COURSE WARE

ON

WORKSHOP TECHNOLOGY

GRINDING
 Contents
Sr. No. Description Page No.
1. Safety 1
a. Abrasive Wheel Regulations 1
b. Care and protection of abrasive wheels 2
c. Wheel safety 3
d. Safety rules 5
e. The safe way to work 5

2. Identification of machine parts 7

a. Main types of grinders 7
b. The surface grinder 8
c. The cylindrical grinder 9

3. Selecting the grinding wheel 10

a. Wheel composition 10
b. Bond materials 10
c. Bond structure 10
d. Hard and soft wheels 11
e. British Standard marking system 11
f. Factors governing wheel selection 12

4. Mounting the grinding wheel 13

5. Balancing the grinding wheel 14

6. Dressing grinding wheels for surface grinding 15

a. Truing and dressing the wheel face 15
b. Relieving and dressing the side of the grinding wheel 16
c. Dressing an angle upon the wheel 16
d. Hand dressing a radius upon the wheel 18
e. Setting a radius dressing attachment 18
f. Dressing the male radius using the radius attachment 19
g. Dressing the female radius using the radius attachment 19

7. Dressing grinding wheels for cylindrical grinding 20

a. Dressing the face of the grinding wheel 20
b. Dressing and relieving the side of the wheel using a diamond dresser 21
c. Dressing and relieving the side of the wheel using a dressing stick 22

8. Feeds and speeds 23

9. Workholding and setting for surface grinding 24

a. Magnetic chuck 24
b. Setting vee block square on the magnetic chuck 25
c. Mounting workpiece in a vee block 26
d. Setting workpiece on magnetic vee block 26
e. Mounting workpiece on the machine table 26
f. Mounting a vice on the machine table 27
g. Setting workpiece in a vice 28
h. Setting the universal vice 28
i. Mounting an angle bracket 29
j. Setting a workpiece upon an angle bracket 30

10. Workholding and setting for cylindrical grinding 31

a. Mounting a chuck 31
b. Setting workplace in the three-jaw chuck 32
c. Setting workpiece in the four-jaw chuck 33
d. Mounting workpiece between centres 34
e. Mounting workpiece on a mandrel between centres 35
f. Mounting a supporting steady for cylindrical grinding 35
g. Mounting a supporting steady for internal grinding 36
h. Mounting workpiece on a face plate 37
i. Aligning workhead and tailstock 38
11. Inspection of workpiece prior to grinding 39

12. Surface grinding operations 40

a. Setting the table traverse stops 40
b. Grinding the surface of the magnetic chuck 40
c. Grinding a flat face 41
d. Grinding two opposite sides flat and parallel 42
e. Grinding a flat face and shoulder 43
f. Grinding two vertical faces parallel and central 45
g. Grinding an angular face 46
h. Grinding slots 47
i. Grinding vees using a disc wheel 48
j. Grinding vees using a cup wheel 49
k. Grinding dovetails using a formed wheel 50
l. Grinding radii 52
m. Grinding forms 53
n. Slitting and cutting 54
o. Plunge cutting 55
p. Grinding thin plate 56

13. Cylindrical grinding operations 58

a. Grinding parallel diameters up to a shoulder 58
b. Grinding a shoulder 59
c. Grinding parallel diameters and shoulders 60
d. Grinding between shoulders 61
e. Grinding a workpiece mounted on a mandrel 62
f. Plunge grinding a parallel diameter 63
g. Grinding a cylinder 64
h. Grinding slow tapers 65
i. Grinding fast tapers 65
j. Grinding radii 67

14. Internal grinding operations 68

a. Selecting a grinding spindle 68
b. Mounting the grinding spindle 68
c. Mounting the grinding wheel 68
d. Dressing the grinding wheel 68
e. Grinding a parallel bore 69
f. Grinding a bore up to a shoulder 70
g. Grinding a bore and a shoulder 71
h. Grinding a face 71
i. Grinding a bore in a long workpiece 72
j. Plunge grinding a parallel bore 73
k. Grinding a tapered bore 74
15. Inspection 76
a. Checking surface texture 76
b. Checking diameters 76
c. Checking lengths 77
d. Checking widths 78
e. Checking tapers 78
f. Checking flatness 79
g. Checking squareness 79
h. Checking parallelism 79
i. Checking angles 79
j. Checking vees 80
k. Checking dovetails 80
l. Checking forms 82
m. Checking parallel bores 82
n. Checking tapered bores 83

16. Common grinding faults and their correction 84

Safety The speed marked on the machine should not exceed
the speed marked on the wheel, its paper washer, or
Abrasive Wheel Regulations 1970 the tag accompanying the wheel.
The bush,if any, should not project beyond the sides
The Abrasive Wheel Regulations came into operation of the wheel.
on 2nd April 1971. It is a substitution for section 14(1) The wheel should fit freely but not loosely on the
of the Factories Act 1961 ('All dangerous moving spindle.
parts of machinery shall be securely fenced'). It now Flanges for straight-sided wheels should be not less
permits a part of an abrasive wheel to be exposed for
the purpose of the work. than one-third of the diameter of the wheel and their
Some of the important provisions of the regulations bearing surfaces should be true and free from burrs.
are outlined below. With the exception of the single flange used for
threaded-hole wheels, all flanges should be properly
Speed of wheels recessed or undercut.
Regulation 6 requires that every abrasive wheel Flanges should have the same outside diameter and
having a diameter of more than 55mm shall be marked diameter of recess.
with the maximum permissible speed in revolutions Wheels, washers and flanges should be free from
per minute specified by the manufacturer, and that the foreign matter.
speed of smaller wheels shall be stated in a notice. In The clamping nut should be tightened only
the case of mounted wheels and points, the overhang sufficiently to hold the wheel firmly. When the
at that speed shall also be stated in the notice. flanges are clamped by a series of screws, they should
Overspeeding is a common cause of the bursting of be first screwed home with the fingers and then
abrasive wheels.The maximum permissible tightened in diametrical sequence.
peripheral speed, that is the maximum safe working Screws for inserted-nut mounting discs, cylinders or
speed expressed in metres per second or feet per cones should be long enough to engage a sufficient
minute at the circumference, has been established by length of thread, but not so long that they contact the
manufacturers for each type of abrasive wheel. This abrasive material.
speed must not under any circumstances be exceeded. The guard should be properly secured and adjusted,
The speed in rev/min of a straight-sided wheel may and the workrest set as close as possible to the wheel.
however be increased as the wheel wears down so as New wheels should be run free at normal operating
to maintain the original peripheral speed of the wheel. speed for a short period before they are used. During
Some machines are equipped with a device which the trial run everyone should stand clear.
enables this to be done safely. Where a machine is not When mounting mounted wheels and points, the
so equipped the speed should be checked every time it
is increased. overhang appropriate to the speed, diameter of
The new speed may be calculated by using the mandrel and size of wheel should not be exceeded,
formula: and there should be sufficient length of mandrel in the
chuck.
New speed (rpm) =
Old speed (rpm) x original diameter Training and appointment of persons to mount wheels
New diameter
Abrasive Wheel Regulation 9 states that no person
Speeds of spindles shall mount an abrasive wheel unless that person:
Regulation 7 requires that the maximum working • Has been trained in accordance with the training
speed or speeds of every grinding machine shall be schedule to these regulations.
specified in a notice attached to the machine. This • Is competent to carry out that duty.
enables the person who mounts a wheel on the • Has been properly appointed and the appointment
machine to check that the speed of the spindle does not made by a signed and dated entry in a register, or a
exceed the maximum permissible speed of the wheel. signed and dated certificate attached to the
register.
Mounting A copy of the entry or certificate shall be supplied to
Regulation 8 requires that every abrasive wheel shall the appointed person.
be properly mounted. Regulation 9 requires that Particulars of the class or description of abrasive
persons who mount abrasive wheels must be trained wheels which the person is appointed to mount must
in accordance with the schedule to the Regulations, be entered in the register or on the certificate. Any
must be competent to carry out the duty and be appointment may be revoked by the company by a
appointed by the factory occupier. signed and dated entry in the register. A copy of this
A wheel should not be mounted on a machine for entry shall be provided to the person concerned.
which it is not intended.
Before a wheel is mounted it should be brushed clean NOTE TO INSTRUCTORS - This does not apply
and closely inspected to ensure that it has not been to a person undergoing training in the work of
damaged in storage or transit. ! mounting abrasive wheels and working during
Washers of paper or other compressible material that training under the immediate supervision of
should be used with all bonded abrasive wheels a competent person who has been appointed
except tapered wheels, threaded-hole wheels, discs, under these regulations. A trainee must be
cylinder wheels, thread grinding wheels and the hub certified as soon as the module has been
section of depressed-centre wheels. Wrinkles in completed.
washers should be avoided.
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Particulars of training required by paragraph (1) of Workrests
Regulation 9 includes suitable and sufficient Regulation 15 requires that where a workrest is
instruction in: provided, it shall be properly secured to the machine
• Approved advisory literature (SHW 11 and 12 - and shall at all times while the wheel is in motion be
HMSO) relating to the mounting of abrasive adjusted as close as practicable to the wheel. Lack of
wheels. adjustment is responsible for many serious accidents
• Hazards arising from the use of abrasive wheels caused by the workpiece becoming jammed between
and precautions which should be observed. the wheel and the workrest and forcing the operator's
• Methods of marking abrasive wheels as to type and fingers against the wheel face.
speed.
• Methods of storing, handling and transporting Care and protection of abrasive wheels
abrasive wheels.
• Methods of inspecting and testing abrasive wheels Examination
to check for damage. Wheels should be carefully unpacked, cleaned with a
• The functions of all components used with brush and examined for possible damage in transit. In
abrasive wheels, including flanges, washers, unpacking, the unwise use of a tool may cause damage
bushes and nuts used in mounting and including to the wheel. The soundness of a vitrified wheel can be
knowledge of the correct and incorrect methods of further checked by suspending it vertically and
assembling all components and correct balancing tapping it with a light non-metallic implement. If the
of abrasive wheels. wheel sounds dead (cracked) it should not be used; in
• The proper method of dressing an abrasive wheel. case of doubt the manufacturers should be notified.
• The adjustment of the workrest to an abrasive
wheel.
• The requirements of the Regulations. Storage
Suitable racks, bins or drawers should be provided to
Guards accommodate the various types of wheels used. Most
Regulation 10 requires that a guard shall be provided plain and tapered wheels are best supported on edge or
and kept in position at every abrasive wheel unless the on a central support. Where the wheels are placed on
nature of the work absolutely precludes its use. edge, the support should take the form of a cradle to
A guard has two main functions: firstly to contain the prevent rolling, with a sufficient number of partitions
wheel in parts in the event of a burst, and secondly to to prevent wheels from falling over. Thin resinoid,
prevent the operator as far as possible from coming rubber or shellac wheels should be laid flat on a
into contact with the wheel. The wheel should be horizontal surface and away from excessive heat, to
enclosed to the greatest possible extent, the opening prevent warping. A heavy steel plate makes a good
being as small as possible consistent with the nature of foundation for stacking. Cylinder wheels and large
the work. Apart from certain guards for portable straight cup wheels may be stacked on the flat side
machines, guards should be capable of adjustment so with corrugated cardboard or other cushioned paper
that the whole wheel except that part necessarily between them, or they may be stored in racks similar
exposed can be enclosed. As the wheel wears down, to those used for straight wheels. The storage room
the guard should be continually adjusted so as to should not be subject to extreme temperatures and
maintain maximum protection. should be kept dry.
The guard should be securely anchored to the machine
frame. On portable machines, the clamp should be of Handling
unit construction with a single high-tensile bolt. Cast All abrasive wheels are relatively fragile and should
iron or other brittle material should not be used for therefore be handled in accordance with the following
guards for other than very small wheels. rules:
• Handle wheels carefully to prevent dropping or
Selection of wheels bumping.
Regulation 13 requires that in selecting a wheel due • Do not roll wheels. A wheel which cannot be
account shall be taken of the factors which affect carried by hand should be transported by truck or
safety. Selecting the correct wheel for the job is other suitable conveyance.
equally important for efficient production and for • If, because no suitable transport is available, a
safety. As a rough and ready rule, soft wheels are more large wheel must be rolled, a soft resilient surface
suitable for hard material and hard wheels for soft is essential.
material. With wheels of unsuitable structure for the • Stack wheels carefully for transport. Do not pile
job, 'loading' may result, ie, the abrasive wheel face heavy castings or tools on top of them or allow
becomes clogged with particles of the material being wheels to topple over.
ground. A wheel may also be too hard or too fine,
resulting in 'glazing'. The operator is then tempted to
press the workpiece too hard on the wheel, causing it
to break. The best policy in selecting grinding plant is
to consult manufacturers of machines and abrasive
wheels and not to experiment without competent
advice.
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 Safety
Misuse of the wheel Hole size
Wheel breakage can occur if excessive pressure is The grinding wheel should be a good fit on the
used to apply the workpiece to the wheel. Operators spindle and remain free under all grinding
may be tempted to do this if the wheel is running conditions. Wheels which are a tight fit on the
slower than the speed recommended by the spindle or have excessive clearance between wheel
manufacturer, or if the wrong wheel has been selected and spindle should not be mounted.
so that the wheel face has become loaded or glazed.
Particular care should be taken when grinding on the
side of a straight-sided wheel. Such work is Machine sideplates
dangerous when the wheel is appreciably worn or if In general, abrasive wheels should be mounted
sudden or excessive pressure is applied. between sideplates made of mild steel or similar
strength material, that are not less than one-third the
Truing and dressing diameter of the wheel. Flanges should have sufficient
The wheel should be dressed when necessary to contact area to drive the wheel and be of proper
remove loading or glazing, both of which reduce the design to prevent distortion causing damaging
cutting action. Wheels used for hand grinding can stresses in the wheel.
become out-of-balance if they are not trued, and if the
out-of-balance force becomes excessive it may The following recommendations on sideplate design
damage the spindle and cause the wheel to burst. and condition should always be observed:
Correct dressing to keep the wheel concentric with the • Both wheel flanges should be of equal diameter
spindle also allows the workrest to be kept adjusted and have bearing surfaces of equal area.
close to the wheel. • The driving flange should be keyed or otherwise
secured to the griding spindle.
Protection of eyes • With the exception of the single flange used on
Persons carrying out dry grinding operations and threaded hole wheels, sideplates should be
truing or dressing an abrasive wheel are required to be recessed or undercut on the side next to the wheel
provided with and wear approved eye protectors in so that pressure is not exerted near the hole.
accordance with the Protection of Eyes Regulation • Flange bearing surfaces should be flat and
1974.
machined true with no exposed, rough edges.
Wheels should not be mounted between worn,
Wheel safety sprung or damaged sideplates.
Mounting should only be performed by a competent
person and the following recommendations should The following types of wheel are not mounted
always be observed. between flanges:
• Mounted points and wheels.
Wheel inspection • Abrasive discs and threaded hole wheels.
Immediately before mounting, abrasive wheels • Plate mounted wheels.
should be inspected for damage. A wheel can be • Cylinder wheels or segments mounted in chucks.
further checked by means of the 'ring test' in which the
wheel is suspended vertically and tapped with a light
non-metallic implement. If the wheel is sound it will
emit a clear ringing tone, if it is cracked, it will sound
dead.
A cracked wheel is unsafe and must not be used under
any circumstances.

Blotting paper washers

Blotters or flange facings of compressible material
should be used to ensure even clamping pressure,
apart from the exceptions listed below. Blotting paper
washers should cover the entire contact area of wheel
flanges.
Blotters should not be used on the following types of
wheel:
• Mounted wheels and points.
• Abrasive discs, threaded hole wheels, plugs and
cones.
• Plate mounted wheels.
• Cylinder wheels or segments mounted in chucks.
• Some types of depressed centre wheels.
• Some types of taper sided wheels.
• Cut off wheels less than 0.5mm thick.
• Small internal wheels less than 20mm diameter.
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 Safety

Tightening of mounting nuts Wheel guards

Spindle nuts should not be overtightened and should Wheels should only be used on machines fitted with a
only be tightened sufficiently to drive the wheel. guard of adequate strength and designed to ensure
Multiple screw flanges should be tightened uniformly that:
to prevent springing of the flanges and to ensure even • In the event of a breakage, fragments of wheel are
distribution of mounting pressure over the entire contained by the guard.
surface of the flanges. • As far as possible the operator cannot come into
contact with the wheel.
Mounted wheels, threaded hole wheels and other
wheels used for internal grinding are exceptions to
this rule.

Workrests
Workrests, when fitted, should be kept adjusted as
closely as possible to the wheel to prevent the work
from being caught between the wheel and the rest.
The workrest should be securely clamped after each
adjustment and adjustments should not be made while
the wheel is in motion.

Maximum operating speed Side grinding

The initial speed of the wheel at full diameter should Side grinding should only be performed with wheels
not exceed the maximum operating speed specified for designed for this purpose. Grinding on flat sides of
the wheel. straight wheels is dangerous and should not be
The maximum operating speed is not necessarily the allowed. This does not preclude their use for form
most efficient grinding speed. Better results can often grinding and shoulder grinding.
be obtained at lower than maximum operating
speeds. Grinding fluid
Before shutting off a wet grinding operation, the
Starting the wheel grinding fluid should be switched off and the wheel
Before running the wheel the guard and workrest,if allowed to rotate until the coolant has been spun out.
fitted, should be properly adjusted and secured. New
wheels should be run free at full operating speed for Machine condition
one minute before they are used. During this trial run, All spindles, adaptors, flanges or other machine parts
all personnel should stand clear. on which wheels fit, should be periodically inspected
for wear and maintained to correct specification.
Balancing, truing and dressing
These operations should only be performed by a
competent person. Wheels should be balanced, trued
and dressed by the user when and as often as necessary.

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 Safety
Safety rules
General safety
Do: Do not:
• Ask if in any doubt. • Run in the workshop.
• Use correct tools or equipment. • Throw things or play practical jokes.
• Keep tools and equipment tidy on work table when • Touch any equipment unless authorised to do so.
not in use. • Leave your machine running when not required.
• Take care of tools and equipment. • Leave crane hook hanging over machine or
• Know the location of the nearest fire extinguisher surrounding area after use.
and how to use it. • Direct compressed air at yourself or workmates. It
• Keep exit and/or fire doors clear at all times. can kill.
• Keep gangways clear. • Give first aid unless qualified to do so.

Personal safety
Do: Do not:
• Report any accident, however small, • Wear rings, watches, etc.
immediately. • Keep sharp tools (scribes, etc,) in overall
• Wear safety glasses - always. pockets.
• Wear safety shoes. • Remove any guard unless machine is stopped.
• Use the barrier cream provided. • Attempt to stop wheel manually.
• Wear your overall buttoned up. • Lift any heavy workpiece or equipment
• Roll up sleeves, or button up the cuffs. manually.
• Keep hair short, or wear a cap. • Lean on the machine.
• Ensure all guards are in position before starting • Wash hands in coolant tanks.
machine. • Leave any lifting tackle lying about in the work
• Check that work area is clear before starting area.
machine.
• Ensure everything is properly secured before
starting machine.
• Inspect slings, etc, for wear before using.
• Use the correct type and size of sling.
• Be careful of burrs and sharp edges.
• Use correctly sized tools at all times.
• Keep hands clear of any revolving grinding
wheel.
• Stand clear when lifting workpiece or equipment
by crane.

Machine safety
Do: Do not:
• Keep machine clean and in a good condition. • Attempt to operate the machine until you are sure
• Ensure you know how to stop your machine, you understand it.
before starting it. • Wind table in 'fast' when workpiece is near to the
• Switch off machine immediately if anything goes wheel.
wrong. • Mount or use a cracked wheel.
• Keep machine and surrounding area tidy. • Use a dressing stick in a limited or confined space
• Check oil levels of machine before first starting. (ie between workpiece and wheel).
• Check wheel rotation before grinding.
• Position dust extractor to take the maximum
amount of dust away from the operator.
• Apply coolant only to a revolving wheel.
• Turn coolant off when wheel is stationary.
• Run the wheel for five minutes before use or wheel
dressing.
• Keep grinding wheels dressed.
• Ensure workpiece is secured in or on workholding
device.
• Report any damage to electrical cables.
• Replace any badly worn or damaged nuts, bolts,
Alien screws etc.
• Switch off machine mains at the end of each shift.
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 Safety
The safe way to work

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Identification of machine parts
Main types of grinders
The three main types of grinding machines in
common use are:
• Cylindrical grinders - for truing up and bringing
to dimensions part such as shafts, spindles and
rollers.
• Internal grinders - for grinding internal surfaces
of cylinders etc.
• Flat-surface grinders - for grinding every type of
flat surface.
There are further sub-classifications.

Cylindrical grinders
There are three types of cylindrical grinders:
• Plain grinder - for standard production grinding
of shafts, sleeves, rollers, spindles etc, either in
cylindrical or tapered form.
• Universal grinder - has a wide range of
applications and its swivelling headstock, which
can grind at any angle, makes it suitable for
special jobs such as parts for small machines and
special tools. It is more complicated but smaller
than the plain grinder and can be adapted to
internal grinding.
• Centreless grinder - operates on a different
principle from the other machines. The part to be
machined is passed between a grinding wheel,
which revolves at high speed, and a regulating or
control wheel, which revolves at slow speed.

Internal grinders
Internal grinders include a wide range of specialised
machines for the internal grinding of gears, gauges,
bushes etc. Examples include:
• Chucking grinders for finishing bores and face
grinding at one setting.
• Traverse spindle grinders for highly accurate
internal grinding of small tools etc.
• Cutter and tool grinders for internal and external
sharpening and grinding of small tools and other
parts such as milling cutters, form tools, dies etc.

Flat-surface grinders
There are two types of flat-surface grinders:
• Horizontal machines - work is carried on a table
travelling backwards and forwards below the
grinding wheel which is fixed on a horizontal
spindle. A machine with a circular table is also
available - its table revolves and the wheel is
mounted on a horizontal spindle.
• Vertical spindle grinders - these are for jobs
carried on either revolving or reciprocating
tables.

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 Identification of machine parts
The surface grinder

Grinding is a method of metal removal which produces a better surface finish with greater accuracy than that
achieved by other processes such as milling, turning and shaping. It is primarily used as a finishing operation.

