Centerless grinding can be used to eliminate a small mismatch, rough surface finish, minimal chatter, workholding marks or other defects in surface finish left behind from a CNC Turning operation. This allows CNC Lathes to spend more time running parts and less time chasing a surface finish.
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Centerless grinding is able to achieve tight tolerances and surface finishes that normal CNC Machining would not typically be able to achieve. Depending on the diameter, length and material of a part, we can often hold tolerances as close as .” and achieve surface finishes as good a 5 RMS. Tolerances of .” and a surface finish of 16 RMS can be achieved with virtually minimal effort in a centerless grinding application.
Centerless grinding can also be utilized to increase production. We have worked internally and with customers to review processes and determine that the addition of a centerless grinding operation can actually save time and money. While the addition of the operation obviously adds up front costs, the savings in machine and operator time far outweigh the minimal costs of centerless grinding.
The biggest challenge of centerless grinding is the setup process. It has often been said that “centerless grinding is an art”. The work blade that the workpiece rides on must be set at the proper height, above centerline of the two wheels. An improper setup can cause issues with chatter, out-of-roundness, straightness, among other issues. Thankfully, our team at Ripley Machine averages over 20 years of experience in working with centerless grinding setups. This enables to ensure a fast and proper setup each and every time.
Another common challenge of centerless grinding is the proper selection of grinding wheel. Different jobs require different wheels. Having the improper wheel (a bond, grain size or hardness that isn’t suitable for the material and/or application) could cause issues in the grinding process. The experienced staff at Ripley Machine is familiar with different grinding wheel options and the best use of each wheel based on the application. We also work closely with the team at Perry Mill Supply to help identify proper grinding wheels and emerging technologies to ensure that we are always using the best grinding wheel for our application.
When grinding bar stock, the straightness and out-of-roundness of the mill supplied material can often create challenges. While our grinding process can improve the out-of-roundness state of material, there are limits as to how much we can improve it. In cases where material isn’t straight or is out-of-round, we work with qualified vendors for straightening services prior to our team grinding the material.
The general concept of centerless grinding has generally remained the same since its inception. While the concept remains the same, the equipment is quickly changing and evolving. Centerless grinders can now be equipped with Computer Numerical Controls (CNC). CNC Controls are commonplace for most machining processes in the 21st century. Adding CNC Controls to a grinder can serve a lot of purposes. First off, it helps to ensure precises adjustments to the machine. When coupled with proper sensors, the CNC controls can ensure that proper adjustments are made to the grinding wheel and the desired finish grind size is achieved. The addition of CNC controls can also help in the dressing of the grinding wheel. CNC controls allow for stepped or other features to be added to a part. Without CNC controls, this would only be possible by utilizing a custom cam to operate the dresser on. CNC controls can also be coupled with sensors to automatically compensate for wheel wear while the wheel is in a cut. When properly used, this helps to provide a more accurate part as well as eliminate human error.
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The utilization of automation is also an emerging technology that is being adopted for centerless grinding. Centerless grinders can be equipped with robots or other loading and unloading tool, such as bowl feeders. This automates the task of putting workpieces into the centerless grinder and removing them from the grinder.
As the world continues to evolve, there are sure to be more advances in centerless grinding and the technology utilized. Internet of Things (IoT) and Artificial Intelligence (A.I.) will certainly play a role in centerless grinding in the future. Ripley Machine is constantly evaluating advances in technology and how they will impact our business, specifically our grinding departments.
Centerless grinding is a process that has been around and popular for over 100 years but still remains a viable process for meeting the demands of customers in and beyond. Ripley Machine’s experience along with investment in the future allows us to meet our customers demands. We encourage you to reach out to our team to learn more about centerless grinding and its impact on you and your manufacturing process.
https://www.sciencedirect.com/topics/engineering/centerless-grinding
https://www.sme.org/technologies/articles//may/tips-trouble-free-centerless-grinding/
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