Tool and Cutter Grinder Guide
Contents
What Is a Tool and Cutter Grinder?
A tool and cutter grinder is extremely versatile and often used in machine shops. It sharpens milling cutters, tool bits, and other cutting tools, and performs various operations such as surface and cylindrical grinding of complex shapes. This type of grinder also features an abrasive grinding wheel on a universal head with a headstock, tailstock, vise, and multiple attachments for work-holding.
The image below shows a manual tool and cutter grinder. Despite its sustained popularity, highly automated CNC grinding machines have started to come out on top. They are easier to operate and only require minimal human oversight. But no matter which type you intend to use, having a concrete understanding of the machines is necessary to ensure smooth operation. Let's read on.
Figure 1. Tool and Cutter Grinder, CT
Construction and Operation
A typical tool-and-cutter grinding machine consists of a vise, which lies across three planes and a table. It can move laterally and longitudinally. The head of the tool is able to swivel and move horizontally. Using the grinding machine in conjunction with the head allows cutting at unusual angles.
Manual tool and cutter grinders demand a higher skill level from the operators. The operators should have solid know-how of the association between the wheel and the metal to cut. They also need to have an understanding of tool geometry, and a selection of accessories that are compatible with the machine. The person needs to be flexible to manipulate the cutter for various types and shapes. Here is a video demonstrating the operation of a manual tool and cutter grinding machine:
(Copyright@TECH STREAM, Youtube)
A Deeper Look into CNC Tool and Cutter Grinders
The tool and cutter grinders today are typically CNC machines with up to five axes. They produce drill bits, end mills, step tools, etc, and are widely used in the metalworking and woodworking industries.
Figure 2. CNC 4-axis Tool and Cutter Grinder, Ching Hsyang Taiwan
CNC tools and cutter grinders have improved productivity thanks to features such as automatic tool load and the ability to accommodate multiple grinding wheels. The high-degree automation enables extended periods of production without worker supervision. With appropriate tool support and configuration, it can easily achieve tolerances under 5 micrometers on any complex parts. The CNC-enabled tooling capability can automatically measure the geometric feature of cutting tools. This way, the tool will always yield optimal surface conditions. The basic grinding operations of CNC tool and cutter grinders consist of the following:
- Surface Grinding: excels in creating smooth and flat surfaces with the grinding wheel.
- Tool Grinding: known for its superb sharpening function.
- Broach Grinding: removes the material from an asymmetrically shaped workpiece.
- Internal Grinding: used to perform grinding of the internal diameter of the workpiece.
- Helical Grinding: specialized in grinding precision spurs or helical gears.
- Internal & Outer Cylindrical Grinding: The workpiece is mounted on the grinding center.
- Step Grinding: A grinding process that is similar to shimming.
CNC Software Explained
The hallmark of CNC grinding machines is the adoption of sophisticated software, such as CAD/CAM software, which brings the following benefits:
- Geometrically complex parts can now be designed consistently.
- CNC grinding machines can produce 3D simulations of the grinding process, including how the finished part will look.
- The computer-controlled system can detect potential collisions and calculate the expected production time
- Parts are verified before production, which greatly optimizes the entire process within the software environment.
With the help of CNC software, tool and cutter grinders can manufacture precision machine components. The advanced CNC grinding system with the multi-axis setup allows the machine to work on exceptionally hard and complex materials without issues.
Versatility and Customizability
CNC tools and cutting grinders are very versatile. With the right accessories, they can grind a wide variety of tools, such as turning cutters and milling cutters. This is why knowing how to maintain accessories are just as important as knowing how to take care of the machine itself. Only when the accessories are in proper condition can they ensure the quality and repeatability of your grinding operations.
In fact, much of its popularity is attributed to the leeway for tooling customization. You can apply a specific type of accessory on the tool and cutter grinder to perform various grinding applications. For example, adding a tool for radius grinding will allow the indexing for straight flute cutters, specifically on face mills and shell end mills.
Work heads and spindle extensions are also popular accessories to enhance functionality. Work heads reduce the need for tooth rest during the grinding operation. Indexing can become much simpler and more efficient with a standard work head. The spindle extension can increase the length of the spindle by three inches. You can easily revoke it to a standard spindle setup anytime. Finally, to ensure smoother operation on smaller cutting jobs, consider mounting a collet chuck.
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