Code Name Function

1 Table Carries suitably mounted workpiece to the wheel
2 Grinding wheel Removes material from workpiece
3 Extractor Removes dust from wheelhead
4 Table traverse handwheel Provides longitudinal table movement
5 Cross feed handwheel Provides table cross travel
6 Fine cross feed knob Provides fine control of table automatic cross travel
7 Vertical wheel feed handwheel Raises or lowers wheelhead (coarse feed)
7a Fine vertical wheel feed knob Raises or lowers wheelhead (fine feed)
8 Table reversing dogs Determine length of table travel
9 Table reversing lever Reverses direction of table travel
10 Electrical controls Controls electrical supply to machine (on/off)

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 Identification of machine parts
The cylindrical grinder

Code Name Function

1 Table Carries suitably mounted workpiece to the wheel
2 Workhead Rotates workpiece
3 Tailstock Supports workpiece
4 Wheelhead Drives grinding wheel
5 Table traverse knob (fine feed) Controls fine hand traverse of table
6 Table traverse handle Enables table to be traversed by hand
7 Table traverse speed control Controls speed of table travel
8 Table reversing dogs Control extent of table traverse
9 Table reversing lever
10 Table traverse start/stop lever Starts/stops table traverse
11 Crossfeed hand lever Enables table to be crossfed by hand
12 Automatic feed engagement lever Engages/disengages automatic feed to table
13 Dead stop engagement lever Provides a dead stop for crossfeed
14 Electrical controls Controls electrical supply to all motors (on/off)

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Selecting the grinding wheel
Wheel composition Resinoid
Grinding with modern abrasive wheels is as much a Wheels of this type are made with one of the resin
metal cutting operation as any other, except that the (bakelite) materials as the bond. Wheels can be made
wheel has thousands of tiny cutting edges instead of extremely thin and for this reason their chief field of
the few large edges possessed by other rotary cutters. If application is for such purposes as cutting off and
the grindings from a modern wheel working on a
ductile material are examined they will be seen to slitting.
resemble short turnings from a tool.
A grinding wheel is made up of a hard substance called Silicate
the abrasive which is embedded in a matrix called the Silicate wheels have a milder action and cut with less
bond. The abrasive grains are second only to the harshness than vitrified wheels. For this reason they
diamond in hardness, projecting from the wheel face are suitable for grinding fine edge tools, cutlery, etc.
they act as tiny cutting tools. All tools eventually
become dulled by use, and the keen edges of those
grains which are cutting will in time lose their cutting Shellac
effect and if the wheel is suitable for its work they will Specially used for finishing chilled irons, hardened
either split and thus form a new edge, or break away steel cams and occasionally for thin cutting-off
from the wheel and expose another grain to carry on wheels.
with the work. This is called the 'self sharpening
effect'. The importance of correct wheel selection is to Rubber
ensure the grains of abrasive do not leave the wheel
before they become dulled (this causes wheel wastage) Very thin wheels of great strength may be produced by
or stay in it too long once their keen edges have been this process and wheels as thin as 0.005" are
worn away as this gives rise to a defect known as sometimes produced. These very thin wheels must run
'glazing'. at speeds of approximately 15 OOOft/min so that the
centrifugal forces will maintain their shape. Rubber
Abrasives bonded wheels are also used as feed wheels for
There are two abrasives in common use. These are centreless grinding.
aluminium oxide and silicon carbide; A and C.
Aluminium oxide (A) is used for tough materials such
as steels, malleable irons and bronzes while silicon Bond structure
carbide (C) is used for ductile materials like This is the density or porosity of the wheel and is a
aluminium, brasses and copper. measure of the distance apart of the grains and gives
Both abrasives are graded for size by sieving through the wheel its own characteristics. There are two basic
screens having so many holes or meshes to the inch. types.
The 'grit' signifies the number of meshes to the inch
used to grade any particular size. Open structure
Large chip clearance and minimum 'loading' or
The bond clogging with chips, resulting in a cool, free cutting
The bond is the substance which when mixed with the
abrasive grains holds them together enabling the wheel. Recommended for soft, tough and ductile
mixture to be moulded into the form of a wheel. The materials, and for surface grinding.
degree of hardness possessed by the bond is called the
grade of the wheel, and indicates the ability of the bond Dense structure
to hold the abrasive grains in the wheel. Little chip clearance with little or no spaces between
A soft bond allows the grains to break away more the grains. Recommended for hard, brittle materials
readily than a hard one, and should be used where the
abrasive becomes rapidly dulled, when grinding hard which have discontinuous chips, for intricate form
materials. wheels where delicate edges and corners must be
A hard bond retains the grains longer and should be maintained and for fine surface finishes.
used on soft materials.
Structure numbers
Bond materials
Dense Medium Open
Vitrified 2 3 4 5 6 7 8 9 10 11 12-15
The vitrified process is used for the majority of wheels
and is responsible for about 80 per cent of the output. Note: Different number scales are used for different
Wheels made by this method can be supplied in a wider product types.
range of grades than any other, and are used on more
varied classes of grinding work. The bonding materials
used consist of various kinds of fusible and refractive
pottery clays with which the grains are thoroughly
mixed. - 10 -
 Selecting the grinding wheel
Grit and grade British Standard marking system
According to the application of a particular wheel, its
grit, grade and abrasive must be varied. The grit or The Abrasive Industries Association have adopted a
grain size is specified according to the meshes per British Standardised marking system for grinding
inch of the grading sieve and vary from about 8 to wheels.
1200.
British Standard 4481: Part 1: 1969, details the four
symbol groups into which a wheel marking is
Coarse Medium divided, as follows:
• Abrasive type.
8, 10, 12, 14, 16 46, 60, 80, 100 • Grain size.
20, 24, 30, 36 . 120 . • Grade.
• Bond.
Fine Very Fine
In addition, there are certain optional symbols which
150, 180, 220 400, 500, 600 are not always included, but often are, at the
240, 280, 320 800, 1000, 1200 discretion of the manufacturer. These are:
• A prefix which denotes more precisely the type of
The grade referring to the hardness of the bond, is abrasive used.
• A symbol (usually a number) indicating the
usually designated by letters of the alphabet ie A,
structure of the wheel.
(very soft), to Z, (very hard).
• A suffix, which denotes the exact type of bond, or
any other identification.
Very Soft Soft Medium Hard Very Hard
A,B,C,D,E,F,G H,I,J,K L,M,N,O P,Q,R,S T,U,V,W,Z
The example given represents an aluminium oxide
abrasive of 46 grit in a vitrified bond of medium
It should be understood that grade is not an exact hardness and structure. The prefix, the structure and
value. Actually, it is a range between narrow limits. the suffix are optional in their use.
All wheels that come within the range designated
by any particular letter are considered to be one
grade and carry the same grade letter.

Hard and soft wheels

Wheel hardness refers to the bond not the grit.
Makers vary the bonds to give desired results, for
example:
• Soft bonds permit easy breaking away of the
grit and should always be used when grinding
hard materials which dull the wheel.
• Hard bonds should be used on softer materials
which do not blunt the grains. This gives the
wheel a longer life.
The following workshop rule sums this up:
• Hard wheel - Soft metal.
• Soft wheel - Hard metal.

- 11 -
 Selecting the grinding wheel

Factors governing wheel selection Speeds and feeds

Material to be ground A general rule is: • For roughing out, use low workspeed - heavy
• With hard material, the softer the grade of wheel infeed - fast traverse.
required. • For fragile work, in order to dissipate heat, use
• With soft material, the harder the grade of wheel high workspeed - light infeed.
required. • If wheel acts hard and glazes, use higher
• Consult the manufacturer's recommendations for workspeed and traverse speed.
choice of abrasive, grain size, grade and bond of • If wheel acts soft and wears rapidly, use lower
wheel for specific requirements. workspeed and traverse speed.

Material to be removed Summary

For rapid removal of material where surface texture Soft wheels are used for:
is of little importance, such as roughing out a batch • Hard, dense, fine grained metals of low ductility.
of workpieces, a coarse grain, open structured wheel • Where high stock removal is required.
is used. • Hardened metals.

Surface texture Hard wheels are used for:

Finish depends to a large extent on the size of grit • Forms, fillets and radii.
employed, but on precision grinders proper truing • Where close tolerances are required.
and dressing can maintain the finish without • Obtaining a good surface texture.
sacrificing metal removal rate which usually occurs
when fine wheels are used.

Wheel contact
The greater the area of contact between wheel and
work, the softer the grade of wheel required.

- 12 -
Mounting the grinding wheel
• Mount inner (driving) flange on spindle using
key, recess facing front.
• Mount first washer.
• Mount wheel.
• Mount second washer.
• Mount outer flange.
• Screw on spindle nut only sufficiently to ensure
flanges drive wheel and prevent slip.

Inspect the grinding wheel as follows:

• Visually check the wheel for cracks. If a loose
bush type of wheel is used, make sure that bush
does not extend beyond the side of the wheel.
• 'Ring' wheel. Balance wheel with finger through
bore and tap with a non-metallic instrument, eg,
handle of screwdriver, the hide end of hammer etc.
If the wheel is undamaged it will give a clear 'ring.'
To mount wheel with large diameter hole:
SAFETY — If wheel does not give a clear
! 'ring' do not use.
• Place arbor on table or bench and ensure
cleanliness.
Never mount wheel without paper washers. • Slide wheel onto arbor. The bore of the wheel
• Check that wheel is correct for machine on which should be about .15mm (.005in) bigger than the
it is being mounted. diameter of the arbor.
It should fit easily but not loosely on the spindle. Note: Place paper washer on the arbor before wheel is
Speed of spindle must not exceed the maximum fitted, and one before flange is fitted.
permissible speed marked on the wheel. • Place flange onto the arbor.
• Line up cap screw holes in the flange, with the
mating holes on the arbor.

Clamp flange to wheel as follows:

• Place cap screws in flange, and screw them all
finger tight.
• Tighten one screw and then the one diametrically
opposite, to give uniform pressure.
• Repeat until all screws are tight.
• Check, starting at first screw and repeat tightening
as before.

To mount wheel with small diameter hole:

• Select flanges.
SAFETY - Do not use ordinary steel washers
!instead of proper flanges.
Check flanges are:
• Recessed on side next to wheel.
• Both same diameter and have equal
bearing surface.
• Not less than one third of wheel diameter.
Corners of wheel seatings must be undercut as
shown.
- 13 -
Balancing the grinding wheel
To mount wheel on machine:
• Remove balance weight.
• Clean internal and external cones.
• Place wheel unit on spindle nose, and tighten
locknut.
Note: Thread on spindle nose is left-hand, locknut
is tightened anticlockwise.
• Replace wheel guard.
To true wheel:
• Start wheelhead and allow to run, for the
machine to attain normal working temperature. To position wheel on unit:
• Dress wheel periphery. • Clean bore of unit and balancing mandrel, then
Note: Dress sides if wheel diameter exceeds mount unit on mandrel.
250mm (l0in). Apply small infeed of diamond until • Raise protection guards.
eccentricity of wheel is removed. • Place the wheel to be balanced on top of the
• Turn off coolant, and allow wheel to run for protection slides and lower gently onto the
approximately one minute. balancing ways.

To balance the wheel:

• Visually ensure the balancing mandrel is at right
To remove wheel from machine: angles to the balancing ways.
• Allow wheel to slowly revolve, by its own
• Stop machine (switch off mains). momentum until stationary.
• Remove wheel guard and locknut. • Place a chalk mark at the bottom, to indicate heavy
• Screw on collet extractor (right-hand thread). point.
• Remove wheel unit complete. • Turn wheel 90° first to left and then the right to
Note: Use both hands when removing wheel. Take check location of heavy point.
care not to knock wheel on any machine part. • Replace weights at 90° to heavy point and
diametrically opposite.
Note: If wheel finds heavy point quickly, balance
weights could be moved to approximately 180° (this
indicates that wheel is considerably out of balance).

• Move weights equally towards light side

To prepare balancing unit: approximately 3mm (,125in) at a time.
• Lower protection guards. • Repeat until assembly remains static in any
• Place levelling plate on balancing ways. position.
• Adjust unit, using two knurled screws on base • Remount assembly onto wheelhead, replace
until the bubble in levelling plate is concentric guard, and re-dress wheel before putting into
with circle engraved on the glass. operation.
Note: This is a precision unit - use it with care. Note: If wheel was a long way out of balance, re-
- 14 - check after final dressing.
Dressing grinding wheels for surface grinding
Truing and dressing the wheel face Note: When the diamond tool is mounted in the
Truing is an operation carried out on all newly vertical position, a trailing angle is achieved by
mounted wheels. It involves the removal of material positioning the diamond point away from the centre
from the cutting face of the wheel, so that the line of the wheel.
resultant surface runs concentric to the spindle axis. • Switch on wheelhead motor.
SAFETY - Ensure that the wheelguard is in
Dressing is carried out to maintain the wheel form,
and to expose new cutting grains on the wheel face.
! position. Stand to the side of the machine
when starting motor.

When mounting the diamond: • Apply downward feed to the grinding head,
• Clean table and diamond holder. bringing the wheel into light contact with the
• Mount and secure the diamond tool in the holder, diamond.
ensuring that a keen edge will be presented to the Note: Control the wheel approach by sighting the
grinding wheel. gap between wheel and diamond. Allow wheelhead
• Position holder at the end of the magnetic chuck, bearing to reach normal working temperature before
switch chuck on and check that the holder is held commencing. Using the table cross traverse clear the
securely. diamond from the wheel.

Alternatively:
The diamond tool can be mounted in a holder direct
to the machine table.
SAFETY — When positioning the diamond
! tool, ensure that the wheel is well clear of
the work area or stopped.

When truing or dressing for rough grinding:

• Switch on coolant pump and direct coolant to
cover the full face of the wheel.
• Traverse the diamond backwards and forwards
across the face of the wheel, applying
approximately .05mm (.002in) down feed to the
wheelhead at each reversal of direction.
When setting the diamond in position: • Use a fast even rate of traverse.
• Position the wheelhead so that the bottom of the • Continue down feed and cross traversing until the
wheel is higher than the diamond point. face is fully cleaned up, or all dull abrasive grains
• Using both table traverses position the diamond and clogging metal removed.
point directly below the wheel centre. • After completing the dressing, allow the coolant
to wash away loose particles from wheel. Turn
off coolant.
- 15 -
 Dressing grinding wheels for surface grinding
When dressing for finish grinding: When dressing the land:
• Dress the wheel for rough grinding. • Touch the stick to the land. Apply light pressure
• Reduce the wheelhead down feed to and traverse stick squarely backwards ant
approximately .015mm (.0005in) at each reversal forwards.
of traverse. • Clean down machine.
• Use a slow even rate of traverse. Two or three Note: If the component to be ground requires a verj
sharp corner, dress the land to form an angle of les:
passes should be sufficient to achieve a than 90° with the wheel face. Frequent re-dressinj
satisfactory result. may be necessary.
• After removing the final cut, at the same setting SAFETY — Gloves and safety goggles must
take two or three idle passes of the diamond ! be worn.
across the face of the wheel.

To remove diamond:
• Traverse table to move diamond maximum
distance from wheel.
• Remove diamond assembly or block.
• Clean machine table or chuck.
Note: When truing or dressing only remove the
minimum amount necessary from the wheel.
• To increase diamond life and achieve good
surface textures, the diamond tool should be
turned frequently in the holder.
! SAFETY - Safety glasses must be worn.
Alternatively:
Relieving and dressing the side of the • Mount diamond holder, with the diamond in the
grinding wheel horizontal position.
Very often vertical faces have to be ground. This • Using table and wheelhead movements, position
operation is carried out using a dished or disc wheel, the diamond to the land.
which has its sides relieved to form a cutting area at Note: Ensure that the wheel does not foul the table or
the wheel periphery. diamond holder.
• Traverse the diamond across the land; apply
Switch on wheelhead motor. approximately .05mm (.002in) cross traverse
Dress wheel face. feed at each reversal, until the land is fully
dressed.
• Traverse diamond clear of wheel, and remove
holder from table.
• Clean down machine.

Dressing an angle upon the wheel

Relieve side of wheel as follows:

• Traverse table to clear magnetic chuck from
under wheel.
• Position and support the body against the
machine, facing half left and slightly to the right
of the wheel. Using an angled plate dress the face of the wheel. To
• Hold the dressing stick firmly in both hands. position the angled plate:
Touch the stick to the side of wheel, (bottom • Select plate with required angle 'C.
right-hand quarter). • Place on chuck against back plate 'D'.
• Applying light pressure, traverse the stick • Place slide support block 'B' against angled
backwards and forwards until the wheel side is plate.
relieved to a sufficient depth and diameter. Leave • Clamp diamond to vee-block 'A'.
a land on the periphery of between .75mm (.03in) • Place vee-block on slide support block.
and 1.5mm (.06in). • Switch on magnetic chuck.
- 16 -
 Dressing grinding wheels for surface grinding

To position the diamond: Using a universal vice

• Position grinding wheel vertically with centre to
the point of the diamond.
• Move table to bring diamond to edge of wheel.

To position vice:
• Position and set vice on machine table/magnetic
chuck.
To dress the angle: • Align vice jaws square.
• Switch on the wheel.
• Slide vee-block backwards and forwards along the To set required angle on vice:
slide support block, feeding in by use of hand • Loosen vertical index nut.
wheel. • Tilt vice to required angle.
• Continue until required form obtained. Switch off • Check angle.
wheel. • Tighten vertical index nut.
• Switch off chuck, remove blocks and clean.
To position diamond block:
Using a sine bar • Place diamond block in vice jaws.
• Position diamond approximately 12mm (.5in)
above top of jaws.
• Hand tighten vice.
• Wind table feed and cross feed handles, to align
point of diamond on vertical centre line of wheel.
To dress angle on wheel:
• Hold diamond block and slightly loosen jaws, to
allow diamond block to slide with minimum side
play.
• Switch on wheelhead motor.
• Apply downward pressure and slide diamond
block backwards and forwards in vice jaws.
A sine bar is used when the angles required are not • Downfeed the wheel to make contact with the
available on standard blocks. Apply the same diamond. Apply about .05mm (.002in) feed to
dressing procedure as used with a setting block. Note: wheelhead.
If a large size angle is required, the angle is roughly • Dress angle to the required size.
shaped with a dressing stick, then finished with the • Clear wheel from diamond.
diamond. • Remove block and vice and clean down.
SAFETY - Gloves and safety glasses must
! be worn.

- 17 -
 Dressing grinding wheels for surface grinding

Hand dressing a radius upon the wheel

To prepare wheel, dress face of wheel.

To position the setting block:

• Select slip gauges appropriate to required radius.
To dress radii: • Rest slip gauges on setting arm rod at rear of
• Grip dressing stick at both ends. Thumb on top, attachment.
fingers underneath. • Slide setting arm forward to pinch gauges. Lock
• Touch wheel corner at approximately 45° with setting arm in position.
flat face of dressing stick. • Check slip gauges for no movement. Note: A block
• With even pressure, move stick through 45° to gauge of 25mm (1 in) will zero the setting arm face
periphery of wheel, and back through 90° to face with the C/L of swivel. When forming an inside
of wheel. Blend radius into diameter and face; radius on wheel, the required slip gauge size is
check radius with appropriate radius gauge. obtained by subtracting the radius from 25mm
SAFETY — Stop wheel, before checking
! with gouge.
(lin). When forming an outside radius, add the
radius to 25mm (lin).
Note: If an accurate radius is called for, a radius
attachment must be used.
SAFETY - Gloves must be worn.
! Wear couered-in safety glasses.
Setting a radius dressing attachment
A radius attachment is used for dressing radii on
grinding wheels, when a closely toleranced radius
is called for.

To set diamond:
• Ensure diamond point is vertical.
• Slide diamond forward to register against
setting block face.
• Maintain slight forward pressure upon
diamond, and lock diamond in position.
• Loosen setting arm, remove slip gauges and
Position radius attachment as follows: retract setting arm to clear block from the
• Clean base of attachment and remove any diamond.
burrs. • Lock setting arm.
• Clean all moving parts of attachment. Alternatively: setting gauges can be used to
• Clean machine table establish the diamond position, when the setting
• Position attachment on table and secure. block face is aligned to the axis of the swivel.

To position diamond:
• Check diamond point.
• Place diamond in attachment.
• Loosen setting arm locking screw.
- 18 -
 Dressing grinding wheels for surface grinding

Dressing the male radius using the radius ! SAFETY — Always wear closed-in type
safety glasses.
attachment
To dress wheel: Dressing the female radius using the radius
• Dress face of wheel for finish grinding. attachment
• Dress side of wheel for finish grinding. To dress wheel:
• Dress face of wheel for finish grinding.
Set the radius attachment. • Dress side of wheel for finish grinding.
Set radius attachment.

Position radius attachment relative to wheel as

follows:
• Adjust the wheelhead until the diamond point is in Position radius attachment relative to wheel as
line with the centre of the wheel. follows:
• Set radius attachment with diamond parallel to • Adjust wheel until diamond is at centre height.
rotating axis of wheel. • Set radius attachment with diamond at 90° to
• Using table handwheels, position diamond to rotating axis of wheel.
peripheral edge of wheel. • Using table handwheels, position diamond to
• Mark or zero crossfeed handwheel and lock. peripheral edge of wheel.
Crossfeed handwheel not to be altered. • Mark or zero crossfeed handwheel and lock.
Crossfeed handwheel not to be altered.

To form radius:
• Turn attachment through 90°.
• Switch on wheel. To form radius:
• Tapping traverse handwheel, apply a cut of a few • Switch on wheel.
thousandths of an inch. Swing attachment • Tapping traverse handwheel apply a cut of a few
through 90° and return. thousandths of an inch. Swing attachment through
• Repeat procedure until diamond just touches face 90° and return.
of wheel. • Repeat procedure until diamond is in line with
• To ensure a good blend of radius, unlock wheel face, when attachment is parallel to the
crossfeed handwheel and feed across wheel face. rotating axis.
Return to zero mark on crossfeed handwheel. Note: Always ensure that diamond is in line with face
Swing attachment through 90° and traverse and side of wheel, or radius will be incorrectly
attachment across side of wheel. formed.
Note: If radius is correctly formed, diamond should If lands are formed re-dress the wheel until they are
just touch side and front face of wheel. removed. Repeat operation to produce correct
If a large radius is required, first rough form by using radius.
a dressing stick. When forming a large radius, initial roughing with a
dressing stick is carried out.
- 19 -
Dressing grinding wheels for cylindrical grinding
Dressing the face of the grinding wheel
Start wheelhead and allow spindle bearings to
reach normal working temperature.

To touch diamond point to wheel periphery:

• Bring diamond either central to wheel width, if
wheel has been used for traverse grinding, or in
To set up diamond in holder attachment: line with unused part of wheel periphery, if it has
• Clean table and attachment. been used for plunge grinding.
• Secure attachment to table.
• Check setting and keenness of diamond.
• Secure diamond in holder, with least possible
overhang.
• Lock diamond in position.

• Wind in wheelhead to bring diamond into lightest

possible contact with wheel. Hear touchdown
made and see line on wheel periphery.
• Apply coolant to cover wheel width and wind
diamond to one side of wheel. Note: Ensure
coolant is clean.
! SAFETY-
• Wear closed-in type safety glasses.
• Ensure wheelhead area is clear before
To set up diamond in tailstock: starting.
• Check and secure diamond, with least possible • Stand at side of wheel when starting.
overhang.
• Position tailstock to bring diamond in line with
wheel.
• Fully tighten tailstock in position.
SAFETY — Keep wheel well clear of work
! area when securing diamond.
General note:
• Frequent change of diamond position will
maintain keenness.
• Rigidity of diamond and holder is
most important.
• Do not allow flats to be worn on diamond.

To dress wheel for rough grinding:

• Infeed wheelhead approximately .05mm (.002in)
each pass of diamond.
• Wind diamond across wheel width quickly at an
even feed rate.
- 20 -
 Dressing grinding wheels for cylindrical grinding
Note: Do not allow diamond to become stationary
while in contact with wheel.
• Direct coolant flow to cover wheel width.
• Continue infeed and traverse until wheel is free of
dull abrasive grain or clogging metal.
• Allow coolant to flow on wheel after completion
of dressing, to wash away free particles.
• Turn off coolant.

Touch diamond to side of wheel as follows:

• Wind table along, until diamond is approximately
.25mm (.01 in) to .35mm (.015in) away from the
wheel.
1
• Infeed until diamond is approximately 6mm ( /4)
in from the periphery of the wheel.
• Hold table crank handle with left hand, and with
right hand tap handle approximately .050mm
(.002in) each time until touchdown is obtained.
To dress wheel for finish grinding: • Turn on coolant. Direct stream at diamond point.
• Infeed wheelhead approximately .025mm (.001
in) to remove dull abrasive grain or clogging To dress side of wheel:
metal. • Wind infeed handle until diamond clears wheel.
• To complete dressing of wheel make two passes • Tap on a .05mm (.002in) cut, and traverse the
at .012mm (.0005in), and one or two idle passes. wheel backwards and forwards the required
• Wind diamond across wheel width fairly slowly distance.
at even feed rate. • Repeat cuts until wheel has been cleaned up.
Note: Do not allow diamond to be stationary while in
contact with wheel.
• Direct coolant flow to cover wheel width.
• Allow coolant to flow on wheel after completion
of dressing, to wash away free particles, then turn
off.

