A grinding wheel is a power driven machine tool that utilizes a high-speed abrasive wheel to produce flat, cylindrical or other surfaces. They are used to finish work pieces, yielding high surface quality (e.g., reducing surface roughness), and high accuracy of dimension and shape. Grinding is in fact one of the most widely accepted finishing methods because it is capable of removing material in very small size of chips from 0.25 to 0.50 mm.
Rough grinding wheels, in particular, are grinding machines commonly used in rough grinding applications. Rough grindings typically refer to the removal of a large amount of material from a work piece. In this type of grinding, good surface finish is usually not the primary concern. Instead, they focus on removing the sprue from the casting product, grinding projections, and sharpening the hand tools.
Rough grinding wheels are often equipped with specialized abrasives to carry out the intended job. For instance, zirconia alumina, a family of abrasives made from different portions of zirconium oxide and aluminum oxide. Such abrasive is tough and durable, making it the ideal choice for roughing grinding applications like cut-off operations on a wide range of steels and steel alloys. You may also choose from a variety of different types of zirconia aluminum that is best fitted for your application.
The structure of rough grinding wheels primarily encompasses a variety of abrasives and a number of pores in unit volume. In fact, the structure of a grinding wheel is dictated by the distribution of abrasives and bore. The fundamental of the grinding wheel structure is called an open or dense grinding wheel. For dense grinding wheels, particles are clumped densely compared with open grinding wheels that have larger porosity. Generally speaking, the structure of a grinding wheel is coded in numbers. Higher numbers indicate an open structure of rough grinding wheels, whereas lower numbers indicate the dense grinding wheels.
How you go about choosing the structure is largely attributed to the hardness of work piece material, required quality of surface finish, and the type of grinding operation. In most cases, an open structure is advisable for rough grinding and softer materials. Dense structured grinding wheels, on the other hand, are more ideal for harder and more brittle materials
This refers to the grain size of abrasives, which is also called grit. The number of grain sizes is determined by the number of holes in one-inch length of sieve used to filter the abrasive particles. Finer grain sizes are indicated by larger numbers. Grain sizes can typically be categorized into four classes: coarse, medium, fine, and very fine, with “coarse” being the lowest numbers and “very fine” having the highest numbers.
The grain size is depended on the quantity of material relative to the required quality of surface finish, as well as the hardness of material of the work piece. Note that only coarse and medium grain size are used for rough grinding, whereas very fine grain size is used for precision grinding.
Compared with stand grinding, rough grinding involves the removal of very rough edges from a foundry casting, surface scale from metals before welding or welding, and so on. Just as intimidating as the grinding operation may seem, it does pose certain hazards if one is not careful. Here are some of the potential hazards from undertaking rough grinding and how we can prevent them.
● Bursting: Bursting sometimes happens during the rough grinding operation, especially when the grinding wheel is operating at a high speed. And there is in fact a trend of increasing speed capacity for these rough grinding wheels. The basic protective measure for bursting is to make sure that your grinding wheel is as robust as possible, meaning taking the nature of the bonding agent into account is very important. Grinding wheels with organic bonds are typically tougher than those of inorganic bonds, and are more capable of handling operations at high speeds.
● Eye Injuries: Abrasives, grains, splinters and dust generated from the rough grinding operation can all be hazardous to eyes. This is why you need to have protective goggles on at all times when working with a rough grinding wheel. Fixed eye shields are exceptionally useful as well.
● Fire: Ignition may also take place when grinding magnesium alloys. To minimize the risk of fire, high stands of maintenance and cleanliness are to be reinforced, as well as making sure that the ventilation system inside the shop is deployed properly. In addition, textile dust is particularly susceptible for ignition, so proper maintenance is definitely required.
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