Industrial manufacturing Is getting more competitive as a result of advancement and evolving technology. With the increase in these rapid changes, there have been challenges to manufacturing high-quality parts at the least possible cost and time. Fortunately, the use of CNC machines has made it possible to overcome these challenges, which is the same way CNC grinding system plays an important role in the grinding industry today.
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CNC grinding machines that use a rotating grinding wheel are machines tools that help to achieve the removal of material on a workpiece utilizing cutting. They are mostly used for the hard-fine machining of parts. To help you gain more insight into CNC grinding, we have curated the most resourceful guide to grinding.
Read on to learn more!
CNC grinding involves removing small amounts of materials via a high-speed abrasive wheel as the cutting tool. This wheel rotates in place while the part or workpiece attached to the machine table moves in the X-, Y-, and Z-axis. While this movement depends on the part size, the grinding wheel may likely take multiple passes to achieve the dimensions desired.
To achieve these, grinding machines are used. These machines have experienced advancement in design, construction, rigidity, and application far more in the last decade in comparison to other standard machine tools in the manufacturing space. Grinding machines fall into five main categories, they include:
It is important to know that the use of CNC grinding machines comes with numerous advantages. In comparison to traditional grinding, it offers very fine finishes and light cuts to your workpiece. It also provides the possibility of using less skilled labor and limited supervision to perform your projects. There are wide varieties of benefits, they include:
Irrespective of the size and quantity of the part you are willing to grind, CNC grinding machines fit the bill. CNC grinding machines can run all year round without interruptions. Consequently, you will be able to meet the demands of personal production or client’s production at all times. In short, no amount is too large for the process.
CNC grinding machines are known for a high level of precision. You can program these machines to produce fines surfaces and top-quality cuts with high accuracy. The grinding machines will have great finishes in line with the provided specification in the operating software. Due to their operation, you’ll reduce the amount of waste and the possibility of products or parts that do not meet the need they are manufactured.
CNC grinding machines function on software. All that is required to improve the performance of your machines is to update the CNC software. In a single setup, the latest software offers the possibility of performing many operations. As a result, cutting costs and time-saving becomes feasible in all aspects of production.
CNC grinding machines, like other CNC machines, can run 24/7, 365 days in one year without interruptions. Once set up, the next thing in line is production. The only situation where stoppage can be experienced is during maintenance activities to help achieve proper functioning. This process is limited in time and doesn’t take much time. Hence, the inconvenience of machine breakdown is eliminated.
CNC grinding offers the possibility of producing identical products in large quantities. This is applicable when bulk production of a part is required. CNC grinders will help you achieve highly similar manufacturing with a uniform resemblance. The end product of such output of using this process will be an exact match to one another.
Surface grinding, generally called Hiraken or Heiken, uses a vertical or horizontal axis grinding machine with a circular or square table and a straight type wheel or a cup type wheel. The grinding wheel in this grinding process revolves around a spindle. The workpiece mounted on either reciprocating or rotary table is brought in close contact with the grinding wheel. There are four types of surface grinders they include:
Centerless grinding helps to eliminate the need for center holes for the work holding device or for the work. In this operation, the workpiece rests on a work-rest blade back up by a second wheel named the regulating wheel. Furthermore, the wheel rotation pushes the workpiece down the work-rest edge and against the regulating wheel. Also, the regulating wheel, which is rubber-bonded abrasive, rotates in the same direction as the grinding wheel to control the longitudinal feed of the workpiece when it is set at a slight angle. The workpiece feed rate can be changed by changing this angle and the speed of the wheel.
Cylindrical grinding involves the process of grinding the outer surface of a cylinder. These surfaces may be tapered, contoured, or straight. In contrast with other CNC operations, this method resembles the lathe-turning operations. They are usually used to replace the lathe when extreme accuracy or superior finish are required, or the workpiece in question is hardened. The grinding wheel that is rotating at a faster rate in the opposite direction is brought in contact with the workpiece as it revolves. The table and the workpiece reciprocate while in contact with the grinding wheel to remove materials from the workpiece.