Clear wheel from work area, remove attachment and

wipe clean.
Dressing and relieving the side of the wheel
using a diamond dresser
To prepare machine:
• Clean machine table.
• Unclamp tailstock and position at right-hand end Form relief on wheel as follows:
of machine table. • Feed in wheel until the diamond is approximately
• Wind table along until headstock is just clear of 3mm (l/8in) in from the periphery.
wheel. To mount diamond holder: • Tap on .05mm (.002in) cut, and traverse wheel
• Clean base of diamond holder. backwards and forwards across the diamond for
• Clamp holder to machine table. the required distance.
• Turn diamond 90° to wheel. • Repeat forming, until the required clearance is
• Start wheel. obtained.
• Stop wheel and check clearance by placing the
SAFETY - Stand to side of wheel when edge of a 150mm (6in) rule across the side of the
! starting.
• Wear closed-in type safety glasses.
wheel.

- 21 -
 Dressing grinding wheels for cylindrical grinding
Dressing and relieving the side of the wheel
using a dressing stick
To prepare machine:
• Clean table.
• Unclamp tailstock and slide to right-hand end of
table.
• Traverse table along until workhead is clear of
grinding wheel.
• Start wheelhead motor.

Check relief by placing the edge of a 15mm (Gin) rule

on the side of the wheel. Clearance should be seen
between the rule and the wheel.

To dress the land:

• Start wheelhead motor.
• Take up original position as above, traverse the
dressing stick across the land to form an angle of
slightly less than 90° with the face of the wheel.
• Clear dressing stick from wheel.
Position body as follows: • Stop wheelhead motor and clean down.
• Position body at the front of the machine, facing
half left, with the left shoulder in line with the wheel.
• Rest left elbow on machine table, with the palm of
the hand upwards.
• Pick up dressing stick with right hand, and rest
dressing stick on left hand finger tips.
• Position dressing stick, so that about an inch
overhangs the tips of the fingers of the left hand and
at 90° to the grinding wheel.

! positioning
SAFETY — Great care should be taken in
the left hand so that it does not
touch the grinding wheel.

Note: The left hand acts as a steady and swivel point

for the dressing stick.
Use a similar procedure for dressing left-hand side
of the wheel.
To dress right-hand side of wheel:
• Touch side of wheel with dressing stick Note: Extreme care must be taken when grinding
approximately 12mm (.5in) in from the outside workpieces with the right-hand side of the wheel,
diameter. as the grinding pressure set up may force the
• Keeping a light and even pressure with the spring-loaded tailstock centre backwards, thereby
dressing stick on the side of the wheel and, releasing the workpiece from the headstock centre
moving right hand forwards and backwards form with dangerous consequences.
relief on the side of the wheel to leave a land of
SAFETY - Gloves and safety glasses must be
between .75mm to 1.500mm (.03 to .06in).
• Stop wheelhead motor.
! worn.

- 22 -
 It is equally important to obtain the correct workhead
Feeds and speeds speed and the chart gives typical values for a range of
It is impossible to lay down hard and fast rules for materials.
determining work speeds and traverse speeds to suit
all conditions of grinding, as they depend to such a
great extent upon the wheel characteristics, the Surface speeds of work in feet per minute
material, operating conditions, in-feed and other
variables beyond the scope of calculations. Grinding Class of work Rough grind Finish grind

wheel speeds are expressed as peripheral speeds and Soft steel 30-50 50 - 70
are measured in either metres per second or feet per
Hardened steel 70-90 90- 120
minute:
Average recommended wheel speeds in surface feet Cast Iron 100 - 160 140 - 200
per minute:
Aluminium and fine brass 150 to 200
• Cylindrical grinding 5500-6500 use a fine in-feed)
• Internal grinding 2000-4000
• Surface grinding 4000-5000 Crankshaft bearings 35 to 40
and out of balance work
• Wet tool grinding 5000-6000
• Cutting off with rubber, Irregular shapes such as 15-30 71/2 - 15
shellac and bakelite wheels 9000-12 000 cam surfaces

Internal grinding (use a 100 - 160 140 - 200

Machine speeds, however, are usually indicated in very fine in-feed)
RPM, and most speed indicators and tachometers
read in RPM. It is therefore frequently necessary to In-feed
translate surface speed into spindle speed.
The rate of in-feed is mainly influenced by the
material being ground, the surface finish required and
To find the RPM for a grinding wheel the same
the method of grinding.
formula is used as for cutting speeds. For example: a
Hard or tough materials require a small in-feed,
10" wheel is to run at 6000 surface feet per minute:
otherwise the high compressive stresses fracture the
grains, which are torn from the bond and wasted
N= 12S before they have done any cutting. In general, feeds
d
Where: of 0.0005" to 0.001" are used for roughing and
N = RPM. 0.0005" to 0.0001" for finishing.
S = Surface speed.
d = Wheel diameter. Note: For roughing out heavy work use a low
workhead speed, a heavy in-feed and a fast table
12 6000 72000 traverse.
N= 3.142 10 = 3.142
When roughing out in preparation for fine grinding
= 2300 RPM. do not attempt to remove too much metal at a time, or
the finish grinding will take a long time to remove the
scratches and inaccuracies caused by the rough
grinding.
For fragile work use a high workhead speed and a
light in-feed to dissipate the heat.
For cast iron use a high workhead speed, a heavy in-
feed and a slow table traverse.
If the wheel acts hard and glazes, increase the
workhead speed and table traverse rate.
If the wheel acts soft and wears rapidly, decrease the
workhead speed and table traverse rate.

Note: Alter one factor at a time.

- 23 -
Workholding and setting for surface grinding
Magnetic chuck

This consists of a base which houses a series ol

permanent magnets. A lever is provided which moves
the magnet system so that the magnetic flux is either: To position magnetic chuck:
• Available for holding steel workpieces to the • Place chuck centrally on machine table, with back
surface of the chuck (on position). plate at rear.
• Diverted through a 'keeper' system (off • Remove back plate and clean rear face of chuck.
position). • Check back edge of chuck is level with rear of
machine table, to align chuck.
• Position bolts and clamps and finger tighten nuts.

A typical system is illustrated:

• 'On' position.
• 'Off' position.

To align chuck parallel to table traverse:

• Position dial indicator on wheelhead, with stylus
engaged upon the back face of chuck.
• Traverse machine table backwards and forwards,
When setting the magnetic chuck upon the allowing the stylus to cover full length of chuck.
machine table: • Note amount of error registered at high reading.
• Check machine table, clean machine table, • Continue traversing and adjusting the chuck
check for burrs and remove with abrasive stone. position until no error is shown on dial indicator.
• Check magnetic chuck, clean magnetic chuck, • Finally tighten nuts and check reading. If no error
is shown, remove dial indicator and reposition
check for burrs and remove with abrasive stone.
back plate.
Note: When dial indicator is showing no error, check
! SAFETY - Ensure that machine is isolated. to see if dial indicator point is engaged on magnetic
chuck. When tapping magnetic chuck use a soft
hammer.

- 24 -
 Workholding and setting for surface grinding

When setting workpiece on magnetic chuck with use

When mounting a workplace on the magnetic of back plate:
chuck: • Adjust and secure the back plate just below height
• Prepare magnetic chuck, clean surface of chuck of workpiece.
Note: Where the back plate is to be used for
and check for burrs. Remove burrs by rubbing lightly alignment purposes, the face of the back plate must
with a fine stone. first be ground in the set position.
• Prepare workpiece. Examine and remove burrs • Place workpiece centrally on magnetic chuck and
and/or loose scale from surface to be located on slide workpiece up to back plate.
magnetic chuck. • Hold workpiece against back plate and magnetise
chuck.
SAFETY — Ensure thai the machine • Ensure workpiece is secure.
! is isolated. Note: A parallel strip, placed between the workpiece
and back plate, increases the surface area of the
workpiece on the magnetic strips and thus the
clamping power.
• Lightly tap workpiece to ensure positive
engagement with back plate.
SAFETY — Never leave workpiece on a
! chuck without the chuck being magnetised.
Rule:
• Workpiece on—Magnetism on.
• Magnetism off—Workpiece off.

Setting vee block square on the magnetic

chuck

Set workpiece on magnetic chuck as follows:

• Place workpiece centrally on magnetic chuck.
• Visually check the workpiece is over the steel
sections of the magnet.
• Engage magnet and check location by
attempting to move workpiece. If any
movement is felt, remove workpiece, check
mating surfaces, rectify and re-locate.
Note: Small work that can only be located on one
or two steel sections of the chuck should be secured
as illustrated. SAFETY — Ensure that the machine
! is isolated.
• Position back plate on magnetic chuck.
• Set vee block on the magnetic chuck.
• Place vee block on magnetic chuck.
• Slide vee block up to back plate. Check with
feeler gauges.
• Ensure horseshoe clamp will clear wheelhead.
- 25 - • Magnetise chuck.
 Workholding and setting for surface grinding
Mounting workpiece in a vee block Mounting workplace on the machine table
To prepare machine table:
• Clean machine table and check for burrs.
• Remove burrs by rubbing them lightly with
abrasive stone.
To prepare workpiece:
• Clean and check for burrs and/or loose scale on
locating face of workpiece.
• Remove burrs and/or scale from workpiece.

Select vee block which will allow the diameter, or

section, to rest approximately midway on groove
faces. Clean and deburr vee block.
To set workpiece in vee block:
• Check machining operation and place workpiece
in vee, with as little overhang as possible.
• Place horseshoe clamp in position on vee block.
Ensure clamp will hold workpiece on maximum Align workplace visually as follows:
area. • Place workpiece centrally on machine table.
• Tighten screw to secure workpiece in vee block. • Visually align one edge of workpiece with the
Note: If surface has been finished ground where the edge of one of the table slots.
clamp will seat, place shim packing on workpiece • Visually check that the maximum amount of
and tighten down screw onto packing. workpiece face is located on machine table.
• Clamp workpiece in position.
Setting workpiece on magnetic vee block • Ensure packing end of clamp is level with, or
slightly higher than, end of clamp on workpiece.
• Bolts should be nearer to workpiece than to
packing.
• Clamp should be shorter from bolt to workpiece
than from bolt to packing.
• Finger tighten nuts alternately to ensure even
pressure on workpiece. Lightly tighten each nut,
then, finally tighten each one alternately. Never
clamp on unsupported part of workpiece.

Use table slots for aligning workpiece as follows:

Select vee block which will allow the diameter, or

section, to rest approximately midway on vee faces.
Check vee block for burrs, and clean.

To position workpiece:
• Ensure magnet is switched off.
• Check machining operation and place workpiece
in vee, with as little overhang as possible.
• Partly magnetise magnet and position vee block
in required position.
• Fully magnetise vee block.
• Feel if workpiece is secure. • Position workplace centrally on table.
• Position tenons or setting plates in table slot
within length of, but as near extremes of,
workpiece as possible.
• Feel tenons are a light sliding fit in table with no
side play.
- 26 - • Push workpiece up to tenons or setting plates.
 Workholding and setting for surface grinding
• Visually check base is seated on table, clear of To set vice on machine table:
slots. • Clean and deburr machine table.
• Position clamps and hold workpiece up to • Turn vice over and place on machine table.
tenons while clamping. Take care not to pick up dirt or swarf on bottom
• Check set up with feeler gauge between face of vice.
workpiece, table and setting plates. • Hold base of vice parallel to table surface and
Alternatively,trap thin paper between workpiece slide vice to feel tenons locate in table slot.
and each setting plate. Check that it remains • Press vice down onto table.
trapped. ! when
SAFETY — Take care not to trap fingers
positioning vice on table.

To clamp vice:
• Slide bolts along table slots and into vice slots.
To use table slot for setting workpiece square, or at
• Engage washers on bolts, ensuring they well
an angle, on machine table:
overlap onto vice flange each side of slot.
• Position tenons, or setting plates in table slot
• Finger tighten nuts, ensuring they are fully
feeling for light sliding fit.
engaged on thread of bolts.
• Check that blade of setting instrument will pass
• tighten nuts securely with spanner.
between workpiece and setting plates.
• Position base of setting instrument to face of
tenons, or setting plates, and press to maintain ! SAFETY - Do not use worn nuts or spanners.
contact.
• Slide base on setting plates until blade lightly Method 2 - Using dial test indicator
touches on face of workpiece.
• Tap workpiece, using soft hammer, to align face
to blade of setting instrument.
• Clamp workpiece and check setting after final
tightening.

Methods of mounting a vice are described in the

milling section.

How to set a workpiece in a vice is described in the

milling section.

Mounting a vice on the machine table Position vice on machine table as follows:
• Clean and deburr the machine table and the vice
Method 1 - Using tenons base.
To prepare vice: • Position the vice centrally on machine table.
• Insert vice, clean and deburr bottom face and • Align the vice, by feeling the vice slots level with
tenon slots. the table slots.
• Fit tenons into appropriate tenon slots. • Position bolts and finger tighten.
• Align clearance hole in tenon, with tapped hole Note: If an accurate setting is not essential, the vice
in vice body. may be finally clamped in this position.
• Engage screws and tighten tenons securely in
position.

- 27 -
 Workholding and setting for surface grinding
Setting workpiece in a vice

To position workpiece in vice:

Accurately set vice as follows: • Clean and deburr faces of workpiece.
• Clean and deburr the vice jaws. • Position maximum amount possible of
• Clamp a parallel in the vice, ensuring that workpiece, in the vice.
approximately 25mm (lin) protrudes above the top • Visually check that the workpiece can be
of the jaws. machined to size without fouling vice with wheel.
Note: The greater the length of parallel used, the Note: Parallel strips may be used to raise workpiece
greater the accuracy of setting obtained. face above top of vice jaws. Ensure that width of
parallels are less than width of workpiece.
• Attach the dial test indicator base to the • Lightly tighten vice jaws.
wheelhead, or to a part of the machine which is
independent of the table movement.
• Engage the dial test indicator stylus to obtain a
reading at one end of parallel ensuring that the
stylus spindle is square to the face.
• Zero dial test indicator.
• Wind the table along, to position the stylus at the
opposite end of the parallel.
• Check dial test indicator reading to see error
obtained.
• If any error is noted, tap the vice body, at the
handle end, until the dial test indicator pointer
returns to the zero reading. To seat the workpiece:
Note: Always tap the vice to move the parallel away • Tap the workpiece down using a soft hammer.
from the dial test indicator. Until a solid note is heard.
• Check seating of workpiece, on vice bed with
• Check and adjust vice until the same reading is feeler gauge or check that the parallels, if they
obtained at each end of the parallel. are used, are tightly trapped.
• Finally clamp the vice, taking care not to alter • Tighten vice securely.
setting. • Re-check seating and adjust if necessary.
• Check setting after final tightening.
Note: Check correct working of dial test indicator and Setting the universal vice
engagement of stylus when no error is found.
• A vice is similarly aligned on a magnetic chuck.
An approximate setting is obtained by visually
aligning vice jaws square or parallel to the wheel.
The vice is clamped by magnetising the chuck.
Re-check alignment after clamping.

To set vice on machine table:

• Clean and deburr table surface and vice base.
• Position vice, approximately in centre of table.
- 28 - • Lightly bolt vice in position.
 Workholding and setting for surface grinding

• Tighten vertical swivel nut securely, taking care

not to alter setting.
• Re-check angular setting.
Note: Compound angle may be set by tilting the vice
to the angle required and rotating the top or bottom
angular scale to the required index.

Mounting an angle bracket

Select angle bracket appropriate to size of workpiece.
Check for burrs and clean faces.

To align vice jaws parallel to wheelhead:

• Set vertical angular index to zero.
• Set horizontal angular indexes to zero.
• Place parallel strip between jaws. Clamp lightly.
Tap down with hide hammer and check between
strip and vice bed with feeler gauge.
• Attach dial test indicator base to wheelhead.
Adjust stylus to touch side of parallel.
• Traverse table, noting dial reading.
• Adjust base by tapping, until dial reads the same
at both ends. To set bracket parallel or square to machine table:
• Bolt vice down securely and re-check alignment. • Place bolts in tee slots, approximately central
along machine table.
• Place bracket onto machine table, engaging bolts
through slot in bracket. Visually align parallel, or
square to tee slot. Finger tighten nuts.
• Place dial test indicator on wheelhead column,
and engage stylus on angle bracket face.
• Using traverse handwheel for parallel setting, or
crossfeed handwheel for square setting; wind
table backwards and forwards, covering length of
face with stylus. Note high reading.
• Tap the end with high reading, away from dial test
indicator.
• Finally tighten nuts with spanner and check
To align vice bed parallel to wheelhead: setting.
• Reset dial test indicator on upper surface of
parallel strip.
• Loosen vertical swivel, sufficient to allow
movement of vice when tapped.
• Traverse table noting dial reading.
• Adjust vice by tapping until dial reads the same at
both ends.
• Tighten vertical swivel securely. Re-
check alignment.
Note: Variations from zero position, caused by
adjustments should be noted.
To set the vice at an angle:
• Align vice jaws and bed, parallel to wheelhead.
• Hold vice and loosen vertical swivel nut. To set bracket at an angle to machine table:
• Tilt vice until the required angular setting is • Place bolts in tee slot, approximately central
obtained. Compensate for any error noted when along machine table.
setting bed.

- 29 -
 Workholding and setting for surface grinding

• Place bracket at required angle, visually, on Setting a workpiece upon an angle bracket
machine table. Engage bolts through slot in Position clamps as follows:
bracket and finger tighten nuts. • Hold workpiece to angle bracket. Select
• Place tenons in tee slot, approximately 50mm appropriate slots to give maximum clamping area.
(2in) away from face of the bracket. • Position parallels or block, to support work and
• Set protractor at required angle and place base give correct position of workpiece.
flush to tenons. • Remove workpiece and position clamps.
• Slide protractor up to bracket and line bracket
flush to protractor blade.
• Finally tighten nuts with spanner.

To clamp workplace to bracket:

• Position workpiece on angle bracket and hold in
To position angle bracket on magnetic chuck: position.
• Ensure back plate is raised and secured to • Position clamps and finger tighten.
magnetic chuck. • Check workpiece setting. Adjust if necessary.
• Slide end, or rear of bracket, flush to back plate • Finally tighten clamps.
and check with feeler gauges.
• Magnetise the chuck.

- 30 -
Workholding and setting for cylindrical grinding
Mounting a chuck
There are many different ways, due to different
makes of machinery, in which to change the
headstock attachments on a cylindrical grinding
machine. Two of the most common are detailed
below. There are however, certain rules to follow
whatever the make of machine. They are:
• Switch off machine at mains when changing
attachments.
• Ensure spindle nose and/or threads are clean, and
free from burrs.
• Ensure grinding wheel is clear of the work area.
• Ensure everything is secure before starting
machine. To free headstock spindle lock:
• Ensure all guards are in position before starting • Remove guard at end of spindle.
machine. • Unscrew knurled nut, (right-hand thread).
• Remove cover.
Type one • Withdraw keyed disc.
This is where no direct switch is available to change • Replace disc in a reversed position so that the
spindle from 'live' to 'dead'. projection is held clear of the housing.
• Replace cover, knurled nut and guard.
Note: The spindle can now be driven and attachments
can be fitted.

Engage spindle drive as follows:

• Switch machine off at mains.
• Eject centre. When mounting a chuck:
• Remove driving bracket and protection bush on • Clean spindle nose and chuck threads.
spindle nose. • Apply a thin film of oil on joint face of spindle.
• Slacken nut that holds the small finger, (in recess • Hold knurled nut on tail end of spindle and
in the face plate). screw chuck on spindle nose, until the chuck
• Rotate spindle nose until finger engages in slot cut register and spindle face come into light
in the machine spindle. contact.
• Tighten nut to lock finger in the driving position.
• Unscrew chuck a quarter of a turn and with a
Note: Store driving bracket, bolts, centre and
sharp clockwise flick, drive chuck home.
protection bush in the machine cabinet.
When removing chuck from head:
• Engage chuck key in chuck.
• With the heel of the hand apply a sharp blow to
the key body, to loosen the chuck on the spindle
nose.
• Unscrew chuck from spindle nose.
• Clean chuck and replace in cabinet.

- 31 -
 Workholding and setting for cylindrical grinding
Type two Setting workpiece in the three-jaw chuck
This is where a direct switch is available to change
machine spindle from 'live' to 'dead' and vice versa.

Clean chuck as follows:

• Remove jaws from chuck, thoroughly clean jaws
scroll and jaw slots.
• Replace jaws, ensuring that jaws are fitted to theii
respective slots, and are engaged successive!]
Make adjustment to headstock as follows: upon the scroll.
• Switch machine off at mains. • Set jaws to approximate diameter of workpiece.
• Eject centre.
• Remove driving bracket.
• Unscrew the six cap screws on driving plate and
remove plate.
Note: Store bracket, plate and screws, in the machine
cabinet.

To set workpiece in chuck:

• Clean workpiece.
• Place workpiece within jaws, and tighten jaws to
workpiece.
When mounting a chuck on the spindle nose: Note: Allow the minimum overhang of workpiece
• Clean spindle nose thread and thread in bore of from chuck that will enable the operation to be
chuck. carried out without the grinding head fouling the
• Apply a thin film of oil on joint face of spindle. chuck.
• Screw chuck on spindle, until faces come into
light contact.
• Unscrew chuck a quarter of a turn and, with a
sharp clockwise flick, drive chuck home.

Make final workhead adjustment as follows:

• Turn lever from 'dead' centre to 'live'.
• Pull out plunger, (at rear of workhead), and turn
90°.
Note: The reverse procedure is adopted, when
resetting for work to be held between centres.

To set workpiece true:

• Revolve chuck by hand and visually note any
eccentricity.
• Lightly tap workpiece at highest point, towards
the centre of the chuck.
• Repeat until the workpiece is visually concentric.
• Tighten chuck jaws.
- 32 -
 Workholding and setting for cylindrical grinding
• Position dial test indicator base on machine table,
engage stylus on end of workpiece furthest from
chuck.
• Revolve chuek by hand and note error.
• Lightly tap workpiece at highest point.
Note: Disengage dial test indicator before tapping
workpiece.
• Repeat until workpiece is concentric.
• Remove dial test indicator.

To set workpiece in chuck:

• Clean workpiece.
• Place workpiece within jaws, and tighten jaws on
workpiece in the order 1, 3, 4 and 2.
Note: Allow minimum overhang of workpiece from
chuck that will enable the grinding operation to be
carried out. Ensure grinding head will not foul
chuck.
To rough true workpiece
When using the tailstock centre: • Turn chuck by hand, visually noting high and low
• Many conditions of work may require that the point of workpiece.
workpiece be supported at the free end. • Slacken jaw at low point and tighten opposite jaw.
• Place workpiece within jaws and tighten jaws to • Repeat until workpiece is visually concentric.
workpiece.
Note: Hold short length of workpiece in chuck.
• Set workpiece true in chuck.
• Lubricate centre hole.
• Move tailstock up to workpiece, slightly retract
barrel, carefully engage centre and lock tailstock
in position.
• Check true running.

Setting workpiece in the four-jaw chuck

To accurately true workpiece:

• Mount dial test indicator stand upon machine bed,
with stylus engaged on top of workpiece, close to
chuck jaws.
• Rotate chuck by hand and establish lowest point
of workpiece, and note total indicated error.
• Slacken jaw at lowest position and rotate chuck to
bring highest position to the top.
• Tighten top jaw to halve the total indicated error,
Clean chuck as follows: and re-tighten slack jaw.
• Remove jaws, thoroughly clean jaws, screws and Note: If the lowest position is between two jaws,
jaw slots. slacken off both jaws, tighten opposite jaws, and re-
• Replace jaws. tighten slack jaws.
• Set jaws to approximate diameter of workpiece, • Repeat checking and adjusting until the
(use index lines as a guide). workpiece runs true.
• Engage stylus on extreme end of workpiece.

