Analysis of the phenomenon of grinding wheel dropping scrap: causes, effects and solutions

In the grinding process, the grinding wheel scrap is a common problem, it not only affects the machining accuracy and surface quality, but also may cause damage to the equipment, and even threaten the safety of the operator. This paper will deeply analyze the phenomenon of grinding wheel chips-off, explore the difference between normal grinding chips dull and abnormal chips drop, analyze the causes of chips-off, and put forward the corresponding solutions.

In normal grinding, the abrasive grains on the grinding wheel surface will gradually wear out and fall off due to grinding resistance, which is a natural phenomenon in the grinding process. This type of chip-off phenomenon is usually even and moderate, and will not cause a significant decline in the overall performance of the grinding wheel. However, abnormal chip-off is characterized by a large amount of chip-off of the grinding wheel in a short period of time, and even the possibility of the grinding wheel breaking up completely. This abnormal chip-off not only seriously affects the processing accuracy and surface quality, but also may cause damage to the equipment.

In ultra-precision grinding, mirror grinding and form grinding and other high-precision machining, the requirements for grinding wheel chips removal are particularly strict. These forms of grinding require extremely high precision and meticulous process control, and any small chips removal can affect machining accuracy and surface quality. Therefore, in these grinding processes, the selection, installation, use and maintenance of the grinding wheel are crucial.

There are various reasons for the grinding wheel to drop chips, mainly including the following aspects:

Unstable installation: If the grinding wheel is not fastened enough or not standardized during installation, it will cause its installation to be unstable, resulting in vibration and shaking during grinding, which will lead to chips removal.

Excessive wear: After prolonged use of the grinding wheel, defects and longitudinal cracks will be formed due to wear, and these cracks will further increase the risk of grinding wheel chips.

Material inconsistency: If the material of the grinding wheel does not match the material to be processed, it may also cause the grinding wheel to chips out. For example, the improper choice of hardness and particle size of the grinding wheel will lead to the occurrence of chips removal.

Improper grinding parameters: Improper setting of grinding parameters (such as grinding wheel speed, feed rate, etc.) will also lead to grinding wheel chips. Too high speed or too large feed will accelerate the grinding wheel wear and chip-off.

Poor grinding wheel quality: Some poor quality grinding wheels, the binding force between the abrasive particle and the binder is insufficient, and it is easy to fall off during grinding.

Solutions for the above causes of chip drop, the following solutions can be adopted:

Standard installation: When installing the grinding wheel, it should be carried out in accordance with the industry specifications to ensure the smoothness of the grinding wheel and the bearing surface, and strengthen the maintenance of the equipment to prevent excessive vibration.

Select the right grinding wheel: According to the characteristics of the processed material and processing requirements, choose the right grinding wheel material, hardness and particle size.

Optimize grinding parameters: According to the processing requirements and grinding wheel type, reasonable adjustment of grinding parameters (such as grinding wheel speed, feed rate, etc.) to reduce grinding wheel wear and chips loss.

Check and replace the grinding wheel regularly: check the wear of the grinding wheel regularly during use, and replace the new grinding wheel in time when it is found that the grinding wheel has cracks, burrs and other defects or chips loss is serious.

Strengthen the grinding wheel maintenance: regularly trim the grinding wheel to keep the grinding performance of the grinding wheel surface stable. At the same time, ensure that the grinding wheel is firmly installed to avoid chips loss caused by vibration and shaking.

The phenomenon of grinding wheel dropping is an inevitable problem in grinding process, but through standardized installation, selecting suitable grinding wheel, optimizing grinding parameters, regular inspection and replacement of grinding wheel and strengthening maintenance of grinding wheel, the occurrence of chips dropping can be effectively reduced and the processing accuracy and surface quality can be improved. In the future grinding processing, we should continue to pay attention to the problem of grinding wheel chips removal, and constantly explore new solutions and technical means to promote the continuous progress and development of grinding processing technology.