When a problem occurs while grinding, finding the cause is not easy due to the variety of complexly intertwined factors involved. In order to investigate the cause of problems, it’s important to understand what is going on during grinding — things like the condition of the workpiece, the condition of the wheel usage surface, and sound and heat generated by the process — by being sufficiently observant on the work site. Please make use of these simple troubleshooting measures that we’ve summarized here.
Frequent Troubleshooting Issues
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The grinding sound suddenly becomes high
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- Decrease the wheel speed (reduce V/v)
- Decrease the stock removal
- Increase the infeed rate and traverse feed rate
- Increase dressing amount and traverse feed rate
- Increase Coolant volume or pressure
- Raise Coolant concentration
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The grinding sound suddenly becomes low
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- Increase the wheel speed (increase V/v)
- Decrease the stock removal
- Decrease the infeed rate and traverse feed rate
- Increase dresser's setting angle
- Decrease dressing amount and traverse feed rate
- Increase Coolant volume or pressure
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The grinding sound fluctuates repeatedly
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- Decrease the infeed rate and traverse feed rate
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Feed marks are left on the workpiece
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- Decrease the wheel speed (reduce V/v)
- Decrease the stock removal
- Decrease dressing amount and traverse rate
- Increase Coolant volume or pressure
- Adjust the parallel of workhead and machine spindle
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Grinding affected layer
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- Decrease the wheel speed (reduce V/v)
- Decrease the stock removal
- Decrease the infeed rate and traverse feed rate
- Increase dressing amount and traverse feed rate
- Increase Coolant volume or pressure
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Grinding ability decreased
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- Decrease the wheel speed (reduce V/v)
- Decrease the stock removal
- Increase dressing amount and traverse feed rate
- Increase Coolant volume or pressure
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The grinding ratio is being decreased
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- Increase the wheel speed (increase V/v)
- Decrease the stock removal
- Decrease the infeed rate and traverse feed rate
- Increase dresser's setting angle
- Decrease the dressing amount and traverse feed rate
- Increase Coolant volume or pressure
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Grinding burns appear
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- Decrease the wheel speed (reduce V/v)
- Decrease the stock removal
- Decrease the dressing amount and traverse feed rate
- Increase Coolant volume or pressure
- Use coolat with good lubricity-penetration
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Warping occurs (for surface grinders)
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- Decrease the stock removal
- Increase Coolant volume or pressure
- Use coolant with good lubricity-penetration
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Poor surface roughness
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- Increase the wheel speed (increase V/v)
- Decrease the stock removal
- Decrease the infeed rate and traverse feed rate
- Do frequent dressing
- Increase dresser's setting angle
- Decrease the dressing amount and traverse feed rate
- Raise the concentration of coolant
- Rebalance the wheel carefuly
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Poor workpiece tolerance
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- Decrease the wheel speed (increase V/v)
- Decrease the stock removal
- Decrease the infeed rate and traverse feed rate
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Roundness is poor
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- Change the grinding cycle
- Correct the center hole by grinding it
- Replace the dresser with a new one
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Cylindricity is poor
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- Modify the stabilizer position
- Adjust the over-run amount in the processing surface end
- Adjust the table swivel
- Modify to a dressaer with large diamond
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Scratches appear irregularly
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- Increase the dresser's setting angle
- Decrease the infeed rate and traverse feed rate
- Clean around the Coolant
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Screw-like scratches appear
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- Fix the dresser securely
- Chamfer the grinding wheel immediately after dressing
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Isolated scratches appear
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- Increase the wheel speed (increase V/v)
- Decrease the stock removal
- Decrease the dressing amount and traverse feed rate
- Increase Coolant volume or pressure
- Change toa dresser with sharp point
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Chattering occurs at regular intervals
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- Decrease the stock removal
- Do dressing frequently
- Fix the dresser securely
- Chamfer the grinding wheel immediately after dressing
- Raise the concentration of Coolant
- Increase Coolant volume or pressure
- Rebalance the wheel carefuly
- Fix the grinding wheel to the flange securely
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Uniformly distributed chattering occurs
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- Decrease the vibrations of the outside, machine, ..etc
- Rebalance the wheel carefuly
- Decrease the wheel speed (reduce V/v)
- Decrease the stock removal
- Decrease the infeed rate and traverse feed rate
- Decrease the dressing amount and traverse feed rate
- Increase Coolant volume or pressure
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Chattering occurs irregularly
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- Decrease the infeed rate and traverse feed rate
- Clean around the Coolant
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