- 33 -
 Workholding and setting for cylindrical grinding
• Rotate chuck by hand and establish in highest • Hold workplace around diameter, with enough of
position of workplace. workpiece protruding to allow engagement of
• Lightly tap workpiece at the highest position to carrier.
correct eccentricity. • Position carrier on workpiece and allow to rest on
• Repeat checking and tapping until the workpiece first finger and thumb. Lock carrier to workpiece.
runs true. • Place small amount of oil in each centre hole.
Note: If holding on a finished diameter, use soft
• Return stylus to original position, check running packing strip for protection.
of workpiece, and adjust as necessary.
• Repeat procedure until true running condition is
achieved in both positions of stylus.
Note: When holding bored work, care must be taken
not to overtighten jaws.

To set centre distance:

• Slacken driving dog on catch plate, and position to
clear carrier.
• Slide tailstock into approximate position.
• Holding the workpiece in the left hand, engage
When using the tailstock centre: carrier end centre upon headstock centre. Hold
• Many conditions of work may require that the workpiece horizontal.
• Slide tailstock towards workpiece, engage centre.
workpiece be supported at the free end. • Retract tailstock barrel, remove workpiece from
• Place workpiece within jaws; lightly tighten jaws centres.
on workpiece in order 1, 3, 4 and 2. • Slide tailstock sufficient distance towards
Note: Hold short length of workpiece in chuck. headstock to enable centre pressure to be applied
• Set workpiece true in chuck. to workpiece.
• Lubricate centre hole in workpiece. • Lock tailstock in position.
• Move tailstock up to workpiece, slightly retract Note: If workpiece is heavy, centre distance should
barrel, carefully engage centres and lock tailstock be set by measuring between centres with a rule
in position. before lifting work into place. If possible, seek
assistance to release tailstock centre.
• Check true running.

Mounting workpiece between centres

To check centres:
• Ensure that centres of workpiece are clean, in
good condition and of correct form.
• Ensure that workhead and tailstock centres are not
worn or pitted.
Note: Cleanliness and good condition of centres is
essential.

To mount workplace between centres:

• Clean and lubricate centres.
• Engage carrier end centre, retract tailstock barrel,
align workpiece and carefully engage tailstock
centre.
To engage carrier: • Ensure that the workpiece is firmly held and free
• Select carrier, the bore of which should be just to rotate.
larger than diameter of workpiece. • Lock tailstock in position.
- 34 -
 Workholding and setting for cylindrical grinding

To set driving dog:

• Engage driving dog pin into carrier slot,
allowing slight freedom of movement between
carrier and dog pin.
• Lock driving dog in position. To mount workpiece on mandrel:
Note: Ensure that the driving dog pin is always • Clean and lightly oil mandrel and bore of
engaged in the carrier slot. workpiece.
SAFETY — Before starting workhead, • Hold workpiece in left hand, the mandrel in
! ensure everything is secure. right hand, and engage mandrel in bore with a
forward and turning movement until a secure fit
Mounting workplace on a mandrel between is achieved.
centres Note: If too loose a fit, there is danger of the
To select mandrel: workpiece spinning when in contact with the
• Measure bore in workpiece. wheel. If too tight a fit, the workpiece will expand
• Select a tapered mandrel, so that when fitted in the with the possible result that the diameter ground
bore the workpiece will be a tight fit upon the will be undersize when the mandrel is removed.
mandrel, and positioned within the length of the
mandrel. To mount assembly between centres:
• Clean and lubricate centre holes in mandrel.
• Check mandrel is securely held.
• Check for play between driving dog pin, and
carrier slot.
Mounting a supporting steady for
cylindrical grinding

To check concentricity of mandrel:

• Select appropriate carrier and attach securely to
the larger end of the mandrel.
• Clean and lubricate centre holes, and mount
mandrel between centres. Adjust driving dog to
To prepare machine:
carrier.
• Switch off mains.
• Mount dial test indicator stand on machine bed
• Clean machine table, and move tailstock to right-
and engage stylus on top of mandrel.
hand end.
• Start workhead motor and take indicator readings
• Select number of steadies required for workpiece,
at the ends and centre of mandrel. Note any
(preferably an odd number).
eccentricity. (Check permissive eccentricity
Note: Sometimes more than one steady is needed,
from workpiece drawing).
especially with long slender work. When this is the
• Stop workhead motor and remove mandrel from
case, use an odd number. The centre one serves as a
centres.
control rest, the remaining ones are then brought into
contact with the work.
• Mount workpiece between centres.

- 35 -
 Workholding and setting for cylindrical grinding
Clamp steadies to machine table as follows: Mounting a supporting steady for internal
• Mount steady on machine table. grinding
• Move steady along table until it is approximately
central to workpiece.
• Clamp steady to table.

To prepare workpiece:
• Move machine table along, until grinding wheel To position workpiece:
is directly opposite steady. • Select and set up appropriate workholding
• Switch on mains, start grinding wheel and device.
workhead.
• Feed grinding wheel into workpiece. • Position workpiece in workholding device.
• Touch down, and clean up diameter. Note: If workpiece is long and heavy, position
Note: Great care must be maintained in this wooden blocks under and towards the end of
operation, to ensure that the diameter where the shoe workpiece, away from workholding device. The
of the steady will touch, is perfectly round, if not, the wooden blocks should be high enough to hold
error in this will be repeated on the workpiece when workpiece parallel to machine table when workpiece
the steady is set. is held in workholding device.
• Secure workpiece.
• Position dial test indicator on machine table with
stylus engaged on workpiece at workhead end.
• Hand turn workhead and adjust workpiece away
from high reading.
• Adjust workpiece until it is concentric.
• Move dial test indicator to extreme end of
workpiece.
• Turn workhead and tap workpiece away from
high reading.
• Re-check at workhead end, adjust if necessary.
• Re-check extreme end and adjust if necessary.
To set steadies to workpiece: To clean steady:
• Raise the lower shoe to support the workpiece. • Clean underside of base.
This is done by turning the vertical knurled screw
in a clockwise direction with just enough • Remove any burrs.
pressure to provide support. • Check for free movement of the three bearing
• Advance the horizontal shoe to bear on the pads.
ground diameter with very light, but firm
pressure. To clean machine table:
• Lock screws. • Clean machine table area where steady will be
Note: The screws that move the shoes in and out placed.
must be very free moving, so that the contact • Remove any burrs.
between them and the workpiece can be easily felt.
Too much pressure on the horizontal shoe will spring
the work in towards the wheel and as a result, the
work will be ground smaller at the point of the
steady. Experience will indicate to the operator the
right amount of pressure to apply for the particular
piece being ground. As grinding of the workpiece
commences, the shoes of the steady must be adjusted
every one, or two, passes of the wheel.
- 36 -
 Workholding and setting for cylindrical grinding
Mounting workplace on face plate
Select bolts and clamps as follows:
• Select four bolts, ensure that a full nut can be
engaged when workpiece is clamped to faceplate.
• Select four clamps, ensure that the heel pins are
long enough to adjust the clamps parallel to
faceplate.
To position steady: • Select four nuts and washers, ensure that the nuts
• Place steady on machine table. will run freely down the threads of the bolts.
• Ensure bearing pads will clear workpiece. ! SAFETY - Before starting to grind ensure
• Check position of steady relative to workpiece. clamps will not foul on wheel or any part of
• Slide steady to position required on machine the machine.
table.
• Ensure steady is correctly located on machine To prepare faceplate:
table. • Clean faceplate, and remove all burrs.
• Secure steady to machine table. • Enter two bolts, diametrically opposite, through
the slots in the faceplate.
• Place clamps on bolts, with the heel pins towards
the faceplate, and fit bolts with a washer and nut.

To set steady to workplace:

• Position dial test indicator stylus on workpiece,
set dial at zero.
• Position and tighten steady moving arm.
• Carefully wind one base bearing pad up to To mount workpiece on faceplate:
workpiece. • Place workpiece on faceplate, and clamp with two
• Stop winding when dial test indicator finger bolts only.
moves. Note: A guide for setting workpiece true can be
• Wind bearing pad off workpiece until pointer obtained from the index lines on the faceplate.
registers zero. • Rotate faceplate by hand, note the high point of
• Wind back into workpiece to take up backlash. workpiece.
Lock pad in position.
• Repeat this procedure with the other base bearing • Tap high point of workpiece with the hide end of a
pad. copper/hide hammer, repeat until workpiece is
visually concentric.
• Place remaining bolts through the faceplate and
fit clamps, washers and nuts.
• Adjust heel pins so that the clamps are parallel to
faceplate.
• Move bolts along slot of faceplate, until they are
approximately 3mm (.125in) from workpiece and
lightly tighten.
• Adjust the remaining two clamps.
• Ensure that equal pressure is applied to all nuts.

• Wind down top pad carefully until it is in contact

with workpiece diameter. Lock.
Note: Place a smear of oil onto workpiece, between
pads to reduce friction. - 37 -
 Workholding and setting for cylindrical grinding

True-up workpiece as follows:

• Place dial test indicator on machine table. To prepare tailstock:
• Engage stylus in bore of workpiece. • Eject centre from tailstock barrel. Clean bore of
• Revolve faceplate by hand, note high point of tailstock.
bore. • Clean both tapers on alignment gauge.
Note: If internal grinding set true to outside • Thrust one end of gauge into tailstock bore. Pull
diameter. tailstock lever to bring barrel in back position and
• Tap at the high point with a hide hammer, to bring lock.
the workpiece to the running true position.
• Repeat two previous steps until workpiece runs
true.
• Check that all nuts on clamps are tight
.
Aligning workhead and tailstock

To align workhead and tailstock:

• Clean machine table.
• Push tailstock towards workhead, until alignment
gauge enters into bore of spindle.
• Visually check equal distance around gauge and
spindle.
To adjust workhead: • Clamp tailstock to table.
• Ensure grinding wheel is clear of work area. • Slowly release tailstock barrel, to allow
• Remove chuck or eject centre from workhead alignment gauge to be forced into spindle nose.
spindle. Clean bore of spindle. Note: Workhead swivel must be free - nuts loose.
• Slacken nuts on workhead swivel base. Swivel • When alignment gauge is firmly engaged in
workhead to align zero reading with index mark. spindle nose, tighten nuts on workhead swivel
base.

Remove gauge as follows:

• Unclamp tailstock and slide to end of machine
table.
• Eject alignment gauge and replace in cabinet or
box.

- 38 -
Inspection of workpiece prior to grinding
Study drawing for:
• Diameter(s) to be ground.
• Concentricity of one diameter to another (or to a
bore).
• Parallelism or squareness of faces.
• Tolerances allowed and surface texture required.
• Material - hard or soft - will it necessitate a change
of wheel grade?
• Ensure that you understand what exactly has to be
done.
SAFETY - Be careful of sharp edges
!
Check dimensions:
• Visually check each diameter and face to be
ground for groove or tool 'dig-ins' that may not be Check concentricity of workpiece if workpiece is
removed after grinding. to be held between centres:
• Check each dimension to be ground and ensure • Visually check centre holes are of correct form,
that there is a grinding allowance, this can vary free from burrs and dirt etc. Oil centres and set
between +.15mm (.006in) to .6mm (.025in) up workpiece on machine.
depending on size and length, the usual grinding • Start workhead, visually check concentricity.
allowance is +.25mm (.Olin) to +.35mm (.15in). • Stop workhead. Check concentricity with dial
• Check at varying lengths along the workpiece. test indicator, if workpiece is thought to be
eccentric.
• Check at worst point. Reading on dial test
indicator should not alter more than half the
amount left on for grinding. Reject workpiece if
diameter will not clean up.

• Check each diameter/dimension for taper and

highest point.
• Memorise or mark highest point on workpiece
to be ground first, for wheel touchdown.

Check concentricity if workpiece is held in chuck or

collet:
• Select appropriate size vee block for diameter of
workpiece.
Note: If vee block is larger than finger span or
workpiece is heavy, always clamp vee block to
surface table.
• Position workpiece in vee block and set height
gauge and dial test indicator to run on a diameter.
• Hold vee block with one hand and rotate
workpiece, keeping downward pressure on
workpiece while rotating, note amount of dial test
indicator movement. Care must be taken not to
move height gauge.
• Repeat on all diameters to be ground.
- 39 -
Surface grinding operations
Setting the table traverse stops • Push stop to traverse trip lever, and lock in position.
• Hand wind table to position one-third of wheel
thickness over opposite edge of workpiece.
• Push stop to traverse trip lever, and lock in position.
• Start traverse and check coverage of wheel over
workpiece.
• Adjust stops if necessary.
Grinding the surface of the magnetic chuck
Dress wheel for rough grinding.

When positioning and setting longitudinal stops:

• Raise wheel clear of workpiece.
• Traverse table, to position one end of the
workpiece just clear of the vertical centre line of
the wheel.
• Push stop up to traverse direction change lever,
and lock in position.
• Traverse table to position opposite end of
workpiece, just clear of wheel.
• Push stop up to traverse direction change lever,
and lock in position.
• Start longitudinal traverse and visually check the
amount of overrun between each end of Set chuck on machine table as follows:
workpiece and wheel. • Remove back plate from chuck.
• Stop traverse and adjust stops until the overrun is • Remove soft metal surrounding pole pieces with a
approximately 6mm (.25in) to 12mm (.5in) at hook scraper.
each end of workpiece. Note: Remove minimum amount of soft metal, but
enough to be level with finished ground surface of
chuck.
To set stops:
• Wind wheelhead down to bring wheel
approximately 1.6mm (.062in) from chuck
surface.
• Set longitudinal and cross-slide table stops, for
wheel to clear each edge of chuck.

Crossfeed stops are rarely used as the direction of

traverse can quickly, and easily, be changed by hand
when approximately one-third of the wheel thickness
is over the edge of the workpiece.

Touchdown wheel to chuck surface as follows:

• Position wheel in line with highest point of chuck
surface.
• Start wheel and longitudinal traverse.
• Carefully down feed wheel until sound/sparks
To position and set: indicate touchdown.
• Raise wheel clear of workpiece.
• Hand wind cross feed handle until approximately • Apply a good flow of coolant between contact
one-third of wheel thickness is over edge of area of wheel and chuck.
workpiece. - 40 - Note: Check magnetism switched off.
 Surface grinding operations
To grind chuck surface: To dress wheel dish back side of wheel.
• Clear wheel to one side of chuck width.
• Apply cuts of .015mm (.005in) - .025mm (.001in).
• Cross-traverse wheel across chuck width.
• Stop traverse, wheel and coolant.

Check surface as follows:

• Wipe surface of chuck clean.
• Visually check that the whole surface has been
ground. Grind back plate as follows:
Note: It may be necessary to take further cuts across • Position wheel within .8mm (.03in) of back plate.
chuck surface until complete area is ground. Keep the • Start longitudinal traverse.
• Bring wheel down to approximately .125mm
wheel openly dressed. (.005in) above chuck surface.
• Manually apply crossfeed, for wheel to flick back
To finish grind chuck surface: plate.
• Re-dress wheel. • Apply coolant.
• Re-touch wheel to chuck surface. • Apply cut of .015mm (.0005in) per pass of wheel,
• Apply cut of .008mm (.0003in) .015mm (.0005in). until wheel grinds complete surface of back plate.
• Cross traverse wheel across chuck width. • Allow cut to spark out.
• Listen for wheel cutting continuously while • Stop traverse, turn off coolant and raise
passing over chuck. wheelhead well clear of chuck.
Note : If sound is not continuous, apply further • Remove sharp edges from back plate.
Note: Remove as little material as possible.
cut(s).
Grinding a flat face
SAFETY - Keep hands away from revolving
! wheel at all times.
• Measure workpiece, check the flatness of the
face, check parallelism and note high position.
• Dress wheel.
Note: The surface area of the face to be ground, the
amount of material to be removed and the surface
texture requirement are factors to be taken into
account in deciding whether the operation can be
successfully carried out with single dressing of the
wheel, or if a roughing out and finish grinding
technique is necessary.
• Mount workpiece.
• Set table traverse stops.

To check surface:
• Clean chuck surface.
• Visually check surface texture.
• Check flatness of chuck with straight edge and
feeler gauge. Touchdown wheel to workpiece as follows:
Note: When grinding surface of a magnetic chuck, • Switch on wheel and visually align wheel over
the smallest amount of material possible should be highest point.
removed. • Hand feed wheelhead down, watching the
To position back plate: narrowing gap until approximately 0.25mm
• Ensure mating surfaces of plate and chuck are remains between wheel and workpiece.
clean and free from burrs. • Engage longitudinal traverse.
• Replace back plate in position to the required • Hand feed wheelhead down, using fine feed, until
height. sparks and/or sound indicate the wheel is
touching top of workpiece.
• Cross traverse workpiece clear of wheel.
- 41 -
 Surface grinding operations
Grinding two opposite sides flat and
parallel

Clean up the face as follows:

• Start coolant pump, direct coolant stream
between wheel and workpiece. Measure workpiece, determine allowance for
• Apply 0.05mm down feed to the wheelhead, and grinding, check parallelism and note high position.
using hand cross traverse, position the side of the Dress wheel for roughing out.
workpiece in line with the front side of the Mount workpiece on magnetic chuck.
wheel. Set table traverse stops.
• Using hand or automatic cross feed, allow wheel Clean up face and remove minimum material.
to pass over whole face of workpiece. Remove workpiece from chuck.
• Stop cross traversing, apply further down feed, Traverse workpiece maximum distance from wheel.
and commence reverse traverse. Measure workpiece, clean workpiece, determine
• Continue applying down feed and traversing remaining allowance for grinding and check
until the face has fully cleaned up. Parallelism.
• Stop all traversing, position workpiece
maximum distance from wheel, turn off coolant.
• Remove workpiece from chuck.
Dress wheel for finish grinding.
Re-set workpiece upon the chuck.
To finish grind workpiece:
• Ensure wheel is clear of workpiece and engage
longitudinal table traverse.
• Using the cross traverse, position the edge of the
workpiece under the wheel.
• Carefully feed the wheelhead down until the
wheel makes light contact with the workpiece.
• Cross traverse the workpiece clear of the wheel.
• Apply 0.012mm cut. Mount workpiece and reverse to grind opposite side.
• Engage cross traverse, turn on coolant, grind Rough grind face removing half remaining grinding
face. allowance minus 0.05mm.
• Continue applying down feed and traversing Remove workpiece from chuck.
until the face is fully ground. Measure workpiece and check size and parallelism.
• Allow wheel to 'spark out'. Mount workpiece and reverse to grind first face.
• Stop all traverses, position workpiece maximum Rough grind workpiece to within 0.05mm of finished
distance from wheel, turn off coolant. size.
• Remove workpiece from chuck. Remove workpiece from chuck.
Dress wheel for finish grinding.
Measure workpiece, check flatness and surface Measure workpiece, determine remaining grinding
texture.
Remove sharp edges using a fine abrasive stone. allowance and check parallelism.
Demagnetise the workpiece. Mount workpiece ensuring that the surfaces of the
chuck and workpiece are clean.

- 42 -
 Surface grinding operations
• When the wheel has passed over the whole face,
stop cross traverse, apply down feed
approximately 0.005mm and engage reverse
traverse.
• Working to the wheelhead index, continue
applying down feed and traversing until
remaining grinding allowance is removed.
• After the final down feed has been applied, allow
the wheel to pass over the face once or twice to
spark out.
• Stop all traverses, clear workpiece from wheel,
turn off coolant.
• Remove workpiece from chuck.
To measure workpiece:
To finish grind workpiece to size: • Check thickness.
• Ensure that the wheel is clear of workpiece, • Check flatness.
engage longitudinal table traverse. • Check parallelism.
• Using the cross traverse, position the edge of the • Check surface texture.
workpiece under the wheel.
• Carefully feed the wheelhead down until the Remove sharp edges using fine abrasive stone.
wheel makes light contact with the workpiece. Demagnetise workpiece.
• Note wheelhead index reading, and cross traverse
workpiece clear of the wheel. Grinding a flat face and shoulder
• Apply 0.012mm down feed, engage cross
traverse and turn on coolant. Dress wheel, dress wheelface, apply relief to rear of
• Allow wheel to pass over the whole surface of the wheel and switch off wheelhead.
workpiece, stop cross traverse. Select workholding device. Use magnetic chuck.
• Apply 0.005mm downfeed, engage reverse cross
traverse.
• When the workpiece clears the wheel reverse the
direction of cross traverse and allow the wheel to
pass over the face once or twice (sparking-out)
with no cut applied.
• Stop all traverses, position workpiece maximum
distance from wheel, turn off coolant.
Note: Do not alter the wheelhead setting.
• Remove workpiece from chuck.
• Thoroughly clean workpiece and surface of
chuck.
• Measure workpiece. Determine remaining
grinding allowance. Check parallelism.
• Reverse and set workpiece upon the chuck.

Position workpiece as follows:

• Check workpiece face for highest point; mark or
memorise.
• Position workpiece on chuck.
• Visually align workpiece shoulder face, in line
with wheel.
• Place dial indicator in wheelhead with stylus
engaged on shoulder face.
• Traverse table backwards and forwards; observe
dial and adjust workpiece until reading is the
same at both ends.
• Secure workpiece and check alignment.
Alternatively, if a back plate is fitted to the chuck and
the plate face is ground in position this can be used as
• Align edge of workpiece with side of wheel, a datum surface enabling the workpiece to be set in
apply 0.012mm down feed, engage longitudinal the correct plane when located against it. A further
table traverse, turn on coolant. advantage is that the workpiece can be removed and
• Engage cross traverse; grind face. reset upon the chuck to a very high degree of
accuracy.
- 43 -
 Surface grinding operations
Position and set longitudinal stops. Note: Dependent upon the face area, traverse
Touchdown onto workpiece, as follows: speed, type and condition of wheel, it may be
• Visually align wheel over highest point of necessary to allow the workpiece to pass across the
horizontal workpiece surface. face of the wheel a number of times before
• Start wheel. applying successive cuts.
• Engage longitudinal traverse. • Cross traverse to clear workpiece, disengage
• Down feed wheelhead carefully until sparks, or longitudinal traverse and raise wheel.
sound, indicate that the wheel is grinding. • Turn off coolant and remove workpiece from
• Zero graduated scale on wheelhead handwheel. table.
• Switch on coolant. • Clean down.
Re-dress wheel face and side, for finish grinding.

To rough grind horizontal face: To finish grind horizontal face:

• Apply 0.05mm down feed to wheelhead. • Clean table and workpiece.
• Hand feed cross traverse, grinding surface to • Rest and secure workpiece on table.
within 1mm of vertical face. • Traverse table to bring workpiece horizontal face
• Stop longitudinal traverse. Set cross traverse under wheel.
stops. • Engage longitudinal traverse, and carefully down
• Hand traverse table to clear workpiece from feed wheel to make light contact with face.
wheel. Engage both longitudinal and cross • Note dial reading.
traverse feeds. Apply further cuts until 0.05mm is • Cross traverse to clear workpiece from wheel,
left for finish grinding. apply 0.025mm down feed, and grind across face
until wheel makes light contact with vertical face.
• Cross traverse table, to clear workpiece from
wheel, take further cuts to bring the workpiece to
size.
To finish grind vertical face:
• Cross traverse table until vertical face makes light
contact with wheel; apply cuts of up to 0.012mm
to bring the workpiece to size.
• Cross traverse to clear workpiece from wheel,
disengage longitudinal traverse, and raise wheel
clear.
• Turn off coolant and remove workpiece from
table.
• Clean and check workplace.
Note: If grinding the vertical face, frequent re-
dressing of the wheel may be necessary.
To rough grind vertical face:
SAFETY — Safety glasses must be worn.
• Cross traverse table carefully until wheel lightly
contacts vertical face.
! Extreme care must be taken when
Note: Traverse stops may have to be adjusted to traversing the table bringing the vertical
enable workpiece to clear wheel. face into close proximity of the wheel.
• Apply cross traverse cuts of 0.012mm, as
necessary to leave 0.025mm upon face for finish
grinding.
- 44 -
 Surface grinding operations
Grinding two vertical faces parallel and
central
This operation relates to the grinding of two vertical
faces parallel, square and central to a base, the face
and sides of the base having been previously finish
machined.

