Grinding Metal Troubleshooting-part One

Metal grinding is a critical step in the process of many welding and fabrication operations, and problems in grinding operations can cause costly downtime, potentially delaying project schedules or slowing parts out. Therefore, it is very important to quickly eliminate the faults in the process of grinding metal.

1. Uneven wear

Uneven wear is a common problem and usually easy to correct. In many routine grinding operations, uneven wheel wear is caused by excessive tool pressure, uneven pressure, low grinding angles, or a combination of the three. You can use the following steps to troubleshoot.

• When installing the wheel on the grinder, make sure the adapter nut is installed correctly and the wheel is properly tightened to the tool. Tighten the nuts just enough to keep the wheels from slipping, but avoid overtightening, which can damage the wheels.

• Make sure the workpiece is clamped securely.

• Before grinding the base metal, allow the grinder to run freely for a short time to check for chatter or excessive vibration, which may be a sign of an unbalanced or improperly installed grinding wheel.

• Especially for uneven edge wear, use less pressure when grinding and be sure to keep the tool at a 25 to 30 degree angle to the workpiece.

2. The cutting wheel is cracked

Using a product that is too hard may cause the wheel to crack. The hardness of the bond in the wheel determines its grade, which has a major impact on wheel control, stock removal rate and life. In general, when choosing a grinding wheel, use a softer or weaker bond when grinding harder materials, and use a harder bond when grinding softer materials such as aluminum. Hardness ratings for grinding wheels vary from manufacturer to manufacturer, and there is no standardized system for measuring hardness across brands, making it difficult to compare the hardness of one wheel manufacturer's wheels to another. Grinding at a low angle can be another cause of wheel cracking. If your wheel is bouncing or chattering on the workpiece, try grinding at a wider angle between 25 and 35 degrees to see if that eliminates the problem.

3. Cutting wheel life is shortened

Many factors can lead to reduced wheel life, including using too soft a wheel binder, using too much pressure, or grinding at too steep an angle. Wheel hardness and grit are factors that affect wheel life. Consider using a stiffer product, which will last longer and reduce stress while using the wheel. The goal is to move the workpiece evenly across the wheel surface using the minimum pressure necessary. Let the tools and wheels do the work the way they were designed. Using underpowered tools or wire gauges or the wrong length of extension cord can also lead to shortened wheel life. Higher powered tools and 10 or 12 gauge extension cords are recommended to ensure maximum power from the tool.

Here we have talked about 3 possible failures in the metal grinding process, and we will continue to discuss other issues in our subsequent articles