Intro to Grinding Methods, Machines and Tools

Grinding is a widely used abrasive finishing process. Did you know grinding machines have been around for centuries? Well, not the electric ones but the ones that are powered via a pedal. 

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Oftentimes grinding operations are compartmentalized by machinists and considered separate from typical cutting processes used in  machine shops. This is most likely for a couple reasons, one being that grinding operations are quite often mistaken as a rubbing process and not a cutting one. Also, grinding is a cutting process that actually creates a smooth finish, unlike the other processes in the category that create unsmooth surfaces. 

There are a variety of machines and tools that perform grinding operations. Read on to learn more about the different methods that are used to get the job done along with some books to check out if you&#;re interested in deepening your grinding knowledge.

How grinding works 

Grinding is used to finish workpieces so that they meet the required surface finish quality. It rids unwanted material from the workpiece, like any rough texture that remains from previous machining applications. 

Grinding machines or tools use an abrasive wheel to remove metal from the workpiece. When the wheel rotates, it cuts material off the workpiece by cutting. The amount of material removal is dependent on factors like abrasive material and grit selection. The video below explains how to select the right abrasive. 

 

Grinding is a pretty diverse segment of machining, as the amount of material removal varies. Depending on the grinding attachment and project, both miniscule and larger amounts of material can be removed. For example, grinding can be used to either produce fine finishes or work in larger production environments to rough out large volumes of metal. Grinders can also be used to sharpen tools as seen in the video below. 

 

 

Grinding methods

There are different ways to accomplish your grinding operations. Several factors to consider are workpiece size, shape and features along with the production quantity. Machine tools are a larger investment whereas handheld tools are more affordable. 

Grinding machine tools 

Belt grinders are versatile and used for different applications like finishing, deburring and stock removal.
Bench grinders are connected to a workbench or some type of floor stand. Depending on the type of wheel, a bench grinder can be used for all sorts of finishing applications.
Cylindrical grinders are great for achieving superior surface finishes. They are able to remove the finest pieces of material. They can also be used to shape the outside of an object. These grinders are most frequently used when manufacturing a cam or crankshaft.
Surface grinders are considered the most common grinding method. They are very precise tools that use a rotating wheel held in place by a vise. The vise then moves back and forth under the abrasive wheel.
Tool and cutter grinders are very versatile tools that can host a variety of different grinding operations, like surfaces and other complex shapes. 

Grinding hand tools

A die grinder is a high-speed rotary tool that is typically powered by compressed air. The tool has a small-diameter abrasive bit that rotates to get the job done. Check out Choosing the Right Air Die Grinder for more information and some recommended models.
Angle grinders are also abrasive hand tools. Unlike die grinders, however, they run electrically. Learn more about angle grinders and some recommended models in our article Top 5 Angle Grinders Recommended by the Practical Machinist Community. 

There are also more specialized grinding tools, for example gear grinders which are specific to gear manufacturing, or jig grinders, which have a variety of uses but are most commonly used for jigs, dies, and fixtures. 

Coolant use when grinding

Whether or not coolant is necessary for your grinding application will depend on how much heat is generated. For example, high precision grinding machines like cylindrical and surface grinders generate so little heat that using coolant isn&#;t necessary. 

Grinding fluid can even increase the material removal rate without subjecting the workpiece to damage. The best fluids to use in this case are water-soluble chemical fluids and oils, synthetic oils and petroleum oils. 

Check out our article How to Select and Maintain Machine Coolant for more information about cutting fluids to make sure you are selecting the correct one. 

Learn more about grinding operations

Grinding technology has come a long way and the industry has a growing need for qualified professionals. But how do you learn about grinding? And where can you learn more about it? Check out some of these handpicked books to either get you started or deepen your knowledge. 

If you&#;re interested in a broader resource that have some sections on grinding topics, check out 5 Machining Books to Keep on Hand and 15 Timeless Books Every Machinist Should Have.

Handbook of Machining with Grinding Wheels

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Handbook of Machining with Grinding Wheels highlights important industry developments that can improve part quality, higher productivity, and lower costs. The book is divided into two parts, beginning with an explanation of grinding behavior and ending with a focus on new and emerging industrial applications.

American Machinist Grinding Book: Modern Machines and Appliances, Methods and Results

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This text is a classic. It was inspired by the columns from the original magazine American Machinist. It provides a thorough description of all the different types of grinding machines and how to take care of them.

Tribology of Abrasive Machining Processes

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Tribology is &#;the study of friction, wear, lubrication, and the design of bearings; the science of interacting surfaces in relative motion&#; (Oxford Languages). This book uses the science of tribology to understand, predict and improve abrasive machining processes. In this book, you will find solutions to the most commonly experienced industrial abrasive machining problems such as poor surface quality, rapid wheel wear, vibrations, high process costs and more. 