• Carefully handfeed cross traverse until the side of

the wheel makes light contact with the vertical
face.
• Turn on coolant.
• Apply 0.012mm cuts until face is cleaned up.
Note: A decreasing volume of sparks will indicate
when successive cuts should be applied.
To dress wheel: • Note cross traverse index reading.
• Dress face of wheel. • Cross traverse to clear the wheel from the face,
• Relieve and dress the sides of the wheel. stop longitudinal traverse and turn off coolant.
To measure workpiece: • Remove workpiece from chuck.
• Check width of tenon. Determine grinding
Measure workpiece as follows:
allowance. • Measure distance from side of base to vertical
• Check the position of the tenon relative to the base, face. Determine amount of material to be
and note direction of errors. removed.
• Check parallelism of face to side of base.
• Check width of tenon.
Re-set workpiece upon chuck.
Rough grind back vertical face as follows:
• Re-position the workpiece to the wheel, the wheel
being just clear of the vertical face.
• Engage longitudinal table traverse, turn on
coolant.
• Carefully cross traverse until wheel lightly
contacts vertical face.
• Check cross traverse index reading.
• Apply cuts to bring the face within 0.05mm of
Mount the workplace. finished size.
Note: The illustration shows use of the magnetic • When wheel clears end of workpiece stop
chuck and back plate. The back plate acts as a longitudinal table traverse, turn off coolant.
positional datum allowing the workpiece to be
removed from the chuck for inspection purposes and
reset in the true plane.
Set table traverse stops and ensure that the wheel will
fully clear vertical face.
Clean up back vertical face as follows:
• Using hand traverses, position wheel
approximately 0.5mm above horizontal face and
0.5mm from vertical face.
• Engage longitudinal table traverse.
• Downfeed wheelhead until the wheel makes light
contact with the horizontal face.

- 45 -
 Surface grinding operations
To clean up front vertical face:
• Note wheelhead index reading, raise
wheelhead.
• Hand traverse table to position wheel just clear
of front vertical face.
• Engage longitudinal traverse.
• Downfeed wheelhead to noted reading.
• Carefully cross traverse until wheel lightly Finish grind front vertical face as follows:
contacts vertical face, apply cuts to clean up • Note wheelhead index reading, raise wheelhead.
face. • Position wheel just clear of front vertical face,
• When wheel clears end of workpiece, stop engage table traverse.
table traverse, turn off coolant, note cross • Downfeed wheelhead to noted index reading.
traverse index reading. • Carefully cross traverse until wheel lightly
• Clear workpiece from wheel. contacts vertical face, note index reading and
• Remove workpiece from chuck. apply cuts of about 0.006mm to bring the face to
size. Allow wheel to spark out.

Measure workpiece and determine amount of

material to be removed from front face. The reset
workpiece upon chuck.
Rough grind front vertical face as follows:
• Re-position workpiece to the wheel.
• Engage longitudinal traverse, and cross
traverse until wheel lightly contacts vertical • When wheel clears end of workpiece, stop
face. longitudinal table traverse, turn off coolant and
• Check cross traverse index reading. position workpiece maximum distance from
• Apply cuts to bring the face within 0.05mm of
finished size. wheel.
• Stop traverse, turn off coolant. • Remove workpiece from chuck.
• Remove workpiece from chuck.
Measure workpiece to:
Dress wheel for finish grinding. • Determine position of tenon relative to the base.
• Check parallelism of tenon to the base sides.
Measure workpiece and determine amount of • Check squareness of tenon faces to the base.
material to be removed from each face, to bring the • Check tenon width. Check surface texture.
tenon central to the base and to size. Then reset
workpiece on chuck. Remove sharp edges and demagnetise workpiece.
SAFETY — When mounting or removing
!
work from machine, ensure that the work is
the maximum distance away from the wheel,
and that the machine is switched off.

Grinding an angular face

In most cases, faces having an angular relationship
Finish grind back vertical face as follows: are ground, using the principle as shown in the
• Position workpiece to the wheel, downfeed the illustrations. The selection of a method of holding
head to lightly contact horizontal face. and setting the workpiece, is dependant upon the
• Carefully cross traverse until wheel makes light angular accuracy required. The grinding procedure is
contact with vertical face, note index reading, and
apply cuts of about 0.006mm to bring the face to the same as for grinding a flat face.
size. Allow wheel to spark out.
• When wheel clears end of workpiece, stop
longitudinal traverse, turn off coolant.

- 46 -
 Surface grinding operations
Grinding slots
This type of operation calls for the grinding of two
vertical faces and a horizontal face, which are to be
parallel and square to datum faces and have been
previously finish-machined.
To select and mount grinding wheel:
• Wheel width should be less than the slot width.
• Wheel diameter should be large enough to prevent
job fouling under wheelhead.
To dress wheel for roughing out:
• Dress face of the wheel.
• Relieve and dress both sides.
Measure workpiece to:
• Check width of slot, determine allowance for
grinding.
• Check position of slot relative to the datum side.
Dress wheel for rough grinding. • Check depth of slot.
Measure workpiece to:
• Check angle between datum and face to be
ground. Note direction of errors.
• Check squareness of angular face to side face.
To mount workpiece:
• Select workholding device.
• Mount workpiece on workholding device, setting
the datum face in required angular position.
• Set table traverse stops.
• Touch down wheel to workpiece.

Select workholdlng method, and mount workplace

as follows:
• Switch off wheelhead motor.
• Visually align the datum side to the axis of table
movement.
• Mount dial test indicator to wheelhead, engage
stylus on datum side and adjust workpiece into
the correct plane.
To clean up the face:
• Remove minimum amount material. • Secure workpiece, re-check alignment.
• Stop traverse, clear wheel maximum distance from Set longitudinal table traverse stops and ensure that
workpiece. the wheel fully clears vertical faces at end of
traverse.
Measure workpiece:
• To check angle and squareness. Touch down wheel on horizontal face as follows:
• Where excessive error is found, adjust the setting • Position wheel central in the slot approximately
to correct; lightly re-grind the face and re-check. .4mm (.015in) above horizontal face.
Repeat as necessary to achieve the required • Start wheelhead motor, engage longitudinal
conditions. traverse.
Note: The angular accuracy requirements will dictate • Carefully apply downfeed until the wheel
whether the workpiece can be checked on or off the makes light contact with the face.
Machine.
To clean up horizontal face:
• Rough grind face. • Remove minimum amount material.
• Dress wheel for finish grinding. • Carefully use cross traverse to ensure that the
• Finish grind face. full width of face is cleaned up.
• Clear wheel from the workpiece, stop table
Measure workpiece to: traverse.
• Check angle. Measure workpiece to measure depth of slot and
• Check squareness. determine amount of material to be removed.
• Check surface texture. Then remove sharp edges.
- 47 -
 Surface grinding operations
• Working to the wheelhead index, apply .015mm
(.0005in) cuts and grind full width of horizontal
face to size.
• Using the cross traverse, bring the wheel into light
contact with the vertical face nearest the datum.
Note index dial reading.
• Apply cuts up to .015mm (.0005in) to bring the
vertical face to size. Allow wheel to spark out.

To rough grind horizontal face:

• Re-position wheel in slot, engage table traverse.
• Working to wheelhead index, apply cuts to bring
the face within .05mm (.002in) of finished size.
Clean up vertical faces as follows:
• Cross traverse table to bring the side of the wheel
into light contact with the vertical face nearest the
datum face. • Carefully cross traverse to bring the wheel into
• Apply cuts to clean up the face.
• Clear workpiece from wheel, stop table traverse. light contact with the opposite vertical face. Note
index dial reading.
Measure workpiece to: • Applying cuts up to .015mm (.0005in), grind slot
• Check width from ground face to datum face. to required size.
• Determine amount of material to be removed. • Clear workpiece from wheel, stop table traverse.
• Check width of slot.
• Check parallelism of face. Measure workpiece to:
• Check width of slot.
Then rough grind first vertical face to within .025mm • Check position of slot relative to the datum side.
(.001 in) finished size.
• Check parallelism of slot.
Clean up and rough grind second vertical face to • Check surface texture.
within .025mm (.001 in) finished size. Then dress Then remove workpiece from machine. Remove
wheel for finish grinding. sharp edges and demagnetise workpiece.

Measure workpiece to determine amount of material Grinding vees using a disc wheel
to be removed to bring the workpiece to size. All datum and auxiliary faces are previously ground
to size. Dress wheel for rough grinding.

Check workpiece as follows:

• Clean workpiece, remove any burrs.
• Check vee depth, note amount of material to be
removed.
• Check position of vee, relative to datum faces.
Note amount of material to be removed.

Position workpiece as follows:

• Select and set up appropriate workholding
device.
• Position workpiece in/on workholding device.
To finish grind slot: • Ensure vee is in alignment with wheel.
• Position wheel in slot, just clear of horizontal • Secure workpiece.
face. • Position workholding device at required angle, to
• Engage longitudinal traverse. bring one angle face parallel to machine table.
• Downfeed wheelhead until wheel makes light
contact with horizontal face, note dial reading.
- 48 -
 Surface grinding operations
• Position workpiece with the face with the largest
amount to be removed in the grinding position
and secure.
• Mark face with marking medium.
• Touch down onto workpiece to remove marking
medium.
• Apply .015mm (.0005in) per pass downfeed and
grind angle face to size. Allow to spark out. Note
dial reading.
• When wheel clears workpiece, stop traverse.
Grind opposite angle as follows:
• Remove workpiece and clean.
• Clean workholding device.
• Re-position workpiece in original position, with
To grind first angle face: unfinished angle in grinding position. Secure
• Position wheel approximately .8mm (.03in) over workpiece.
face. • Touchdown onto workpiece and apply .015mm
• Position edge of wheel over recess at the bottom (.0005in) per pass.
of the vee. • Grind face to exactly the same reading on dial as
Note: Ensure wheel edge is not touching the other when grinding other face. Allow wheel to spark
angle face. out.
• Switch on wheel and coolant. • When wheel clears workpiece, stop traverse.
• Start traverse and touch down on to workpiece
until sparks, or sound, indicate the wheel is To check workpiece:
grinding. • Remove workpiece and clean.
• Note wheelhead dial reading. • Remove any sharp edges wit a fine stone.
• Apply .025mm (.001 in) per pass and grind angle • Check size of vee relative to datum faces.
face to within .025mm (.001 in) of required size.
• When wheel clears workpiece, stop traverse. Grinding vees using a cup wheel
All datum and auxiliary surfaces are previously
To grind opposite angle face: ground.
• Remove workpiece and re-position in same place
in workholding device, with unground angle face
in grinding position.
• Touch down onto workpiece and note wheelhead
dial reading.
• Apply .025mm (.001 in) per pass downfeed and
grind angle face to within .025mm (.001in) of
required size.
Re-dress wheel for finish grinding.
Check workpiece as follows:
• Remove workpiece and clean. Dress wheel as follows:
• Check angle depth and position from datum faces. • Hold dressing stick, with both hands at one end.
• Note amount of error. • Position edge of dressing stick approximately on
centre line of wheel.
• With dressing stick at an angle of approximately
30°, apply inward pressure and move dressing
stick in and out.
• Continue action until angle meets periphery.
Position workpiece as follows:
• Select and set up appropriate workholding
device.
• Clean workpiece, deburr if necessary.
• Check vee angle and position of vee from datum
faces.
• Note amount of material to be removed.
• Position workpiece in workholding device and
To finish grind angles: secure.
• Clean workholding device. • Adjust workholding device to half the included
• Re-position workpiece in/on workholding device angle of vee, to bring angle face in the vertical
in the original position. position.
- 49 -
 Surface grinding operations

Rough grind first angle face as follows: To finish grind second angle face:
• Position wheel approximately .4mm (l/64in) • Remove workpiece and clean.
from face of angle, bottom edge of wheel in recess • Clean workholding device.
at the bottom of the vee. • Re-position workpiece on workholding device,
• Start wheel. unfinished angle in grinding position (vertical).
• Crossfeed table to feed workpiece onto wheel, • Crossfeed table, applying .015mm (.0005in) per
until sparks or sound indicate the wheel is pass, to exactly the same dial reading for first
grinding. angle face.
• Apply .025mm (.001 in) feed per pass and hand • When wheel clears workpiece stop feed.
feed workpiece across wheel. • Switch off wheel.
• Grind face to within .025mm (.001 in) of required • Remove workpiece and clean.
size.
• When wheel clears workpiece, stop feed. Finally, check finished vee for size and position.
• Switch off wheel.
Note: When hand feeding across wheel, ensure all the Grinding dovetails using a formed wheel
wheel is clear of the workpiece at either end. Workpiece should be milled before grinding takes
Rough grind second angle face as follows: place, and a sufficient grinding allowance left on.
• Remove workpiece and clean. The workpiece should be undercut in the
• Clean workholding attachment. dovetail corners.
• Position workpiece on workholding device, Before commencing to grind the dovetail, the
unground side vertical. workpiece is fully ground to size on all datum and
• Crossfeed table until sparks or sound indicate the auxiliary surfaces.
wheel is grinding the workpiece.
• Apply .025mm (.001 in) per pass and hand feed To dress wheel:
workpiece across wheel. • Relieve rear face of wheel.
• Grind face to within .025mm (.001 in) of required • Form required angle on wheel for rough grinding.
size. Ensure angle surface is wide enough to cover
• When wheel clears workpiece, stop feed. width of workpiece angle face.
• Switch off wheel. • Clean magnetic chuck.
To check position and size of vee: To position workpiece:
• Remove workpiece and check size and position of • Position a laminated block longitudinally up to
vee. back plate, approximately central on chuck.
• Note amount of material to be removed. • Check size of dovetails and mark or memorise
highest point.
To finish grind first angle face: • Position workpiece on magnetic chuck up to
• Mark angle faces with marking medium. laminated block.
• Re-position workpiece, so that angle with largest • Place a second laminated block in front of
amount to be removed is in grinding position (ie, workpiece. Ensure the laminated block is flush.
vertical). • Switch on chuck, check workpiece is secure.
• Crossfeed table until wheel removes marking
medium.
• Apply .015mm (.0005in) per pass and grind angle
to size. Note dial reading.

- 50 -
 Surface grinding operations
• Remove any burrs from surfaces which have been
ground.
• Clean magnetic chuck and replace workpiece in
the original position, to grind opposite dovetail.
Engage magnet.
• Position wheel just clear of base and angle faces.
• Switch on wheel and coolant, touch down onto
base and angle face.
• Grind dovetail, to exactly the same dial readings
used when grinding the first dovetail.
• When wheel clears workpiece, stop traverse.
• Switch off wheel and coolant, remove workpiece.
To check workpiece, check depth of dovetail, also
distance over dovetail. Note amount to be
Position wheel over high point in dovetail removed.
approximately 6mm (.25in) from angle and base face Note: Amount to be removed over dovetail distance
of dovetail. will be half each side.

Set machine traverse stops and position and set

longitudinal stops.

To rough grind dovetail:

• Clean magnetic chuck and replace workpiece in
Touchdown onto workpiece as follows: the same position on magnetic chuck.
• Switch on wheel and coolant, position stream • Touchdown wheel onto base and angle face.
between wheel and workpiece. • Crossfeed wheel .015mm (.0005in) per pass to
• Carefully wind across feed until sparks, or sound,
indicate the wheel is touching dovetail base. give finished depth size, .05mm (.002in). Note
• Carefully downfeed wheel until sparks, or sound, dial' reading.
indicates the wheel is touching dovetail angle. • Downf eed wheelhead .015mm (.0005in) per pass
• Apply crossfeed of .015mm (.0005Sin) per pass, to grind axle to size, ie, half amount required plus
until dovetail base has cleaned up. .05mm (.002in). Note dial reading.
• Apply downfeed .015mm (.0005Sin) per pass • When wheel clears workpiece, stop traverse and
until angle has cleaned up. Note both dial coolant.
readings.
• When wheel clears workpiece, stop traverse. To rough grind opposite dovetail:
• Switch off wheel and coolant. • Switch off magnet and remove workpiece,
remove any burrs with a dressing stick.
• Re-position workpiece in the original place on
magnetic chuck, with previously ground dovetail
downwards.
• Touch down onto base and angle face, grind to
previous dial readings. When wheel clears
workpiece, stop traverse.

Touchdown on opposite dovetail as follows :

• Switch off magnet and remove workpiece. - 51 -
 Surface grinding operations
Align workpiece parallel to wheelhead.
Set machine stops and position and set machine
longitudinal stops.

To finish grind workpiece:

• Re-position workpiece on magnetic chuck and
mark dovetail with a marking medium. To rough grind radius:
• Switch on wheel and coolant, start traverse. • Position workpiece edge central in wheel radius
• Touch down onto base to remove marking just clear of wheel.
• Switch on wheel and start traverse.
medium. • Carefully feed wheel down onto workpiece.
• Touch down onto angle face to remove marking • Apply .025mm (001 in) per pass downfeed until
medium. radius starts to blend in with top surface of
• Crossfeed .015mm (.0005in) per two passes and workpiece.
grind base to tolerance. Note dial reading. • Apply crossfeed of .025mm (.00lin) per pass onto
• Downfeed wheelhead .015mm (.0005in) per two workpiece until radius starts to blend in with side
passes and grind angle face to traverse. Note dial surface.
reading. • When wheel clears workpiece, stop traverse and
switch off wheel.
• When wheel clears workpiece stop traverse.
• Switch off coolant, remove workpiece. Re-dress wheel

Finish grind opposite dovetail as follows:

• Remove any burrs with a dressing stick.
• Clean chuck. Replace workpiece in the same
position on chuck with previously ground
dovetail downwards.
• Position wheel just clear of base and angle faces.
• Touch down onto base face and angle.
• Finish grind to exactly the same dial readings
observed when finish grinding the other dovetail.
• When wheel clears workpiece, stop traverse.
• Switch off wheel and coolant, remove workpiece
and clean.
Finish grind radius as follows:
Check finished size of all dimensions of dovetail with • Check visually.
• Mark radius area with marking medium.
appropriate measuring instruments and rollers. • Switch on wheel and start traverse, carefully
blend wheel radius onto workpiece radius.
Grinding radii • Downfeed .015mm (.0005in) per two passes until
top of radius starts to meet top surface of
workpiece.
Grinding male radii To dress wheel: • Downfeed .003mm (.0001 in) per two passes until
• Set up radius attachment for required radius. radius has blended in with top surface.
• Form radius on wheel for rough grinding. • Apply .015mm (.0005in) crossfeed per two
passes, over workpiece, until radius starts to meet
To position workpiece: side face.
• Select and set up appropriate workholding • Apply .003mm (.0001 in) crossfeed per two
attachment. passes until radius blends with side face.
Note: When aligning wheel radius with work radius,
• Clean workpiece and place in/on workholding prior to finish grinding, place a piece of white paper
device. or card behind the two radii; this will aid vision when
the radii are mating, as no light should be seen
- 52 - between the two radii.
 Surface grinding operations

To check workplace, clean and check radius with Re-dress the wheel to finish grind radius:
gauges. • Mark radius area with marking medium.
• Switch on wheel, start traverse. Carefully blend
Grinding female radii To dress wheel: wheel radius onto workpiece radius. Crossfeed
• Set up radius attachment for required radius. until wheel touches vertical face of radius.
• Form radius for rough grinding. • Downfeed .015mm (.0005in) per pass until
radius is ground. Note dial reading.
To position workpiece: • Check size of radius with appropriate measuring
• Select and set up appropriate workholding device. Note error.
device. • Finish grind radius to size, applying .003mm
• Clean workpiece and place in/on workholding (.0001 in) per pass.
device. • When wheel clears workpiece, stop traverse.
• Switch off wheel.
Align workpiece parallel to wheelhead. Set machine • Remove workpiece.
stops.
To check workpiece, clean workpiece and check
radius with gauge.
! SAFETY - Always wear closed-in type
safety glasses.

Note: When grinding radii extreme care should be

taken when blending radius onto side or top faces.

Grinding forms
In most cases the form required will have been
previously milled to shape with a grinding allowance
left on. All datum and auxiliary faces are ground
To rough grind radius: before form grinding.
• Position workpiece edge central in wheel radius
just clear of wheel. Select appropriate wheel for form grinding and dress
• Switch on wheel and start traverse. form on the wheel for rough grinding.
• Carefully feed wheel in to workpiece.
• Apply a crossf eed of .025mm (.001 in) per pass To position workholding device, select and set up
until radius starts to blend in with side face of appropriate workholding attachment and clean.
workpiece.
• Apply a downf eed of .025mm (.001 in) per pass To check and align workpiece:
until radius starts to blend in with side face of • Check workpiece form relative to datum face(s).
workpiece. • Visually align workpiece form with form on
• When wheel clears workpiece stop traverse and wheel.
switch off wheel. • Position form in line with wheel using dial
indicator.

Set machine stop and position and set longitudinal

stops.

- 53 -
 Surface grinding operations

Touch down onto workpiece as follows: Finish grind form as follows:

• Position wheel just clear of form. • Mark form with marking medium and align wheel
• Carefully lower wheel and visually mate wheel visually with form on workpiece.
form with form on workpiece. • Switch on wheel and coolant, start traverse.
• Lift wheel just clear and switch on wheel and • Carefully feed down wheel to touch down onto
coolant. form to remove marking medium. Note dial
• Start traverse and applying .015mm (.0005in) per reading.
pass. Grind workpiece until form is cleaned up. • Downfeed wheel and grind form .015mm
• When wheel clears workpiece stop traverse and (.0005in) per pass to size. Allow to spark out.
switch off wheel and coolant. • When wheel clears workpiece, stop traverse.
• Clean workpiece and check form with gauge. • Switch off wheel and coolant.
Note: Only remove workpiece when absolutely • Remove workpiece, clean and check finished
necessary. If possible check on machine. form.
• Adjust form position/form on wheel if necessary. Note: Always ensure wheel form is in line with form
Note: If form, or form position are altered, re-touch on workpiece before commencing grinding.
SAFETY — Always wear closed-in type
down and grind form. Check workpiece again for
position and correct form. Adjust, grind, and check
! safety glasses.
until correct. Slitting and cutting
Select wheel as follows:
• For slitting and cutting an elastic type wheel is
used.
• The diameter of the wheel should be such as to
allow for full depth of cut when slitting or cutting
fully through the workpiece.

To rough grind workplace:

• Mark form with marking medium and line wheel
form, visually, with form on workpiece.
• Switch on wheel and coolant, start traverse.
• Touch down onto workpiece to remove marking
medium. Note dial reading.
• Downfeed .025mm (.001 in) per pass and grind To mount and dress wheel:
depth to within .05mm (.002in) of finished size. • As these wheels are very thin, extreme care
Allow to spark out. should be taken when mounting the wheel.
• When wheel clears workpiece stop traverse and
coolant. • Hold dressing stick at extreme points with both
• Remove workpiece from chuck. hands and touch centre of dressing stick to wheel.
To re-dress wheel: • Hold dressing stick square and rigid to wheel,
• Re-dress form on wheel for finish grinding. apply very slight pressure.
SAFETY — Extreme care must be taken
• Switch off wheel.
• Re-set workpiece on chuck.
!when using the dressing stick to avoid risk of
wheel bursting.
- 54 -
 Surface grinding operations

Position workpiece as follows: Grind slit as follows:

• Select and set up appropriate workholding • Switch on coolant and continue downfeed of
device. wheel to required depth.
• Visually position wheel up to workpiece face • Downfeed .025mm (.001 in) per pass until slot is
where slit is required. approximately 1.6mm (.06in) deep, then increase
• Place rule up to wheel face and measure distance to .05mm (.002in) per pass.
to slit from edge of workpiece. Note: A small amount of downfeed is advisable when
• Wind crossfeed, to position wheel correct starting slitting.
distance from datum face, and lock cross SAFETY — Do not move crossfeed when
traverse. ! wheel is cutting or the wheel will break.
Note: If clamping is selected as a workholding
method ensure the work is held securely on both
sides of slitting area.
To set machine stops, position and set longitudinal
machine stops so that the vertical centre line of the
wheel is approximately 1.5mm (.06in) past each end
of the workpiece.

