5 Most Common Grinding Problems with Solutions

In this article, we'll go through some of the most popular methods for removing grinding errors. We will also discuss common grinding problems, such as noise during grinding (chatter), and suggestions for laying a solid foundation for grinding increasing efficiency.

Let’s begin with the what are common grinding problems,

5 Common Grinding Problems and Solutions

Following are the five most common problems that occur while grinding metals-

• Grinding Chatter
• Wheel Loading 
• Wheel Glazing 
• Burning of Work 
• Searching of Work - Indication

Now let’s discuss each problem & its solution in detail-

Grinding (Irritating Noise)

Causes & Method of Correction – Grinding Chatter

• Use a softer grade or fine grit if your wheel grading is too hard.
• Rebalance after truing procedure if the wheel is out of balance. Run the wheel without the coolant to get rid of any excess moisture. When removing a wheel from the machine, keep it on the side to avoid water from collecting at the wheel's lower edge.
• Before and after balancing, the wheel is out of round.
• Work-rest centers that aren't real or aren't appropriately lubricated Examine the fit of the centers and the remainder. Ensure that lubrication is consistent and uniform.

Wheel Loading 

Causes & Method of Correction

• To create chip separation, use a coarser grain size or a more open bond.
• Use a sharper dresser if your dressing isn't up to par. Dress more quickly.
• Coolant- Use more coolants that are cleaner and thinner.

Wheel Glazing

Causes & Method of Correction

• Use coarser grain size, softer grade when wheel grading hard, and finer grit.
• Improper dressing- Use a sharper dresser to keep the wheel crisp. Traverse using a speedier dressing tool. More dressing tool penetration is required.

Burning of Work

Causes & Method of Correction

• Use a gentler grade if your wheel grading is too hard. Preventing glazing and loading is a must. More coolant should be used.
• Faulty operation: Slowly bring the wheel to work and utilize less in-feed. Prevent work from coming to a halt while in touch with the steering wheel.

Searching of Work – Indication

Causes & Method of Correction

• Cause-ragged wheel with a wavy traversing line Use wheel edges that are rounded.

• Wheel dressing that isn't up to par uses sharper dressing tools. After dressing, brush the wheel.
• In the wheel face, there are coarse grains or foreign material. Make it look nice.
• The cause of deep irregular markings is loose wheel flanges. Using blotters, tighten flanges.

Read More: How To Select The Right Grinding Wheel

• If the wheel is too coarse or soft, use a tougher grade wheel with finer grain size.
• The difference in grain size between the roughing and finishing wheels is too great. – Use a finer roughing wheel or a roughing wheel to finish the job.
• Dressing too coarsely results in less penetration of the dresser and slower traversal.