. These vital pointers could prove useful while choosing a machine: > Speed of production > Desired accuracy > Finish required and the > Amount of material to be removed Now lets try and understand the various finishes obtained by using different types of machines: > Surface produced by grinding with the periphery of a straight wheel with the work carried on a reciprocating table will produce fine parallel straight lines > While a horizontal straight wheel with a rotary table will result in circular lines > The rim of a cup wheel on either a horizontal or a vertical spindle reciprocating table machine would produce a finish that clearly shows concentric curved grinding marks and, > The vertical spindle type of machine with a segmental wheel when grinding work on a rotary table produces a criss-cross pattern of circles These patterns produced by the machine could depreciate in quality by several influencing factors, but they are fully under your control. If you notice depreciation of work finish, you should check for the spindle bearings slide adjustments, location and the stability of work piece. Also check for lubrication of all moving parts. On machines designed for accurate production it is essential that all mechanical arrangements are checked and maintained, besides the wheel being properly dressed. On the Job Having understood the basics of grinding and having focused on surface grinding, let's begin the session that provides a hands- on experience of the machine and the job. In the part of the tutorial we shall learn more on the machine used for surface grinding and get a good description of the various fixtures such as the optidress unit, optidress DRO, Vertical column, wheel cover, magnetic chuck, the horizontal side handle, cross fine feed, cross feed angle and the vertical feed handle and the fine feed. The machine also has a optidress unit and accessories, magnetic chuck with ON/OFF handle, DRO of the machine slides, dust collector, coolant tank with motor and the hydraulic table movement adjusters. Now lets move on to understanding how one goes about using this machine on the job. Once you have picked the drawing from the rack, begin by first studying the drawing, it is recommended that you make a hand sketch of needs to be ground following the study. 3 Having done this you can mount the appropriate grinding wheel on to the machine spindle. Ensure you have cleaned the machine bed thoroughly and dress the wheel to make it true to the spindle. Then place the job on the cleaned magnetic bed with appropriate fixtures and ensure you support the job adequately. The support must be at least 75% of the job height. Having done this you can turn the magnet on, apply blue to the job surface and lower the grinding wheel closer to the job surface. You must touch the job surface using the fine feed until the blue is ground, then proceed to make reset DRO to zero. Now use the fine feed to touch the surface of the job with the grinding wheel, set the DRO to zero again. Now you can continue grinding as per the stock available to the drawing dimensions. On completion take the job out of the machine bed and clean it. You can now measure the job using the digital micrometer. Note here that if the job needs to be checked by a digital height gauge you can use the Trimos to do this. You can also use a profile projector to inspect jobs for accuracy. How much to remove has been the biggest challenge in surface grinding, hence grinding allowance is of utmost importance as a work practice to operators. Lets understand more - the amount of stock to be left on for grinding depends largely on the character of the work, whether it is long or short, stocky or thin the nature of the material; whether it is to be hardened the facilities for straightening and the nature of the previous machining, whether rough or smooth. As surface grinding does not remove metal rapidly grinding allowances should be kept on the most economical limits. For ex, if a horizontal machine with a 600mm x 200mm table and a 180mm x 13mm grinding wheel were being used to grind a cast iron or mild steel plate flat and parallel, a grinding allowance of 0.13mm on each side could be sufficient to remove the tool marks, however if the material were thin and liable to wrap during heat treatment a grinding allowance of 0.4mm to 0.5mm might be necessary.
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