To cut off the same setting up and positioning of

wheel as when slitting is followed except:
• Continue with .05mm (.002in) downfeed of
wheel per pass until wheel is within .8mm (.031
in) of breaking through workpiece.
• Downfeed .015mm (.0005in) per pass until wheel
breaks through.
Touch down onto workpiece as follows: Note: To ensure wheel is cutting correctly,
• Switch on wheel, longitudinal traverse and periodically dress wheel diameter with dressing
coolant. stick.
• Carefully feed wheel down until sparks (or
sound) indicate the wheel is grinding. Plunge cutting
• Note dial reading. This method is used on small diameter or small
• Stop traverse when wheel clears workpiece. sectioned workpieces.
• Switch off coolant and re-check position of slit. Select a resinoid elastic wheel.
Mount and dress wheel using the same method as in
traverse slitting and cutting.

- 55 -
 Surface grinding operations
To position workpiece:
• Choose and set up appropriate workholding
! safety
SAFETY — Always wear closed-in type
glasses.
device.
• Mark position on workpiece where cutting is Grinding thin plate
required.

Position wheel as follows:

• To side of workpiece so that lower edge of wheel
will be under lower edge of workpiece.
• Up to workpiece at approximate positon where
cut is required.
• Measure from edge of wheel to outside edge of
workpiece to obtain correct position of cut.

Dress wheel for rough grinding.

To set workpiece:
• Check workpiece for burrs, and clean.
• Place convex side of workpiece onto magnetic
chuck.
• Place steel shim under workpiece, where
necessary, so that the workpiece will not rock.
• Attach dial test indicator onto the wheelhead with
stylus engaged on face of workpiece to obtain
reading.
To cut workpiece: • Wind the table to move dial indicator to each
extreme of workpiece, noting the position, and
• Switch on wheel and coolant. reading, of each high spot.
• Hand feed workpiece to touch wheel and check • Adjust packing to obtain not more than .05mm
position of cut. (.002in) error of reading on top of high spots.
• Hand feed table so that wheel cuts off required
piece of work. Then position and set table stops.
Note: If a quantity of workpieces are required to be To touch down onto workpiece:
cut, a stop can be positioned on the machine table, or • Line wheel over one of the highest spots.
workholding attachment, so that the workpieces can • Switch on wheel, turn on coolant, and start
all be positioned in the same place. traverse.
• Downfeed wheelhead until sparks (or sound)
indicate that the wheel is touching highest point.
Note wheelhead dial reading.

To set up work stop:

• Position workpiece vice, using shaped vice-grips.
• Position wheel ready to cut workpieces.
• Position work stop attachment onto machine table
or workholding attachment.
• Position workpiece against stop, cut slot Grind face of workplace as follows:
through. • Apply downfeed of .015mm (.0005in) and grind
• Position next workpiece in workholding high spots.
attachment and slide workpiece up to stop. • Continue adding .015mm (.005in) feed until
Note: Using a work stop avoids marking the position ground area is larger than dented surfaces.
of the slit on all workpieces. - 56 -
 Surface grinding operations
• Stop traverse when workpiece is
suitably ground.
• Switch off wheel and coolant, remove workpiece
from chuck.

To finish grind opposite side:

• Place finish ground side onto chuck, in
sameposition.
• Position wheel over previously ground surface,
Touch down on opposite face as follows: start traverse, downfeed wheelhead until wheel
• Remove workpiece, turn over and place on touches workpiece. Note index reading.
magnetic chuck in same position as when • When wheel clears workpiece, add .015mm
grinding first side. (.0005in) and grind workpiece.
• Check workpiece for highest spot and mark or • Continue this process until workpiece is ground
memorise. to the size required.
• Place steel shim under workpiece, where • Stop traverse when wheel clears workpiece after
necessary, to prevent rocking and switch on surface is fully ground.
magnet. • Switch off wheel and coolant.
• Position wheel over highest spot. Switch on • Remove workpiece and check size.
wheel traverse and coolant. Note: When grinding thin sheet, only take .015mm
• Downfeed wheelhead until sparks or sound (.0005in) cuts with wheel.
indicate the wheel is grinding. Note index
reading. ! SAFETY - When removing workpiece from
chuck keep fingers clear of sharp edges.
• Grind face of workpiece at that setting.

Grind face of workpiece as follows:

• When wheel clears workpiece add .015mm
(.0005in) and grind workpiece.
• Continue this procedure until all workpiece
surface is ground.

Then re-dress wheel for finish grinding. To finish

grind the face:
• Touch down onto workpiece. Wind wheel clear of
workpiece, add .015mm (.0005in).
• Full finish grind workpiece surface.
• Stop traverse when wheel clears workpiece.
• Remove workpiece and check amount of metal to
be removed.

- 57 -
Cylindrical grinding operations
Grinding parallel diameters up to a Start workhead, adjust speed as necessary. Start
shoulder wheelhead. Use hand traverse and feed wheel into
Check workpiece, measure diameter, establish workpiece very slowly until wheel makes light
grinding allowance. Check parallelism. contact with the workpiece. Note touchdown
SAFETY - Wear safety glasses. Stand to the
! side of the machine when starting wheelhead.
position, this will give an indication if table is set
parallel. Note: If taper was present when diameter
Start wheelhead and dress wheel (or 'roughing out'.
Stop wheelhead. was previously checked, wheel should touch highest
Mount workpiece as follows: point first.
• Clean workpiece.
• Position wheel clear of work area.
• Select method of holding workpiece, mount
workpiece.
• Check concentricity of workpiece, and that the
grinding allowance is sufficient for the diameter
to fully clean up.

Clean up diameter as follows:

• Hand feed wheel along the length of the
workpiece to remove all high spots.
• Start table traverse and apply coolant.
• Feed in about 0.005mm per pass until eccentricity
of diameter is removed.
• Allow cut to spark out. Allow wheel to clear
workpiece.
• Stop table traverse (wheel at tailstock end).
• Stop workhead and turn off coolant.
Set table traverse as follows: SAFETY - Ensure thai no loose clothing or
• Check table setting (parallelism). ! long hair can be trapped by revolving
• Traverse table and wheelhead to bring the working piece.
wheel just clear of workpiece diameter. Measure workpiece, check diameter and parallelism,
• Traverse table to bring the shoulder and check the diameter for ovality.
approximately 1.5mm from side of wheel. Adjust for parallelism. If unnecessary taper found
• Set traverse stop to trip reversing lever. retract wheel and adjust swivel table setting -
• Traverse table to allow for about one-third touchdown wheel at highest point. Clean up diameter
width of wheel overrun at the free end of and recheck. Repeat as necessary to achieve a parallel
workpiece. condition.
• Set traverse stop to trip reversing lever.
• Engage automatic table traverse and visually
check stop settings, adjust as necessary. Ensure
wheel will not foul shoulder or tailstock.
• Feed in wheel to within 0.50mm of diameter to be
ground. Finely adjust traverse stops as necessary.
• Stop table traverse.
Note: Select table traverse speed that will be used in
the grinding operation.

Rough grind diameter to within 0.05mm of finished

size as follows:
• Start workhead and engage table traverse.
• Set in-feed index to the amount the diameter is
oversize less 0.05mm, and set stop.
• Turn on coolant.
• Use manual or automatic in-feed to bring
workpiece to size (0.01mm per cut).
• Allow cut to 'spark out', clear workpiece from
wheel, stop workhead and table traverse.
- 58 - • Turn off coolant.
 Cylindrical grinding operations
Measure workpiece, check diameter and parallelism Note: Where it is known that a diameter and shoulder
and determine remaining grinding allowance. Dress are to be ground, the side of the wheel should be
wheel for finish grinding. relieved before roughing out the diameter.

To finish grind diameter: Ensure the side relief is sufficient to clear the
• Start workhead and table traverse. Adjust speeds shoulder diameter.
as necessary. Dress the wheel land.
• Feed wheel in until light contact is made, turn on
coolant. Rough grind shoulder to clean up.
• Set wheelhead index stop to bring diameter to Note: Table movement is now manually controlled,
finished size. and where possible the automatic table traverse
• Manually infeed approximately 0.005mm at each should be secured in the 'off position.
reversal of traverse. • Start workhead, adjust speed as required.
Note: After taking one or two finishing cuts, clear • Feed wheel in to within 012mm of finished
workpiece from wheel at free end, stop traverse and diameter.
wheelhead, measure the diameter and confirm stop
setting. Adjust as necessary.
• Re-start and feed wheel up to the stop position.
• Allow wheel to 'spark-out'.
• Clear workpiece from wheel, stop traverse and
workhead, turn off coolant.

Measure workpiece. Check that the diameter,

parallelism and surface texture are within drawing
requirements.
Remove sharp edges. Use a fine grade abrasive
stone.
Remove workpiece from machine.
Note: Generally, work of this nature has an undercut
at the shoulder. If an undercut is not present more
• Traverse the table to position the shoulder
frequent dressing of the wheel must take place to approximately 0.12mm from the wheel.
ensure a perfectly square corner. More care must also • Traverse table very slowly until the shoulder
be taken when setting the traverse stops. makes light contact with the wheel. Turn on the
coolant.
Grinding a shoulder • Holding the traverse wheel with the left hand to
With shouldered workpieces it is generally a act as a brake, gently tap in the wheel handle with
requirement that the shoulder be ground square to the the right hand to advance the face onto the wheel.
Note: Very small movement is necessary. Too heavy
axis of the diameter. In most cases this is a secondary cuts will tend to break down the wheel land.
operation and follows the grinding of the diameter. • Allow cuts to 'spark out'.
Finish grind diameter to size. Note final wheelhead • Clear workpiece from wheel and visually check
index reading. face has fully cleaned up. Take further cuts until a
Measure workpiece. Check lengths, determine satisfactory condition is achieved.
shoulder grinding allowance. • Traverse workpiece clear of the wheel, stop
Dress wheel. workhead, turn off coolant.

- 59 -
 Cylindrical grinding operations

General note: For a workpiece requiring this type Grinding parallel diameters and shoulders
of operation, the shoulder is generally undercut.
Where an undercut is not present, more frequent
dressing of the wheel must be carried out to
maintain a sharp corner.
Measure workpiece. Check shoulder
length, determine remaining grinding allowance.
Dress wheel. Apply slight angular relief to the land
on the side of the wheel.
SAFETY - Keep hands away from revolving
! workpiece at all times. Wear safety glasses.

To grind shoulder to length.

• Start workhead.
• Position wheel approximately 0.12mm clear of
the diameter. While the grinding of a parallel diameter and a
• Traverse table to bring the shoulder into light shoulder has been covered in previous sections, the
contact with the wheel. grinding of two or more diameters and shoulders
• Turn on coolant. involves a sequence of operations:
• Apply light cuts. Allow individual cuts to • Measure workpiece. Check all diameters and
lengths, determine grinding allowance.
'spark out'.
• Dress wheelface for roughing out. Relieve the
side of the wheel. Ensure sufficient relief to
clear shoulder diameters.
• Mount workpiece.
• Set table traverse stops.
Note: The use of the automatic table traverse will
depend upon the lengths of the diameters to be
ground. The illustration shows a workpiece with
short length diameters and in this case manual
traverse would be employed.
• Clean up small diameter. Check diameter and
parallelism. If unnecessary taper found, retract
wheel, adjust swivel table setting, lightly re-
Note: As the depth of cut cannot be determined grind the diameter and check for parallelism.
accurately while grinding, frequent stops must be Repeat as necessary to achieve a parallel
made and the length checked. As a guide, experience condition.
will show a relationship between a depth of cut and • Measure small diameter. Determine remaining
the volume of sparks produced. grinding allowance.
When very close to actual size, it may be advisable to • Rough grind small diameter to within .05mm
re-dress the wheel before taking the final cut. (.002in) finished size.
• Clear workpiece from wheel, stop workhead and
coolant.

Measure workpiece. Check length and surface

texture.
Remove sharp corner. Use fine grade abrasive
stone.
Remove workpiece from machine.

- 60 -
 Cylindrical grinding operations
Grinding between shoulders
Measure workpiece to check diameter and lengths
for grinding allowance, and to check parallelism of
diameter.

To dress wheel:
• Start wheelhead, dress face of wheel for roughing
out, relieve and dress lands on both sides of
wheel.
• Ensure sufficient relief to clear shoulder
diameter.
SAFETY — Wear gloves and safety glasses.
! Stand to the side of machine when
• Clean up small diameter shoulder. starting wheelhead.
• Measure length. Determine remaining grinding
allowance. To mount workpiece:
• Rough grind shoulder to within .025mm (.00lin) • Clean workpiece.
finished size. • Select workholding method and mount
• Clean up large diameter. workpiece.
• Measure large diameter. Determine remaining • Check concentricity, and whether grinding
grinding allowance. allowance is sufficient to 'clean up'.
• Rough grind large diameter to within .05mm • Check table setting (parallelism).
(.002in) finished size.

• Clean up shoulder. Rough grind diameter as follows:

• Measure length. Determine remaining grinding Note: If length is great between shoulders, traverse
allowance. stops should be set, but on small lengths use hand
• Rough grind to within .025mm (.001 in) finished traverse.
size. • Feed wheel into diameter between shoulders until
• Dress wheel for finish grinding. Dress face of touch down is made.
wheel. • Note touch down position to give indication of
• Dress land on side of wheel. parallel setting.
• Finish grind small diameter. • Adjust table if necessary.
• Finish grind small diameter shoulder. • Apply coolant.
• Finish grind large diameter. • Traverse wheel between, but not touching, the
• Finish grind large diameter shoulder. shoulders.
• Measure workpiece. Check all ground • Check diameter for parallelism and adjust table if
dimensions and surface texture. necessary.
• Remove sharp corners. • Grind diameter to size plus .025mm (.001in).
• Remove workpiece from machine. Note: If adjustment of the table is necessary, slightly
retract the wheel before making adjustment.

- 61 -
 Cylindrical grinding operations

Clean up shoulders as follows: Finish grind diameter as follows:

• Retract wheel slightly from diameter. • Apply very small cuts to take diameter to size.
• Position wheel within .25mm (.0l0in) of one • Grind diameter right up to shoulders.
shoulder. • Grind diameter to top limit (eg, for 25mm (lin)
Note: If a datum face has already been ground, grind ± 0.025mm (0.00 lin), grind to 25.025mm (1.00
the shoulder that will be easiest to measure from the lin)).
datum first.
• Touch wheel to shoulder by gently tapping Finish grind shoulder faces as follows:
handwheel by hand. • Retract wheel 0.12mm (0.005in) from diameter.
• Hold handwheel steady with one hand and tap on • Touch wheel to the shoulder with the
small amount of cut with other hand. measurement from datum face.
• Allow cut to almost 'spark out' before applying • Apply light cuts to grind shoulder to size.
another. Note: Use density of sparks as a guide for stock
Note: Density of sparks indicates amount of cut. removal.
• Repeat until shoulder face has fully cleaned up - • Check size of shoulder.
see shiny surface all round face. • Wind table across longitudinally and grind width
• Wind table longitudinally and repeat operation between shoulders to drawing dimension.
onother shoulder. Note: Frequent checking of the shoulder dimensions
Note: If the workpiece is between centres and a will be necessary in this type of operation.
spring loaded tailstock centre is used, grind shoulder
toward headstock, and reverse the workpiece in the General note: On workpieces requiring operations
centres and grind the other shoulder. such as this an undercut at 45° is usually present in
the corner, between shoulder and diameter. If,
To measure workpiece: however, no undercut is present, more frequent
• Clear shoulder from wheel. dressing of the wheel may have to take place to
• Stop workhead. maintain a sharp corner in the shoulder.
• Check lengths and distances as necessary,
establish amount of material to be removed from Grinding a workpiece mounted on a
each face. mandrel
To rough grind face: This is a convenient and accurate method of
• Grind face nearest to datum to size plus 0.025mm mounting bored workpieces for grinding. The
(0.001 in). concentricity of the finished workpiece diameters is
• Grind distance between shoulders to size minus dependent upon the true running of the mandrel
0.05mm (0.002in). between the centres, and the degree of fit between
mandrel and workpiece. Standard mandrels have
To re-dress wheel: approximately .05mm (.002in) taper in a 230mm
• Dress wheel periphery for finish grinding. (9in) length. The grinding procedure is identical to
• Dress sides of wheel to ensure sharp corners. that for grinding a parallel diameter.

To measure workpiece:
• Check diameters and parallelism, determine
grinding allowance.
• Select mandrel to suit bore.

- 62 -
 Cylindrical grinding operations
Then dress wheel for roughing out. Set centre To mount workpiece:
distance. • Clean workpiece.
• Select workholding method and mount
workpiece.
• Check concentricity.

To mount workpiece:
• Check true running of mandrel between centres.
• Mount workpiece upon mandrel, ensure secure fit.
• Clean and lubricate centres. Position workpiece relative to wheel, then:
• Mount the assembly between centres. • Start workhead.
• Check movement between driving pin and • Traverse table to bring workpiece within 3mm
carrier. (.125in) of shoulder.
• Feed in wheelhead to bring the wheel within
Then set table traverse stops and check swivel table .5mm (.02in) of diameter to be ground.
setting. • Traverse table to bring workpiece shoulder just
clear of wheel.
Clean up diameter as follows: • Lock table in position.
• Remove minimum material. Touch down wheel on workpiece, then:
• Apply small infeed. • Feed wheelhead in slowly until contact is made.
• Where table setting is obviously wrong, adjust Note: A swishing sound will indicate when the
setting. wheel is approximately within .100mm (.005in) of
Note: Heavy infeed may tend to move the workpiece diameter.
upon the mandrel, causing the workpiece to spin • Note wheelhead index reading.
upon the mandrel in some cases. • Turn on coolant.
To clean up diameter:
• Measure workpiece to check diameter, • Slowly infeed wheel until diameter is cleared.
parallelism, and to determine grinding allowance • Note wheelhead index reading.
remaining. • Retract wheel, turn off coolant and stop
SAFETY — Where movement of workpiece is workhead.
observed, stop machine immediately • Measure diameter and check parallelism. Note:
and re-secure workpiece to mandrel. If the diameter is tapered, adjust table setting,
and repeat procedure as above until parallel
• Rough grind diameter to within .05mm (.002in) condition is achieved. Remove minimum
finished size. material.
• Dress wheel for finish grinding.
• Finish grind diameter to size.
• Measure workpiece to check diameter,
parallelism and surface texture.
• Remove sharp corners.
• Remove workpiece from machine.
• Remove workpiece from mandrel.

Plunge grinding a parallel diameter

To measure workpiece:
• Check diameter for grinding allowance.
• Check parallelism of diameter.
To finish dress wheel: To grind diameter to size:
• Start wheelhead and dress side and face of wheel. • Infeed wheel to contact diameter, check contact
Stop wheelhead. index reading.
• Move work area maximum distance from wheel. • Set index stop plate, to allow for sizing of
workpiece.
• Infeed wheelhead to the stop, and allow to 'spark
- 63 - out'.
 Cylindrical grinding operations
Retract wheel, turn off coolant and stop Mount workpiece as follows:
workhead. • Ensure workhead and tailstock centres are clear
and in good condition.
• Set centre distance.
• Engage carrier securely on workpiece.
• Examine, clean and lubricate centres in
workpiece.
• Mount workpiece between centres.
• Set driving pin to engage in carrier.

• Check diameter, parallelism and surface texture.

Note: If the diameter is incorrect, adjustment of the
stop is necessary, and the procedure above must be
repeated.

To set table traverse stops:

• Set left traverse stop to reverse traverse when
wheel is approximately 25mm (lin) clear of
carrier. l
• Set right traverse stop to allow /3 wheel overrun
at the free end.
• Check swivel table setting, adjust as necessary.
• Start wheelhead and remove sharp corner on To clean up diameter:
workpiece with carborundum stone. • Remove minimum of material.
• Stop wheelhead and remove workpiece from • Where table setting is obviously wrong, adjust
setting.
machine. Measure workpiece as follows:
Note: Generally work of this nature is undercut at the • Check diameter, determine remaining grinding
shoulder. If no undercut is present the wheel should allowance.
be re-dressed to remove the last .05mm (.002in) if a • Check parallelism.
square corner is required. • Adjust table setting as necessary, lightly re-grind
SAFETY — As wheel and workpiece are very diameter and re-measure.
! close together, extreme care must be taken • Repeat as necessary until a parallel condition is
when measuring diameter of workpiece. received.
Then rough grind diameter to within .05mm (.002in)
Grinding a cylinder finished size. Note index reading.
The grinding of a cylinder presents the problem of
holding and driving the workpiece in a manner that
will enable the full length of the diameter to be
ground in one setting. This can be achieved by the
use of a false centre which can ultimately be
removed, or by using a driving pin screwed into the
end face of the cylinder. The example shows,
however, an approach to the problem using the
reversal of the workpiece between centres. The
grinding procedure is similar to that for grinding a
parallel diameter.
To measure workpiece:
• Measure diameter and determine allowance for
grinding. To reverse workpiece between centres:
• Check parallelism. • Remove workpiece from machine.
• Remove carrier, and securely replace on opposite
Then dress wheel for roughing out. end of workpiece.
- 64 -
 Cylindrical grinding operations
Note: Protect ground diameter with a piece of soft • Measure workpiece to check diameters, lengths
material. and taper.
• Clean and lubricate centres in workpiece. • Then dress wheel for roughing out.
• Re-set workpiece between centres. • Mount workpiece.
• Using a dial test indicator, check true running of • To set swivel table, swing table through required
workpiece. angle, ie, half the included angle of taper.
• Then set table traverse stops.
Note: Where error is noted, this is probably due to a • To clean up diameter, remove minimum amount
faulty centre condition. Clean and examine centres. material and adjust table setting if obviously in
error.
To measure workpiece:
• Check taper (and diameter at datum position if
required) and adjust table setting as necessary,
regrind and re-check until satisfactory condition
is achieved.

Rough grind remaining length to within .05mm

(.002in) of finished size. Adjust left traverse stop so
that the wheel just clears ground length.
Then dress wheel for finish grinding.
To finish grind diameter to size:
• Thoroughly clean centres and lubricate.
• Re-set left traverse stop to original position.
To reverse workpiece between centres: • Rough grind to within .05mm (.002in) finished
• Thoroughly clean centres and lubricate. size.
• Adjust left traverse stop so that the full width of • Dress wheel for finish grinding.
the wheel just clears the length to be ground. • Finish grind diameter to size.
• Mount dial test indicator and check true running. • Measure workpiece to check taper, diameter
Finish grind diameter to size as follows: and surface texture.
• When within .012mm (.005in) of finished • Remove sharp corner.
diameter reduce the in-feed rate down to about • Remove workpiece from machine.
.003mm (.0001 in).
• Measure workpiece frequently. Grinding fast tapers
Then remove sharp corners. The term 'fast' relates to tapers with angles outside
Finally remove workpiece from machine. the range that can be accommodated by the swivel
Grinding slow tapers table adjustment.
The term 'slow' relates to tapers which can be There are three methods of producing fast tapers
accommodated within the table swivel movement. on a cylindrical grinding machine. They are:
The grinding procedure is similar to that for grinding • By turning the wheelhead to the required
a parallel diameter, with the additional requirement degree setting and presenting the flat periphery
that the swivel table is swung through an angle of the wheel to the workpiece angle.
corresponding to half the included angle required. • By dressing the required angle on the grinding
wheel and then presenting the wheel square to
the workpiece.
• By turning the workhead the required number
of degrees, so that the taper is presented parallel
to the periphery of the wheel.

