As we continue to strive to provide our customers with references to troubleshooting information, we have conducted many tests in our business for competitors’ abrasive cutting wheels. Did you know that simple changes can dramatically change the results. There are some key factors that can greatly affect the efficiency of the grinding wheel.
1. Speed: Do not exceed the maximum running speed of the grinding wheel. This is obvious, but slower speeds can be equally harmful. The abrasive discs were developed to achieve maximum efficiency at maximum working speed. This means that the rated speed maximizes the removal of the blank compared to the amount of wheel wear. The lower selected speed will have a major impact on how the abrasive cutting wheels work, as they will tend to “jump” or “bounce.” This can result in uneven wear of the abrasive cutting wheels and the grit will fall off the bond.
2. Power: In order to maintain a high speed during operation, there must be sufficient power. In less expensive mills, the design strength of the motor is lower than the appropriate strength. This usually causes the grinding wheel to slow down when pressure is applied to the workpiece. It is a common mistake to blame the abrasive cutting wheels for responsibility. Sometimes a weakly bonded abrasive cutting wheels can solve this problem because the cutting speed will be faster. However, the life of the abrasive cut off wheel will be shortened.
3. Angle: The angle at which the grinding wheel needs to be applied to the workpiece is 35o. Not 10-15o! Extended testing has shown that the applied 35 degree angle provides the most effective abrasive cutting wheels wear and maximum amount of cut. By reducing the angle of application, a thin tapered edge can be formed at the edge of the abrasive cutting wheels. If the grinding angle is then changed slightly, the thin edge will no longer be able to withstand the grinding pressure and rupture.
Regardless of the type of material you are grinding, it is good to keep these three points in mind as they are problem-oriented relative to workpiece-based tools/mechanics.