Accessories and work-holding devices for center-type cylindrical grinders are similar to the ones used on engine lathes. However, universal, independent, and collet chucks can be used on cylindrical grinders if the workpiece contains no center hole or is odd-shaped.
Internal Grinding involves a similar operation to a boring process in the lathe. Internal grinding machines are used to finish tapered, straight, or formed holes accurately. It functions by holding the workpiece by a work-holding device, usually a collet or chuck, and revolving it with a motorized headstock. Furthermore, a separate motor follows the same direction as the part that rotates the grinding wheel. While it can be adjusted for the depth of cut, it can be fed in and out the workpiece.
Special grinding involves special types of operations and works. Special grinders named for specific processes are used in this case. For example:
√ Tool and Cutter Grinders
These grinders are fashioned to sharpen reamers, milling cutters, taps, and other machining tool cutters. The most popular and versatile tool-grinding machine is the general-purpose cutter grinder. In attachments are various tools for sharpening most types of cutting tools.
√ Thread Grinding Machines
These grinders are special, and they resemble cylindrical grinders. They feature a precision lead screw for producing the correct pitch or lead on a threaded workpiece. The thread grinders offer a way of truing or dressing the cutting periphery of the grinding wheel to build a precision thread form on the workpiece.
√ Jig Grinding Machine
These types of specials are designed to locate and accurately grind straight or tapered holes. They are equipped with a high-speed vertical spindle for driving and holding the grinding wheel. In addition, they use the same precision locating system as in jig borers.
To initiate a grinding process, an operator or a programmer feed the CNC machine’s computer with commands to carry out a specific operation. The machine then uses the commands to move its parts such that the grinding head moves onto the workpiece. Now, know that there are many grinding machines with different techniques for removing materials from a workpiece. An option is to advance the grinding head across or through a workpiece in a slow manner. Another is to move the grinding head that spins at high speed across the surface of a workpiece.
Here are mind-blowing tips that can help you make the most effective use of every grinding operation. These tips will give excellent ideas on how to free your griding bottlenecks. They include:
Grinding machines feature a wide range of applications, and their applications can be seen in many ways. They include the production of flute grinding, thread and cylinder grinding, grinding milling cutters, surface grinding, contour grinding, broach and hob grinding, reamers, and step-drill grinding, and many more. All these applications are spread across a wide variety of industries, including:
1. Are There Any Disadvantages?
Yes, the advantages of CNC grinding operations outweighs the disadvantage. However, the disadvantages include:
2. Why Choose a CNC High Precision Grinding Machine?
CNC high-precision grinding machines can be chosen due to their application in various materials such as steel, brass, hardened aluminum, bronze, plated aluminum, powdered metals, tungsten carbide, plastics, and titanium alloy. Also, they are the best choice for machining bearings, bushings, shafts, valves, pistons, industrial nozzles sleeves, and industrial needles.
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3. Why Are Coolants Necessary in a Grinding Process?
As the grinding process runs, the machine sprays a coolant on the grinding head and workpiece to prevent overheating. Coolant exists in varieties including pastes, oils, gels, oil-water emulsion, gases like air or aerosols. Apart from cooling the grinding head and the workpiece, the coolants maximize the lifetime of the working tip and prevent corrosion of machine parts. While come coolants contain toxic chemicals, biocides, and corrosion inhibitors that can irritate skin or cause respiratory problems, it is important to wear protective gear to avoid exposure to them.
In conclusion, CNC grinding utilizes abrasive techniques for the removal of materials from the surface of a workpiece. This process requires high precision or accuracy to increase the surface quality to get the best out of your machining processes. Irrespective of the grinding, maximizing productivity and getting the best results from your CNC machine is the goal of every dedicated partner. If you desire CNC grinding services for your high precise machined projects, contact RapidDone for all your grinding projects in small or large quantities. We will offer you a decade of experience and professionalism to make your project a successful one. Contact us today if there is such a need!
The term CNC is the abbreviation of computer numerical control. That is, the whole machine tool can be controlled by computer programs.