Turning and Mechanical Manipulation: Abrasive and Other Processes Not Accomplished With Cutting Tools

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Are you interested in learning more about china cnc shaft machining? Contact us today to secure an expert consultation!

See also:
Unleashing the Power of Permanent Magnet Variable Frequency Screw Compressors
4 Advice to Choose a Industrial Laser Cutter

This book covers a wide selection of different finishing processes. You will find information about the production of cylindrical, spherical, conical and plane surfaces by abrasion and surface grinding. 

Eco-efficiency of Grinding Processes and Systems

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Eco-efficiency is a term related to sustained growth and development. If you&#;re interested in how to further optimize your grinding systems and processes, checkout the research in this book. Various combinations of grinding process parameters and system configurations can be evaluated based on the eco-efficiency and this book will assist you in analyzing those economic and environmental impactors.

 

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The term CNC is the abbreviation of computer numerical control. That is, the whole machine tool can be controlled by computer programs.

Internal grinding is one of the difficult grinding techniques used for grinding bores and holes. This technique is usually used to make cylindrical parts with high accuracy.

Internal grinding machines, as known as internal grinders, are the machine tools to apply this technique. They use grinding wheels for machining the workpieces into the finished products.

They may include multiple grinding wheels for different purposes. While working, the cylindrical workpieces would be passed through one or more grinding wheels and the inner wall would be formed. Usually, internal grinding machines are used to form precision pipes, tubes, bearing races, or bushings, etc.

Combined with the concepts above, a CNC internal grinding machine would be a type of machine tool that is responsible for internal grinding tasks and can be controlled by the CNC (computer numerical control) system.

CNC internal grinding machines, also called CNC internal grinders, are generally used to deal with internal cylindrical grinding tasks. Sometimes they would be designed not only for the specific internal wall grinding machines but also can deal with the outer surface of the workpieces.

Generally, grinding machines with CNC systems can work better and more accurately than the ones without the control system. It is because the CNC internal grinder can be controlled and pre-programmed by computers that the machine would just work along the designed programs which is rarely making mistakes.

While the grinding machine is working, they would but not only deal with the internal part of the cylindrical parts, also, the external parts which are round would be grinded smoothly as well.

e-tech CNC Internal Grinding Machine

As a professional and experienced grinding machine manufacturer, e-tech has developed numbers of high quality grinding machines and provides them to the global market.

During these decades, e-tech has provided various grinding machines including cylindrical grinders, internal grinders, surface grinders, centerless grinders, and complex grinders for internal and external diameters.

The CNC internal grinding machine developed by e-tech is designed with both internal and external grinding functions that can machining the required cylindrical workpieces complete at one time. During the grinding progression, the grinding wheels would deal with the outer walls and internal cylindrical structures and grind both sides smoothly.

The CNC controller would help to operate the grinding machines smoothly without mistakes. High speed box type dressing function efficiently reduces the dressing time and the time spent for initial set up. Moreover, the CNC controller provides anti-collision function which can avoid the potential consumption and program saving function that can help to start the task quickly next time.

With this system, the users can set-up the grinding machine through simple graphic display icons and select riding modes as well. Every step can be set up before the grinding progression.

The grinding wheels on the internal grinding machine are various in shapes and sizes in the purpose to be able to be used in dealing with different angles and surfaces.

For example, grinding wheels dealing with the outer surface could be designed with specific angles and shapes to cut the basic shapes out from the raw materials. As for the internal cylindrical structures, the machine tool also offers grinding wheels in different thickness and sizes to make cylindrical structures in different diameters.

CNC Internal Grinding machines made by e-tech are consisted of:

&#; Work Head

This is a large servo motor drive which offers steady speed and torque during the whole progression. It can be coolant by the positive air purge system and longer the lifespan.

&#; Tail Stock

On the tail stock, there would be a coolant nozzle installed on the top for cooling the center tip. This device is air floated that can protect the working table. Moreover, the tailstock on the CNC internal grinding machine made by e-tech is adjustable and does not need to rest dressing zero.

&#; Rigid Machine Base

It is designed with ribbed-box structure with the thickness of 25 mm and the internal coolant guide with three outlets. The excellent design of this rigid machine base provides perfect rigidity and stability of the machine and then ensures the quality of completed products.

&#; X-Axis Guideway

The double V-shaped guideways provide the maximum support to the wheel head in the purpose of keeping stability. Thus, the accuracy of the products coming from this grinder would be ensured.

&#; Rotary Table

This rotary table performs well on water-proofing and is able to deal with heavy duty working. It is positioned by three-pieces tooth type clutch gears that can provide high weight loading and smooth working ability.

&#; ID Grinding Spindle

This is a built-in spindle which is not only space saving but also high-torqued and stable.

&#; Wheel Head

The NN bearing in the wheel head works the spindle and ensures rigidity and accuracy while the grinding progression is operating. Moreover, the wheel head is able to provide big output power to increase productivity.

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