s
Technical Tips

General Tips

Problem/Symptom Problem Category Recommendation
Abnormal grinding sound that becomes high
  • Wheel speed
  • Stock removal
  • Feed rates
  • Dressing Coolant
  • Decrease wheel speed
  • Reduce stock removal
  • Increase the in-feed rate, Increase the traverse feed rate
  • Increase the dressing amount
  • Increase coolant supply and its pressure
  • Try increasing coolant concentration
Abnormal grinding sound that becomes low
  • Wheel speed
  • Stock removal
  • Feed rates
  • Dressing
  • Coolant
  • Increase the wheel speed
  • Reduce stock removal
  • Decrease the in-feed rate, Decrease the traverse feed rate
  • Increase the dresser's setting angle, Decrease the dressing amount
  • Increase coolant supply and its pressure
Abnormal grinding sound that fluctuates
  • Feed rates
  • Decrease the in-feed rate, Decrease the traverse feed rate
Feed lines on job
  • Wheel speed
  • Stock removal
  • Dressing
  • Coolant
  • Spindle Alignment
  • Decrease wheel speed
  • Reduce stock removal
  • Decrease the dressing amount
  • Increase coolant supply and its pressure
  • Re-align work head and spindle
Decrease in grinding ability
  • Wheel speed
  • Stock removal
  • Feed rates
  • Dressing
  • Coolant
  • Decrease wheel speed
  • Reduce stock removal
  • Increase the traverse feed rate
  • Increase the dressing amount 
  • Increase coolant supply and its pressure
Rough finish
  • Wheel speed
  • Stock removal
  • Feed rates
  • Dressing
  • Wheel balance
  • Coolant
  • Wheel selection
  • Increase wheel speed
  • Reduce stock removal
  • Decrease the in-feed rate Decrease the traverse feed rate
  • Increase dressing frequency Increase the dresser's setting angle Decrease the dressing amount
  • Rebalance the wheel
    Try increasing coolant concentration Clean the coolant"
Decrease in grinding ratio
  • Wheel speed
  • Stock removal
  • Feed rates
  • Dressing
  • Coolant
  • Increase wheel speed
  • Reduce stock removal
  • Decrease in-feed rate Decrease traverse feed rate
  • Increase the dresser's setting angle Increase the dressing amount
  • Increase coolant supply and its pressure
Burn marks
  • Wheel speed
  • Wheel selection
  • Spindle Alignment
    Coolant
  • Decrease wheel speed Ensure that wheel is operated below the max. RPM
  • Suggest a softer grade Suggest using finer grit Consult production for use of a different bond
  • Re-align feed table with the work holder
  • Clean the nozzle and water lines Remove sludge and chips from coolant tank Ensure that nozzle is aimed at the area where the wheel and material are in contact Increase coolant supply and its pressure Use coolant with better lubricity
Irregular scratch marks on the workpiece
  • Dressing
  • Feed rates
  • Coolant
  • Wheel selection
  • Spindle alignment
  • Increase the dresser's setting angle Decrease the dressing amount
  • Decrease the traverse feed rate
  • Clean the coolant
  • Suggest using finer grit
  • Tighten flanges using blotters
Isolated scratch mark on the workpiece
  • Wheel speed
  • Stock removal
  • Dressing
  • Feed rates
  • Coolant
  • Increase the wheel speed
  • Reduce stock removal
  • Decrease the dressing amount Replace dresser with a sharper point Check for foregin matter lodged in wheel surface and remove
  • Decrease the traverse feed rate
  • Increase coolant supply and its pressure If grain pulls out, coolant concentration may be too strong. Decrease the soda content
Narrow and deep, regular scratch marks on the workpiece
  • Wheel selection
  • Suggest using finer grit
Wide, irregular scratch marks of varying depth on the workpiece
  • Wheel selection
  • Suggest a harder grade
Widely spaced spots on the workpiece
  • Wheel balance
  • Rebalance the wheel after truing Avoid getting oil on the wheel face
Screw like scratch marks on the workpiece
  • Dressing
  • Feed rates
  • Ensure that dresser is firmly fixed Chamfer the wheel immediately after dressing Replace cracked or broken diamonds Set the dressing tool at an angle of 5° down and 30° side Decrease the dressing amount If the problem persists even after chamfering, traverse the diamond evenly and round off wheel edges Dress wheel face parallel to work
  • When making numerous passes, make slight change in the traverse rate at each pass to break the pattern
Wide, irregular scratch marks of varying depth on the workpiece
  • Wheel selection
  • Suggest a harder grade
Chattering at regular intervals
  • Stock removal
  • Dressing
  • Coolant
  • Wheel balance
  • Wheel selection
  • Spindle Alignment
  • Reduce stock removal
  • Increase dressing frequency Ensure that the dresser is firmly fixed Chamfer the wheel immediately after dressing Use sharper diamond
  • Increase coolant supply and its pressure Try increasing coolant concentration Run the wheel without coolant to remove excess water
  • Rebalance the wheel Rebalance the wheel after truing Ensure that the wheel is firmly fixed to the flange
  • Suggest a softer grade
    Replace spindle bearings in grinder
Uniform chattering
  • M/C vibration
  • Wheel balance
  • Wheel speed
  • Stock removal
  • Feed rates
  • Dressing
  • Coolant
  • Wheel selection
  • Overhang
  • Decrease vibrations from other machines Rebalance the wheel
  • Decrease the wheel speed
  • Reduce stock removal
  • Decrease the in-feed rate Decrease the traverse feed rate
  • Decrease the dressing amount
  • Increase coolant supply and its pressure Run the wheel without coolant to remove excess water
  • Suggest a softer grade
    Decrease the overhang
Irregular chattering
  • Feed rates

    Coolant Overhang
  • Decrease the in-feed rate Decrease the traverse feed rate
  • Clean the coolant Run the wheel without coolant to remove excess water
Wheel loading (glazing)
  • Wheel selection
  • Wheel speed
  • Coolant
  • Dressing
  • Suggest a softer grade Suggest using coarser grit
  • Ensure that wheel speed does not exceed max. RPM
  • Increase coolant supply and its pressure Clean the coolant Avoid gummy coolant. Select a thinner coolant Increase soda content if water is hard
  • Increase the dressing frequency Use a sharper dresser Increase the dressing speed Clean the wheel after dressing
Quick wheel wear out
  • Wheel speed
  • Feed rates
  • Wheel selection
  • Reduce the wheel speed
  • Decrease the in-feed rate Decrease the traverse feed rate
  • Suggest a harder grade
Surface shows irregular, short comma scratches
  • Coolant
  • Remove abrasive grains from the coolant Check coolant filtration, change if required Clean the wheel guard Clean the machine
Angular scratch marks on the job
  • Dressing
  • Reduce wheel dressing speed Ensure that wheel dressing is done in only one direction