- 65 -
 Cylindrical grinding operations
Method (a) - Setting the wheelhead Method (b) - Forming the wheel
To prepare workplace, finish grind all diameters and To prepare workpiece:
shoulders. • Finish grind all diameters and shoulders.
• Remove workpiece from centres.

To set wheelhead angle:

• Stop wheelhead and isolate machine. Dress angle as follows:
• Loosen nuts on base of wheelhead. • Set wheelhead to required angle.
• Turn wheelhead required number of degrees. • Ensure angle will be formed on the correct side ol
• Tighten all nuts on wheelhead base. the wheel.
SAFETY - Wind wheelhead as far back as SAFETY - Ensure wheel stationary when
! possible, so as not to foul wheel on ! setting the wheelhead.
machine table. • Rough out angle with dressing stick.
• Ensure diamond is set on centre line of wheel
spindle, and finish dress angle.
Note: Dress smallest possible length of angle or
wheel,
1
ie, if length of taper on workpiece is 12mm
( /2in) dress 14mm (9/16in) length of angle or
wheel.
• Set wheelhead back to zero.
SAFETY - Ensure wheel stationary when
! setting the wheelhead.

Clean up taper as follows:

• Wind in wheel to within .8mm (.03in) of taper
diameter.
• Visually check that gap between wheel and taper
is parallel.
• Start wheelhead and workhead.
• Slowly feed in wheel until touch down is made.
Note: Fast tapers, short in length, can be plunge
ground. Clean up taper as follows:
• Apply a light infeed until taper has been cleaned • Line up wheel angle to that on workpiece.
up. • Infeed wheel to within .8mm (.03in) of taper.
Then measure taper to check angle and determine • Visually check that gap between wheel and
amount of material to be removed. taper is parallel.
• Start wheelhead and workhead.
Grind taper to size as follows: • Slowly feed in wheel until touch down is made.
• Apply light infeed to wheel visually checking • Apply a light infeed until taper has been
that full wheel width is in contact with taper. cleaned up.
• Continue infeed until required amount is
removed from workpiece. Then check taper.
Note: When grinding fast tapers, the infeed index
reading must be virtually ignored for amount of To grind taper to size:
stock removal. • Apply a light infeed to wheel.
• Continue infeed of wheel until taper is size.
- 66 -
 Cylindrical grinding operations
Method (c) - Setting the workhead Grinding radii
To prepare workpiece, finish grind all diameters and While both male and female forms can be ground,
shoulders. the illustration is a typical example of a workpiece
requiring a radiused corner. The grinding procedure
is similar to that for grinding a diameter and
shoulder.
Measure workpiece to check diameter, parallelism,
radius on workpiece and determine grinding
allowance.
Dress wheel for roughing out as follows:
• Dress face of the wheel. ',
• Slightly relieve the side of wheel.
• Dress radius on wheel using dressing stick or
radius attachment.
Note: Rough out large radii with the dressing stick
and finish dress with the attachment.
Then mount workpiece.
To set table traverse stops, set and adjust shoulder
To set workhead angle: stop so the wheel is just clear of the shoulder face and
• Wind table longitudinally to move workhead as radius.
far from the wheel as possible. Rough grind diameter to within .05mm (.002in)
• Stop wheelhead and workhead. finished size.
• Loosen workhead securing nuts.
• Swivel workhead to required angle.
• Tighten locking nuts.
Then dress wheel.

To clean up radius and shoulder:

• Note wheelhead index reading and retract wheel
approximately .125mm (.OOSin).
• Hand traverse table, to bring the wheel into light
To clean up taper: contact with radius.
• Wind table to align wheel to taper. • Turn on coolant.
• Wind in wheel to within .8mm (.03in) of taper to • Hand tap on cuts until the shoulder and radius are
diameter. cleaned up.
• Visually check that gap between wheel and taper • Traverse the table to clear the side of the wheel
is parallel. from face, and feed wheel in to roughing out index
• Start wheelhead and workhead. reading.
• Slowly feed in wheel until touch down is made. • Bring the side of the wheel into light contact with
• Apply a light infeed until taper has cleaned up. the radius, apply cuts until full shoulder face is
Then check taper. ground.
• Clear wheel from workpiece, stop workhead and
To finish grind workpiece: coolant.
• Apply a light infeed of wheel and wind wheel Measure workpiece to check lengths and radius.
across taper longitudinally. Note: If taper is Rough grind radius and shoulder to within .025mm
long, stops should be set. (.001 in) finished length.Dress face and radius on
• Continue infeed of wheel until required wheel.
dimensions are achieved. Finish grind diameter to size, then finish grind radius
and shoulder, using hand traverse and taking light
General note: After an operation such as this, when
the angle of the workhead is moved, the centres cuts.
between the workhead and tailstock should be Finally, measure workpiece, remove sharp corners
realigned. and remove workpiece from machine.
- 67 -
Internal grinding operations
The universal grinding machine may be adapted for Mounting the grinding wheel
internal grinding by bringing a special spindle into
operation. This spindle is usually mounted at the rear
of the machine wheelhead and is brought into
position by swinging the wheelhead through 180°. It
is the general practice, however, to concentrate
quantities of internal grinding work on a purpose
built internal grinding machine. This machine
incorporates a table with workhead which carries the
chuck or other suitable workholding device. At the
other end of the machine is the wheel spindle with its
driving mechanism mounted on the cross slide. The
operating conditions imposed by internal grinding
requires the use of very small grinding wheels
operating at a high rate of RPM. This together with Note: Balance of the wheel is not required. To mount
the fact that part of the spindle may need to enter the wheel:
hole being ground makes the use of a range of special • Fit appropriate size paper washer to spindle
spindles necessary. spigot.
• Fit metal and paper washers to securing screw.
Selecting a grinding spindle Note: Ensure that washers are slightly smaller thanthe
Select largest diameter spindle possible, in relation to diameter of wheel recess.
the diameter of grinding wheel used. • Engage wheel on spigot.
Select shortest length of spindle consistent with the • Engage screw and tighten to secure wheel to the
length of bore to be ground. spindle. Note: Do not exert undue pressure.
Note: Use largest diameter and shortest length
spindle, in order to reduce to the minimum the Dressing the grinding wheel
spindle Position diamond attachment as follows:
deflection under cutting conditions. • Clean base of diamond attachment.
• Clean machine table.
Mounting the grinding spindle • Position attachment on machine table.
• Slide moving attachment back to clear wheel.
• Tighten attachment.
• Locate diamond in attachment, with minimum
overhang, and tighten.
Position diamond to wheel as follows:
• Wind table longitudinally until diamond is
approximately central to wheel length.
• Bring diamond point approximately .4mm (.01
Sin) from wheel.
• Tighten in position.

To prepare machine:
• Clean bore of internal grinding workhead.
• Ensure bore is free of burrs.
• Remove locknut.
Select spindle and check spindle taper is clean and Rough dress wheel as follows:
free of burrs. • Switch on wheel.
To mount spindle: • Wind in wheelhead to bring diamond into lightest
• Push taper of spindle into the barrel, slightly possible contact with wheel. Hear touch down
turning it to ensure a good seat. made and see line on wheel.
• Locate locknut and hand tighten. • Traverse the diamond across the wheel.
• Finally tighten locknut with 'C spanner. • Add .05mm (.002in) infeed.
• Traverse diamond with a fast even speed.
To check spindle concentricity, start spindle and • Continue infeed and traverse until wheel is free of
visually check concentricity. dull abrasive grain or clogging metal.
Note: If in doubt about amount of spindle run-out,
check with dial indicator.
- 68 -
 Internal grinding operations
Set table traverse stops as follows:
• Using hand traverse, position the wheel inside the
bore and set traverse stops to allow approximately
a third of the wheel length to overrun the ends of
the bore.
• Engage automatic table traverse and finely adjust
traverse stops as necessary.
To finish dress wheel: • Stop traverse, clear workpiece from wheel.
• Touch down wheel onto diamond.
Then dress wheel for roughing out.
• Rough dress wheel.
• Apply .015mm (.0005in) infeed.
• Slowly hand feed or traverse diamond across
wheel.
• To complete dressing of wheel make two passes
of .015mm (.0005in) and one or two idle passes.

Clean up bore as follows:

• Manually traverse table, to position the wheel
inside the bore.
• Select workhead speed, and start workhead.
• Engage table traverse.
• Infeed the wheel to make light contact with the
bore. Sound and sparks will indicate when contact
To dress front of wheel (this only applies to a is made.
recessed wheel):
• Hold dressing stick with both hands at one end.
• Position edge of dressing stick approximately on
centre line of wheel.
• With dressing stick at a suitable angle, apply light
pressure and move dressing stick backwards and
forwards across the face of the wheel.
• Continue action until required angle is obtained.
SAFETY — Safety glasses must be worn.
!
Grinding a parallel bore
Measure workpiece to check diameter and
parallelism of bore.
To mount workpiece:
• Select appropriate workholding method. Note: Having previously measured the bore, the
• Set the workpiece to run true. wheel should first contact the smallest diameter.
This will give some indication as to the table setting
Mount spindle and wheel as follows: for a parallel bore.
• Select and mount most rigid spindle. • Turn on coolant.
• Select and mount appropriate wheel (diameter • Apply infeed, to remove the minimum material
approximately two-thirds bore diameter). to clean up the bore.
• Allow the wheel to 'spark out'.
• Note index reading.
• Retract wheel, clear workpiece from wheel, stop
table traverse and workhead.
SAFETY - Before attempting to measure the
! bore, ensure maximum distance between
workpiece and wheel, and either the wheel
guard is in position or the spindle motor is
switched off.
- 69 -
 Internal grinding operations
To measure bore, clean and check size of bore and Measure bore of workplace to mount workpiece, to
parallelism. run true.
Note: If the bore is not parallel, the head or table must To mount spindle and wheel, select and mount a
be adjusted to correct this condition. After recessed type wheel, diameter approximately two-
adjustment, the bore must be lightly ground and then thirds of the bore diameter.
measured. This procedure is repeated until a parallel Note: Ensure that the securing screw head is well
condition is achieved. Note final index reading. below the wheel face.
Dress wheel for roughing out.
Rough grind bore as follows: Set table traverse stops as follows:
• Start workhead and table traverse. • Stop wheel.
• Re-touch the wheel to the bore and check index • Measure the distance from the centre of the
reading.
• Set the index feed stop, to allow for the removal of undercut to the front face of workpiece.
grinding allowance less .05mm (.002in) for finish • Measuring from the front face of the wheel mark
grinding. this distance on wheel spindle.
• Apply .025mm (.001 in) - .05mm (.002in) for • Manually traverse to position the grinding wheel
finish grinding. inside the bore, and traverse table until the mark
• Apply .025mm (.001 in) - .05mm (.002in) infeed on the spindle is approximately 6mm (V4in) away
until index stop is reached. from the face of the workpiece.
Note: Sound, or volume of sparks, will indicate when • Set and secure the table traverse stop against the
to apply infeed. trip lever. The trip lever must be in the fully
• Allow wheel to 'spark out'. reversed position.
• Retract wheel, clear workpiece from wheel, stop • Traverse table to allow approximately one-third
table traverse and workhead. wheel length to overrun the open end of the bore.
• Set and secure traverse stop.
Then measure bore to determine remaining grinding • Engage automatic table traverse, and sighting
allowance. across the face of the workpiece, finely adjust the
Dress wheel for finish grinding. head traverse stop so that the table reversal
To finish grind bore: position brings the mark on the spindle in line with
• Start workhead and table traverse. Adjust speeds as the face of the workpiece.
required.
• Lightly touch wheel to the bore. To clean up the bore:
• Note index reading. • Remove minimum amount of material.
• Working to the feed index reading, apply light feed
and grind bore to size. • Check that the wheel is grinding fully up to the
• Allow wheel to 'spark out'. undercut.
• Clear workpiece from wheel, stop traverse and
workhead. Measure bore and parallelism and:
• Adjust for parallelism as necessary, take further
Measure bore to check size, parallelism and surface light cuts, check bore, until parallel condition is
texture. achieved.
Note: Ensure workpiece is at normal temperature • Note final index reading.
when taking final measurement.
Remove sharp corners using a fine abrasive stone. Rough grind bore to within .05mm (.0002in) of
Finally, remove workpiece from machine. finished size.
Dress wheel for finish grinding and ensure square
Grinding a bore up to a shoulder corner on front edge of wheel.
The grinding of this type of workpiece very closely
follows the procedure for grinding a parallel bore. The To finish grind bore to size:
table traverse must be finely adjusted to allow the • Apply light infeed, approximately .005mm
wheel to overrun the edge of undercut without coming (.0002in).
into contact with the face of the shoulder. • When within .015mm (.0005in) of finished size as
indicated by the index reading, clear workpiece
from wheel and check bore. Verify amount of
material still to be removed.
• Ensure that the bore is parallel up to the undercut.
• Dress wheel if necessary.
• Finish grind bore to size.
• Allow wheel to 'spark out'.
• Clear workpiece from wheel, stop traverse and
workhead.
Measure bore to check diameter, parallelism and
surface texture.
Remove sharp corner on workpiece using a fine grade
abrasive stone.
Finally, remove workpiece from machine.
- 70 -
 Internal grinding operations
Grinding a bore and a shoulder To grind shoulder face:
For this particular requirement two procedures are • Start workhead.
adopted. Firstly the bore is ground to size as covered • Working to the infeed index, position the wheel
in the previous section, and secondly, a procedure is to clear the finished bore diameter by
used to grind the face of the shoulder. In work of this approximately .125mm (.005in).
nature an undercut may not be required in the • Hand traverse table, to position the wheel inside
finished workpiece and the undercut shown in the the bore and just clear of shoulder face.
following illustrations is used purely as an aid to the Note: The line previously marked upon the spindle
grinding process. will give indication of distance between wheel and
face.
Measure workpiece to check diameter and depth of • Traverse table very slowly until sparks or sound
bore. indicate the wheel is grinding the face.
Mount workpiece. • With the left hand holding the traverse wheel to
To mount spindle and wheel, select a recessed type act as a brake, gently tap the handle with the
wheel, ensuring that the head at the securing screw right hand to advance the workpiece onto the
will seat below the face of the grinding wheel. wheel.
Dress wheel for roughing out by applying slight Note: Very small movement is necessary. Take
angular relief to the front face of wheel. extreme care in applying feed, as too heavy a cut
will tend to make the spindle whip, causing the
wheel to bite into the finished bore.

Set table traverse stops.

Clean up the bore.Then measure bore size and
parallelism.
Rough grind bore to within .05mm (.002in) of
finished size. At the completion of this operation
there should be little or no evidence of undercut. • Clear workplace from wheel and visually check
Dress wheel for finish grinding. face has fully cleaned up. Take further cuts until
Finish grind bore, noting final index reading. Then a satisfactory condition is achieved. Allow
measure bore. wheel to 'spark out'.
Check wheel diameter. The wheel diameter must • Re-dress the front face of wheel.
be of a size that will grind the face flat. In the • Position wheel in bore.
example shown, the wheel diameter must not be • Adjust infeed index to bring the wheel within
greater than bore radius plus the central hole .015mm (.0005in) of the bore diameter.
radius, or less than bore radius minus the central • Traverse table until contact is made and apply
hole radius. feed as above.
Dress the front face of wheel as follows: Note: If a reasonably square corner is required, it
• Apply slight angular relief. will be necessary to re-dress the wheel face
• Slightly relieve wheel diameter,
leaving approximately 3mm (.125in) land at frequently as the corner of the wheel tends to break
front. down.
• Clear workpiece from wheel, stop workhead.
SAFETY — Before attempting to measure
! the bore ensure maximum distance between
workpiece and wheel, and either the wheel
guard is in position or the spindle motor is
switched off.

Check depth of bore and surface texture. Remove

sharp corners on workpiece. Remove workpiece
from machine.

- 71 -
 Internal grinding operations
Grinding a face • Clear workpiece from wheel and visually check
This type of operation is generally carried out to face has fully cleaned up.
ensure that the face of the workpiece is square to the • Re-dress face of wheel as necessary.
axis of the bore. Basically the procedure is similar to • Take further cuts as necessary, until a satisfactory
that for grinding a shoulder, and is a secondary condition is achieved.
operation following the grinding of the bore. • Clear workpiece from wheel, stop workhead.

Finish grind bore. Check surface texture and flatness of face. Remove
Mount spindle and grinding wheel as follows: sharp corners, then remove workpiece from machine.
• Select and mount short robust spindle.
• Select and mount a recessed wheel of diameter Grinding a bore in a long workpiece
larger than the width of face to be ground. Ensure
the head of the securing screw is below the wheel
face.
Dress the wheel by applying slight angular relief to
the front face.

Long workpieces, such as the example shown in the

illustration, require the use of a supporting steady.
The procedure is similar to that used for the lathe.
Where high precision is required, it is necessary to
determine the roundness of the outside diameter
where the steady pads will engage. This is to ensure
Grind the face as follows: roundness in the ground bore. In practice, either the
• Start workhead. full length of the diameter or short bearing bands are
• Use hand traverse, to position the wheel square to, first ground.
and just clear of, the face to be ground.
• Traverse table slowly, until the wheel lightly Measure workpiece to:
• Check diameter and determine grinding
contacts the face. allowance.
! SAFETY — Safety glasses must be worn. • Check roundness of diameter.
Mount chuck. Then mount workpiece and set true.

• With the left hand holding the traverse wheel to

act as a brake, gently tap the handle with the right Mount steady and fully retract bearing pads.
hand to advance the workpiece onto the wheel.
Note: Very small movement is required. Extreme
care should be taken in applying cuts, as too heavy a
cut will tend to make the spindle whip. Allow wheel
to spark out.
- 72 -
 Internal grinding operations
Adjust bearing pads to the diameter as follows: To mount workplace:
• Carefully adjust bottom pads to bear upon the • Select and set up appropriate workholding
diameter without moving the workpiece from its device.
true plane. • Set up workpiece.
Note: A dial indicator, engaged upon the diameter
above the bottom pads, will indicate deflection when Mount spindle and wheel as follows:
adjusting. • Use shortest and strongest possible wheel spindle.
• Adjust top pad to bear. • Choose a wheel approximately two-thirds
Note: The pads must bear lightly, yet firmly upon the diameter of bore and 12mm (.5in) longer than
bearing diameter. Any undue pressure will tend to bore.
develop heat affecting the finished result. • Dress wheel for rough grinding.

Mount spindle and wheel. Dress wheel for roughing To position wheel in bore:
out. Set table traverse stops. Clean up the bore. • Centralise wheel to bore.
Measure bore to check diameter, parallelism and
roundness. • Hand feed table, to position wheel approximately
Rough grind bore to within .05mm (.002in) finished central to bore length.
size. • Set left hand stop, so that wheel can be re-
Dress wheel for finish grinding. positioned in the bore in the same place. Note: Do
Finish grind bore. not move table longitudinally, once wheel is
Measure bore. positioned.
Remove sharp corners.

To clean up bore:
Remove workpiece from machine as follows: • Switch on wheel.
• Raise top pad to clear workpiece. • Switch on workhead.
• Retract bottom pads. • Carefully apply crossfeed until sparks or sound,
• Reverse workpiece and repeat procedure for the indicate that touch down is made.
other end. • Clear wheel from workpiece by one revolution
of handwheel.
Plunge grinding a parallel bore • Traverse wheel out of bore.
Measure workpiece to: • Switch off workhead.
• Check bore for size and note amount to be • Check bore for parallelism.
removed. Note: If bore was parallel, touch down will have left
• Check bore for taper. grinding marks full length of bore.
- 73 -
 Internal grinding operations
• Adjust machine table if necessary. Check finished size of bore, parallelism and surface
Note: If machine table is adjusted, touch down again texture. Remove sharp corners then remove
and remove as little material as possible, re-check workpiece from machine.
bore for parallelism.
Grinding a tapered bore
The procedure for grinding a tapered bore is similar
to that for grinding a parallel bore. To achieve the
tapered condition the workhead is swung through an
angle corresponding to half the included angle of the
taper required. This brings the side of bore in line
with the longitudinal axis of traverse.
Measure workpiece to:
• Check taper.
• Check diameter at a datum position.
To mount workpiece, set true with largest diameter
towards wheel.

Rough grind bore to within .025mm (.00lin) of

finished size as follows:
• Wind table up to stop.
• Switch on wheelhead and coolant.
• Touch down wheel onto workpiece again. Note
dial reading.
• Apply .015mm (.0005in) feed each time spark
density fades.
• Grind bore to within .025mm (.001in) of size.
• Allow to spark out.
• Clear workpiece from wheel by one revolution
of handwheel.
• Traverse wheel out of bore.
• Switch of workhead. To set workhead:
• Slacken index head locking bolts.
Check bore for size. Note amount to be removed. • Swing workhead through required angle, ie, half
Re-dress wheel for finish grinding. the include angle of taper.
Note: Most workhead indexes are graduated only in
degrees (°), and where setting requirements run into
minutes (') and seconds (") final taper corrections
should be made on the table taper adjustment.
• Tighten index head locking bolts.

To finish grind bore:

• Switch on workhead.
• Wind table up to stop.
• Carefully apply crossfeed until wheel touches
down onto workpiece. Note dial reading.
• Apply light cuts .005mm (.0002in) every time Mount spindle and grinding wheel and select
sparks density fades out. grinding
• Grind bore to size. wheel, approximately two-thirds diameter small end
• Allow to spark out. of bore.
• Clear wheel from workpiece by one revolution of Set table traverse stops.
handwheel. Dress wheel for roughing out, then clean up bore.
• Traverse out of bore.
• Switch off wheel, workhead and coolant.
- 74 -
 Internal grinding operations
Note: Having previously checked the taper, the
grinding wheel contact position will give
some indication on the head setting. For example,
if the inclusive angle is small, the grinding wheel
will contact the large end of the bore first. Also if
the inclusive angle is big, the grinding wheel will
contact the small end of the bore first.
Where there is an apparent error, the workhead
setting should be adjusted.
Remove minimum amount of material, to enable
bore to be measured.
SAFETY — Before attempting to measure
! the bore, ensure maximum distance
between workpiece and wheel and, either,
the wheel guard is in position, or the Rough grind bore to within .05mm (.002in) finished
spindle motor is switched off. size.
Measure bore to: Measure bore to determine remaining grinding
• Check taper. allowance. Dress wheel for finish grinding.
• Determine diameter and remaining grinding
allowance at datum position. Finish grind bore then measure bore to check taper,
Note: If the taper is incorrect, adjust the workhead, diameter and surface texture. Remove sharp corners
lightly grind the bore and re-measure. This and remove workpiece from machine.
procedure is repeated until the correct taper is
achieved. Note final index reading.

- 75 -
Inspection
Checking surface texture
Comparison plates are a range of metal blocks,
machined to various surface textures, with the
texture of each one marked in micro-inches, and
microns.

Visual check
• Select the appropriate plate for finish required.
• Visually check plate and workpiece alternately.
• Check from as many angles as possible, holding
the plate near the workpiece. After traverse grinding a diameter:
• Note any marks on the workpiece and, if when • Note index reading on infeed handwheel.
compared to the plate, they are deeper or more • Wind off wheel from diameter one revolution.
irregular, the texture is not up to the required
standard. • Turn off coolant.
• Compare the fineness, or sheen, of the workpiece • Position table, to take wheel to one end of
with the plate. If it is coarse or dull it is not to diameter.
standard. • Select micrometer and open spindle to
Note: The surface texture of the workpiece should be approximate diameter of workpiece.
at least as good as, or preferably better than, the • Position micrometer over workpiece at opposite
appropriate comparison plate. end to wheel, measure diameter.
SAFETY - Keep hands and arms clear of
Checking diameters ! revolving wheel.
• Remove micrometer and note reading.
Using a micrometer • Check for variations in size at different positions
along diameter.