Internal grinding is one of the difficult grinding techniques used for grinding bores and holes. This technique is usually used to make cylindrical parts with high accuracy.
Internal grinding machines, as known as internal grinders, are the machine tools to apply this technique. They use grinding wheels for machining the workpieces into the finished products.
They may include multiple grinding wheels for different purposes. While working, the cylindrical workpieces would be passed through one or more grinding wheels and the inner wall would be formed. Usually, internal grinding machines are used to form precision pipes, tubes, bearing races, or bushings, etc.
Combined with the concepts above, a CNC internal grinding machine would be a type of machine tool that is responsible for internal grinding tasks and can be controlled by the CNC (computer numerical control) system.
CNC internal grinding machines, also called CNC internal grinders, are generally used to deal with internal cylindrical grinding tasks. Sometimes they would be designed not only for the specific internal wall grinding machines but also can deal with the outer surface of the workpieces.
Generally, grinding machines with CNC systems can work better and more accurately than the ones without the control system. It is because the CNC internal grinder can be controlled and pre-programmed by computers that the machine would just work along the designed programs which is rarely making mistakes.
While the grinding machine is working, they would but not only deal with the internal part of the cylindrical parts, also, the external parts which are round would be grinded smoothly as well.
e-tech CNC Internal Grinding Machine
As a professional and experienced grinding machine manufacturer, e-tech has developed numbers of high quality grinding machines and provides them to the global market.
During these decades, e-tech has provided various grinding machines including cylindrical grinders, internal grinders, surface grinders, centerless grinders, and complex grinders for internal and external diameters.
The CNC internal grinding machine developed by e-tech is designed with both internal and external grinding functions that can machining the required cylindrical workpieces complete at one time. During the grinding progression, the grinding wheels would deal with the outer walls and internal cylindrical structures and grind both sides smoothly.
The CNC controller would help to operate the grinding machines smoothly without mistakes. High speed box type dressing function efficiently reduces the dressing time and the time spent for initial set up. Moreover, the CNC controller provides anti-collision function which can avoid the potential consumption and program saving function that can help to start the task quickly next time.
With this system, the users can set-up the grinding machine through simple graphic display icons and select riding modes as well. Every step can be set up before the grinding progression.
The grinding wheels on the internal grinding machine are various in shapes and sizes in the purpose to be able to be used in dealing with different angles and surfaces.
For example, grinding wheels dealing with the outer surface could be designed with specific angles and shapes to cut the basic shapes out from the raw materials. As for the internal cylindrical structures, the machine tool also offers grinding wheels in different thickness and sizes to make cylindrical structures in different diameters.
CNC Internal Grinding machines made by e-tech are consisted of:
● Work Head
This is a large servo motor drive which offers steady speed and torque during the whole progression. It can be coolant by the positive air purge system and longer the lifespan.
● Tail Stock
On the tail stock, there would be a coolant nozzle installed on the top for cooling the center tip. This device is air floated that can protect the working table. Moreover, the tailstock on the CNC internal grinding machine made by e-tech is adjustable and does not need to rest dressing zero.
● Rigid Machine Base
It is designed with ribbed-box structure with the thickness of 25 mm and the internal coolant guide with three outlets. The excellent design of this rigid machine base provides perfect rigidity and stability of the machine and then ensures the quality of completed products.
● X-Axis Guideway
The double V-shaped guideways provide the maximum support to the wheel head in the purpose of keeping stability. Thus, the accuracy of the products coming from this grinder would be ensured.
● Rotary Table
This rotary table performs well on water-proofing and is able to deal with heavy duty working. It is positioned by three-pieces tooth type clutch gears that can provide high weight loading and smooth working ability.
● ID Grinding Spindle
This is a built-in spindle which is not only space saving but also high-torqued and stable.
● Wheel Head
The NN bearing in the wheel head works the spindle and ensures rigidity and accuracy while the grinding progression is operating. Moreover, the wheel head is able to provide big output power to increase productivity.
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