After plunge grinding diameter:

• Note index reading on infeed handwheel.
• Retract wheel from workpiece diameter. Using a gap gauge:
• Turn off coolant. • Wind back wheelhead enough to allow gap gauge
• Select appropriate size of micrometer and open to pass freely between wheel and workpiece if
spindle to approximate size of diameter. plunge grinding, or wind wheel to one end of
• Position micrometer over one end of workpiece diameter if traverse grinding.
and hold vertical to machine table. • Hold gap gauge firmly in one hand and square to
SAFETY- the diameter of the workpiece.
! • Keep fingers to the rear of micrometer. • Lightly ease gap gauge over the diameter,
• Keep hands clear of revolving wheel. allowing its own weight to complete the pass.
• Do not allow micrometer too much Note: On a diameter of correct size the gap gauge
movement. should stop as the diameter comes into contact with
• Remove micrometer and note reading. the 'no go'.
• Check at other end of diameter for size and • Check at both ends of diameter.
parallelism. Note: Do not hold gauge in the hands for long
General note: It is inadvisable to stop the grinding periods, or the body temperature will affect its
wheel to check diameters, as a different 'infeed' index accuracy.
reading may be obtained.

- 76 -
 Inspection

Checking lengths

Using external micrometer

Using a comparator:
This is one of the most accurate ways of checking a
diameter. It eliminates the different 'feel' people have
when using a micrometer. A disadvantage, however,
is that the workpiece must be removed from the • Select appropriate size of micrometer and open/
machine, so it is important when setting a workpiece close spindle to approximate length to be
between centres that everything is clean and the measured.
centre holes and centres are of correct form. • Position micrometer over length, and parallel to
• Clean comparator stand. machine table.
• Select slip gauges to build up to middle tolerance • Apply sliding motion and adjust thimble until the
of workpiece dimension. correct 'feel' is obtained, note reading of
Note: Refer to slip gauge calibration chart for correct micrometer.
size. • Remove micrometer and turn workpiece
• 'Wring' slip gauges together. approximately 90°, and re-check length.
• Make a further two checks, turning workpiece
90° each time, to ensure squareness of the
shoulder.

Using a gap gauge

• Place slip gauges on comparator stand and adjust

head to position the stylus above the gauges.
• Lower comparator head, using fine adjusting
screw, at the same time sliding slip gauges under
stylus, until a reading approximately in centre of
• Select correct size of gap gauge.
scale is obtained.
• Hold gauge firmly in the hand and square to
• Zero comparator dial.
shoulders of workpiece.
• Clean workpiece and place on base.
• Lightly ease gap gauge over the shoulder. Note: If
• Hold workpiece flat on base and roll it slowly
the shoulders are of the correct length the gauge
under plunger. Note reading of dial.
should tighten as the 'no go' comes into contact.
Note: It is important that the workpiece is not tilted
• Check at different positions around
or a false reading will be obtained.
circumference.
Note: Do not hold gauge in the hands for long
periods, or the body temperature will affect its
accuracy.

- 77 -
 Inspection
Checking widths

Using slip gauges

Check diameter:
Note: Taper ring gauges are often made with their
large end diameter equal to a stated dimension,
and, when checking, its end must stand at a certain
distance down the taper, from its largest
• Select appropriate size of slip gauges. dimension. This length is often stated on the
Note: Refer to calibration chart for correct size, drawing, but if not it must be calculated.
and use as few slips as possible. • Ensure taper of gauge is correct.
• 'Wring' slip gauges together. • Insert taper of workpiece into gauge.
• Enter slip gauges in gap to be measured. • Push gauge along taper until it lightly tightens.
Note: If the gauges will not enter, do not use force • Either, measure distance from end of gauge to
but change one of the slips for a smaller size. datum on workpiece, or, check that end of taper
protrudes from gauge between the high and low
• Obtain the correct 'feel' by moving the gauges tolerances allowed.
backwards and forwards.
Using a sine bar To set up sine bar:
• Withdraw gauges and re-check on opposite • Select appropriately sized sine bar and clean.
side of workpiece. • Select required slip gauges to build up required
angle.
Checking tapers • Clean and 'wring' slip gauges together.
• Place sine bar and slip gauges on surface plate.
Using taper ring gauge • Position an angle bracket against back edge of
sine bar.
Position workpiece as follows:
• Deburr and clean workpiece.
• Position taper of workpiece on top of sine bar
and with a reference diameter flush to angle
bracket.

Check taper:
• Select appropriate taper ring gauge.
• Clean gauge and taper of workpiece.
• Smear a thin line of marking medium down
length of workpiece taper, in three positions.
• Carefully insert workpiece taper into gauge.
• Push gauge on taper as far as possible and feel for Check angle as follows:
any 'rock'. • Position dial test indicator on surface plate.
• Apply slight pressure and turn gauge on taper. • Engage stylus to one end of workpiece taper.
• Remove gauge and visually check marking • Slide stylus across width of taper to check highest
medium is smeared equally along and around point.
taper. • Zero dial test indicator at highest point.
Note: If marking medium is unequal, taper • Check zero reading at other end of taper.
is incorrect. • Note amount of error.
- 78 -
 Inspection
Note: If angle is correct, a zero reading should be • Run dial test indicator over top face of
obtained at both ends of taper. workpiece.
Checking flatness • Tap workpiece with hide hammer to set top side
To prepare workpiece: parallel to surface table.
• Remove all burrs from workpiece and clean • Tighten clamps.
faces. • Re-check top face of workpiece.
• Select three small jacks and position on the Check squareness as follows:
surface table to form a triangle, within the bounds • Turn cube 90°, taking care not to move
of the workpiece. workpiece.
• Position workpiece on the jacks, ground face • Set dial test indicator stylus on one end of face and
uppermost. zero reading.
• Adjust height of jacks to visually align top face of • Run dial test indicator over face of workpiece.
workpiece parallel to the surface table. Note: Error of squareness will be indicated by the
movement of the dial test indicator needle off zero.
Checking parallelism
To prepare workpiece:
• Remove all burrs from workpiece and wipe faces
clean.
• Select a pair of parallels, and place on surface
table.
• Place one ground face of workpiece onto
parallels.

To check workplace:
• Set top face of workpiece parallel to the surface
table by adjusting the jacks to obtain a dial
indicator reading of zero in all corners of
workpiece.
• Check along each edge of workpiece and in the
middle for flatness.
Note: Error will be indicated by the amount the dial
test indicator needle moves from the zero reading.

Checking squareness Check parallelism as follows:

To set up workpiece: • Set dial test indicator, mounted on a vernier
• Clean surface table and small cube block. height gauge, on one end of workpiece.
• Pack up workpiece on parallels to approximate • Zero dial test indicator reading.
position on cube. • Run dial test indicator over length of workpiece
Note: Faces to be checked should be near to top and face.
one side of cube. Note: Error in parallelism will be indicated by
• Clamp workpiece lightly in position with movement of the dial test indicator needle from the
toolmakers clamps. zero reading.

Checking angles
This can be done in two ways, using a vernier bevel
protractor or a sine bar.

Align workpiece parallel to surface table as follows:

• Mount a dial test indicator on a vernier height
gauge.
- 79 -
 Inspection
To set up sine bar: • Turn workpiece 180° and check for zero on apex
• Select and clean appropriate size of sine bar. of roller.
• Select slip gauges to build up sine bar to
required angle.
• Clean slip gauges on chamois or soft cloth.
• Wring slip gauges together.
• Place sine bar on surface and position slip
gauges.
To position workpiece:
• Deburr and clean workpiece.
• Position workpiece angle face resting on sine
bar.
• Hold parallel strip against the side of the sine
bar. Slide workpiece against strip, ensuring that
workpiece is flush to sine bar edge.

To check depth of vee:

• Select a suitable diameter roller and mount in
vee block as shown.
• Using a suitable measuring device, measure
height from the base of the block to the top of the
roller.
• Calculate the height to the centre of the roller, ie,
height to top of roller minus radius of roller.
Note: This measurement can now be used to
calculate the dimensions relating to the position of
the vee in the block.
Check angular face as follows:
• Position dial test indicator on surface plate with
dial stylus engaged on one end of workpiece Checking dovetails
face.
• Set dial face at zero.
• Slide dial test indicator to bring stylus to other
end of workpiece face.
• Note any error, from zero.
Note: If angle is correct, dial stylus will be zero for
full length of angle face.
Checking vees

To check depth of dovetail:

• Clean top and bottom faces of workpiece and
dovetails.
• Place workpiece on a surface table.
• Build up appropriate slip gauges for depth
required.
• Place slip gauges on base of dovetail.
• Slide dial test indicator, attached to a vernier
To check symmetry of vee with centre line: height gauge, over slip gauges and zero reading.
• Select a suitable roller, diameter such that roller • Slide dial test indicator over topface
makes contact about midway down the face of the of workpiece.
vee. Note: Amount of error is shown by the movement of
• Place roller lengthways in vee, and slightly the dial test indicator off zero.
protruding over end of vee.
• Clamp roller in vee.
• Turn workpiece on its side and set a dial test
indicator at zero on the apex of the roller. - 80 -
 Inspection

Check angles of dovetail as follows: To check dovetail slide:

• Clamp workpiece on an angle bracket so that the • Leave workpiece clamped to angle bracket.
base of the dovetail is in a vertical position. • Place a roller in the angle of the topmost
• Place roller 'A', of known size, in the angle of the dovetail.
dovetail. Note: Roller lettered 'A' in the • Find height of roller with dial test indicator and
illustration. slip gauges.
• Find height of roller 'A' by means of dial test • Note measurement.
indicator and slip gauges.
• Note measurement obtained.

• Hold roller firmly in the bottom angle of the

dovetail.
• Find bottom-most point measurement of roller by
means of dial test indicator and slip gauges.
• Subtract measurement obtained in previous point
• Select a slip gauge (approximately 12mm (.5in) from measurement of height of rollers found with
and position on base of dovetail with a roller on dial test indicator. Width of dovetail slide equals:
the ange of the dovetail. Measurement across rollers minus diameter of
Note: Roller lettered 'B' in the illustration. roller minus twice the calculated length, from
• Find height of roller 'B', by means of a dial test centre of the roller to the meeting angle of the
indicator and slip gauges. dovetail.
• Note measurement obtained. Note: Error is indicated by the difference between
• Subtract measurement over roller 'A' from roller the actual measurement and the calculated distance.
'B', for length of XY (see illustration). Length of
YZ is equal to slip gauge used. Angle of
X—tangent YZ.
VY

General note: Dovetail forms of the female type

can be checked in a similar manner, or the use of
- 81 - rollers and slip gauges may be employed.
 Inspection
Checking forms Checking parallel bores

Use of the projector

The projector is one of the best available methods of
checking irregular shapes and profiles. It can also be
used for linear measurement.
Projectors are equipped with a series of lenses that
give various magnifications of the image. Each lens
has an adjustment so that the magnification can be
calibrated to a known length standard, thus giving a
very high degree of accuracy.
The designs of projectors vary but the essential
details are a condenser, or collimator, for projecting a
parallel beam of light onto the workpiece which is
placed between the condenser and the projection lens.
After passing through the lens, the light may shine
directly onto the receiving screen or be reflected onto Using internal micrometer:
it by one, or more, mirrors. • Position micrometer in mouth of bore, using the
extension handle.
Checking radii • Insert the anvil at the barrel end into bore, tilt
To set projector: micrometer at a slight angle to allow opposite
• Select appropriate lens. anvil into bore.
Note: The greater the magnification chosen, the • Unscrew thimble, at the same time rocking the
smaller the image area magnified. anvil at the top of the bore.
The greater the magnification, the less intense the • Repeat adjustment and rocking action, until a
projected image will be. light contact is obtained.
As a general rule choose the smallest magnification • Check for variations in diameter, by moving the
that will still give the accuracy required to measure micrometer further into the bore.
the work. • Rotate approximately 90° and check bore to
• Secure lens in projector. ensure it is round.
• Clean projection table. • Remove micrometer and note reading.
• Set enlarged image on projection screen.
To set workpiece:
• Clean workpiece.
• Place workpiece on projector table with radii
directly below lens.

Using vernier caliper:

• Hold fixed jaw in left hand and movable jaw in
the right hand.
• Position closed vernier caliper into bore of
workpiece.
• Slide moveable jaw until both jaws touch walls of
bore. Ensure shoulders of vernier are flat against
To check workpiece: face of bore.
• Switch on light beam. • Tighten locking screw directly above fine
• Bring image into focus by means of focus adjustment screw and lightly tighten locking
handle. screw on moveable jaw, sufficient to allow
freedom of movement for fine adjustment.
• Adjust table to match radii form of workpiece • Turn fine adjustment screw until smooth sliding
with image on projection screen. fit is obtained. Note: Do not strain jaws by
Note: Error can be seen by the amount the projected overtightening.
image of the workpiece overlaps the englarged image • Tighten moveable jaw locking screw and remove
on the projection screen. vernier from workpiece.
• Rotate workpiece 90° and check bore to ensure it
is round.
• Take vernier reading and add width of jaws.
- 82 -
 Inspection

Checking tapered bores

Using plug gauges:

• Position 'go' end to mouth of bore, ensuring gauge
is held parallel. To check bore:
Note: 'Go' end is usually longer than that of the 'no go' • Select appropriate taper gauge.
end. • Clean taper gauge.
• Insert 'go' end into bore. Do not force into bore. • Clean bore of workpiece.
An even sliding fit should be obtained. • Smear a light thin line of marking medium down
• Turn plug gauge round and offer 'no go' end to gauge in three positions.
bore. It should not enter. • Carefully insert gauge into bore.
Not: Plug gauges should not be held in the hand for • Apply inward pressure and turn gauge in bore,
long periods, as the body temperature will affect their approximately three to four times.
accuracy. • Remove gauge and visually check the marking
medium.
Note: If taper is correct, marking medium should be
smeared equally along, and around, taper. If taper is
incorrect, marking medium will only be smeared in
one position.

Using telescopic gauges:

• Position closed gauge in bore.
• Extend small leg out, until both walls of the bore
are touched by the gauge.
• Lock gauge in position, by turning the knurled
screw in the handle. Check large diameter of taper:
• Obtain correct 'feel' by rocking the gauge both • Ensure taper of workpiece bore is correct.
along and around the bore, holding the gauge by • Insert gauge into workpiece bore.
the handle. • Note distance gauge enters into bore. Note: Large
• When correct 'feel' is obtained, withdraw diameter of bore should lie between the high and low
telescopic gauge and measure with a micrometer. tolerance marks on the large end of the taper gauge.
• Check diameter at 90°.

- 83 -
Common grinding faults and their correction

To assist you to attain the required standards you • The first column headed 'Fault' gives the name and
should know, and be able to recognise, the faults description of the fault.
which can, and do, occur. You must also be able to • The second column headed 'Early warning'
take the necessary action to deal with faults and, describes warning signs of a fault developing and
above all, know how to prevent them. The following how it may be isolated to a particular cause.
pages are intended to give guidance on this matter. • The cause of the fault is given in the third column.
Because of the wide variety of work, the types of • The last column gives preventive and corrective
machine and associated equipment used, it is not actions.
feasible to give in this guide the cause of each fault.
Only examples of common faults have, therefore,
been shown:

Fault Early warning Cause Prevention and/or correction

Chatter marks Uneven cutting sound Wheel out of Rebalance carefully on own
may take any of and intermittent sparks. balance. mounting.
several forms Rebalance after truing operation.
and may be the Run wheel without coolant to throw
result of any of off excess water.
the causes When wheel is removed from machine
listed. store on side to prevent water from setting
at lower edge of wheel.

Wheel out of True before and after balancing.

round. True sides to face.

Wheel glazing. Wheel grading Select softer grade, more open bond
too hard. or coarser grit.

Incorrect Check diamond for wear.

dressing. Check diamond is securely held.
Re-dress wheel correctly.

Vibration noise. Work centres or Check workrests, for adjustment.

Uneven cutting sound. workrests not Check work centres.
Intermittent sparks. true, or Check machine centres for wear,
improperly and correct angle. Check that
lubricated. work centres fit properly in spindles.
Provide constant and even
lubrication.

Incorrect Clamp workpiece securely.

clamping of
workpiece.

Workholding
device
loose. Clamp workholding device securely.

Chatter ie, irregular

mottled surface. Erratic infeed or
Reduce work speed traverse. Faulty traverse. Check hydraulic oil level.
and check workpiece
for balance. Improper
operation. Reduce rate of wheel feed.

Work vibration. Reduce work speed and check

workpiece for balance.

- 84 -
 Common grinding faults and their correction

Fault Early warning Cause Prevention and/or correction

Inferior finish Narrow and deep Wheel too coarse. Use finer grain size.
regular marks

Wide irregular marks of Wheel too soft. Use harder grading.

varying depth.

Oil spots or
Widely spaced glazed areas on Balance and true wheel.
spots on work. wheel face. Avoid getting oil on wheel face.

Fine spiral or thread on Faulty wheel Replace cracked or broken diamonds

work. dresser. Use slower dressing traverse.
Set dressing tool at angles of 5° down
and 30° side.
Turn diamond every third dressing.
Tighten holder or diamond.
Dress with less penetration.
Do not allow tool to dwell in contact
with wheel.
Do not start dressing cuts on face -locate
tool on face, but start cuts from edge.
Make final pass in dressing in opposite
direction to grinding traverse.
Traverse diamond across face of
wheel evenly.
Round off wheel edges - chamfering
or dressing back is not sufficient.

Faulty Prevent penetration of advancing or

operation. following edge of wheel by being careful
to dress wheel face parallel to work.
Reduce wheel pressure.
Provide additional steady-rests.
Reduce traverse in relation to work rotation.
When making numerous passes, make slight
change in traverse rate at each pass
to break up pattern.

Wavy traverse Ragged wheel

lines. edges. Round off wheel edges.

Use sharper dressing tools.

Isolated deep Improper wheel Brush wheel after dressing, preferably
marks. dressing. with a stiff bristle brush
.
Coarse grains or
foreign matter in
wheel face. Dress out.

Bond Coolant too strong for some organic bonds;

disintegrates, decrease soda content.
grain pulls out

Inferior finish. Irregular marks. Loose dirt. Keep machine clean.

Irregular marks Dirty coolant. Clean tank frequently.

of various lengths Plush guards, etc. after dressing and
and widths; scratches when changing to finer wheels.
usually 'fishtail'.

eep, irregular marks. Loose wheel Tighten flanges, using blotters.

flanges.

- 85 -
 Common grinding faults and their correction

Fault Early warning Cause Prevention and/or correction

Grain marks. Wheel too Select finer grain size of harder

coarse or too soft. grade wheel.

Too much Use finer roughing wheel or finish out

difference in better with roughing wheel.
grain size
between roughing
and finishing
wheels.

Dressing too Less dresser penetration and slower

coarse. dresser traverse.

Improper cut from Start with high work and traverse

finishing wheel. speeds, to cut away previous wheel
marks; finish out with high work
and slow traverse speeds, allowing
wheel to spark out entirely.

Ridges on wheel. Wheel damaged Dress wheel to correct form. Check

or not properly diamond for wear. Check diamond is
dressed. securely held.

Workface burnished. Incorrect grade of Fit wheel of correct grade.

wheel.

Insufficient Increase coolant supply.

coolant.

Feed too coarse. Reduce feed rate.

Cut too large. Decrease size of cut.

Work shows Improper wheel. Use softer wheel or manipulate to get

discoloration softer effect.
Prevent glazing and loading.
Use more coolant.

Faulty operation. Bring wheel to work more gradually,

use less infeed.
Prevent stoppage of work while in
contact with wheel.

Taper Feel for rock, when Particles or burrs Clean and deburr machine table and
ie, faces not locating workpiece and between table and locating faces of workpiece
parallel. workholding device. workpiece or table and or workholding device.
workholding device or
workholding devio and
workpiece.

Feel for rock when Particles or burrs Clean and deburr faces of parallels
locating parallels or between workholding and workpiece.
workpiece on parallels. device and parallels or
parallels and workpiece.

Faces not square. Light seen between Machine table Check alignment of table.
edges of square and incorrectly Check accuracy of square,
work pieces when aligned. if used, for setting
checked. Inaccurate setting or checking.
of measuring
equipment.

- 86 -
 Common grinding faults and their correction

Fault Early warning Cause Prevention and/or correction

Workpiece faces Work piece moves on Workpiece distorted Check workpiece is supported under
not flat. clamping. through clamping. clamps.

Discolouring of Distortion, by wheel Increase coolant supply.

workpiece surface. burning material. Dress wheel frequently.

Inaccuracies in Errors found by Misalignment of Check deadstock and tailstock for

work, ie, work out checking component machine parts. alignment and proper clamping.
of round, not before taking finishing Check table setting and adjustment
parallel or tapered. cut. for parallelism.
Check headstock bearings.

Work centres. Check centres in work.

They must be deep enough to clear
centre point.
Keep work centres clean and lubricated.
Re-grind work centre if worn.
Work centres must fit taper of work
centre holes.

Wheel traverses Incorrect traverse Check length of traverse - set traverse so

beyond end of work. setting. that wheel does not clear work.

Workpiece springing. Excessive wheel Decrease wheel pressure.

Intermittent sparks pressure on
workpiece.
.
Workpiece burnishing. Insufficient coolant. Increase volume of coolant.

Uneven cutting and Wheel out of Re-balance and re-dress

intermittent sparks. balance. wheel.

Wheel incorrect form Improper dressing. Re-dress wheel.

or face uneven.

Wheel glazing. Shiny appearance, Improper wheel. Use coarser grain size, softer grade.
Smooth feel Manipulate operation to soften effect.
(See 'Wheel grading effect.')

Improper dressing. Keep wheel sharp with sharp dresser.

Use faster dressing tool traverse.
Use more dressing tool penetration.

Faulty coolant. Use less oily coolant. Use more coolant.

Gummy coolant. Increase soda content if water is hard.

Do not use soluble oils in hard water.

Faulty operation. Use greater infeed.

(See 'Wheel grading effect.')

Wheel loading. Metal lodged on grains Incorrect wheel. Use coarser grain size, or more open
or in wheel pores. bond, to, provide chip clearance. Use
more coolant.

Faulty dressing. Use sharper dresser. Dress faster.

Clean wheel after dressing.

Faulty coolant. Use more, cleaner and thinner coolant.

Faulty operation. Manipulate operation to soften.

Effect of wheel.
(See 'Wheel grading effect.')
Use more infeed.

- 87 -
 Common grinding faults and their correction

Fault Early warning Cause Prevention and/or correction

Wheel grading Lack of cut; glazing; Wheel too hard in Increase work and traverse
effect. some loading; burning effect. speeds and wheel pressure (infeed).
of work, chatter. Decrease spindle speed, wheel diameter
and width of wheel face.
Open up wheel by sharper dressing.
Use thinner coolant.
Avoid dwelling at end of traverse.
Avoid gummy coolants.
Use coarser grain size and softer grade.

Wheel marks; short Wheel too soft in Decrease work and traverse speeds
wheel life, not holding effect. and wheel pressure (infeed).
cut; tapered work. Increase spindle speed, wheel diameter
and width of wheel face.
Dress with slow traverse and slight
penetration.
Use heavier coolants.
Do not pass off work at end of traverse.

Wheel breakage Radial break, three or Reduce wheel speed to rated speed.
more pieces. Correct improper mounting such as lack
of blotters, tight arbors, uneven flange
pressure, dirt between flanges and
wheel.
Prevent overheating due to lack of
coolant. Prevent excessive wheel
pressure on work.
Do not allow wheel to become jammed
on work.

Radial break, two Prevent excessive side strain.

places.

Irregular break Do not allow wheel to become jammed

on work.
Prevent blows on wheel.
Do not use wheels that have been
damaged in handling.
Examine wheel before using.
Sound wheel by tapping.
.
General. Do not use a wheel that is too light on
the arbor as wheel will break when
started.
Prevent excessive hammering action of
wheel.
Familiarize yourself with the provisions of
wheel.
Abrasive Wheel Regulations governing
the use of grinding wheels
and observe the rules.

- 88 -