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Troubleshooting

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When a problem occurs while grinding, finding the cause is not easy due to the variety of complexly intertwined factors involved. In order to investigate the cause of problems, it’s important to understand what is going on during grinding — things like the condition of the workpiece, the condition of the wheel usage surface, and sound and heat generated by the process — by being sufficiently observant on the work site. Please make use of these simple troubleshooting measures that we’ve summarized here.

Frequent Troubleshooting Issues

Problem

The grinding sound suddenly becomes high

Solution

  • Decrease the wheel speed (reduce V/v)
  • Decrease the stock removal
  • Increase the infeed rate and traverse feed rate
  • Increase dressing amount and traverse feed rate
  • Increase Coolant volume or pressure
  • Raise Coolant concentration

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Problem

The grinding sound suddenly becomes low

Solution

  • Increase the wheel speed (increase V/v)
  • Decrease the stock removal
  • Decrease the infeed rate and traverse feed rate
  • Increase dresser's setting angle
  • Decrease dressing amount and traverse feed rate
  • Increase Coolant volume or pressure

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Problem

The grinding sound fluctuates repeatedly

Solution

  • Decrease the infeed rate and traverse feed rate

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Problem

Feed marks are left on the workpiece

Solution

  • Decrease the wheel speed (reduce V/v)
  • Decrease the stock removal
  • Decrease dressing amount and traverse rate
  • Increase Coolant volume or pressure
  • Adjust the parallel of workhead and machine spindle

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Problem

Grinding affected layer

Solution

  • Decrease the wheel speed (reduce V/v)
  • Decrease the stock removal
  • Decrease the infeed rate and traverse feed rate
  • Increase dressing amount and traverse feed rate
  • Increase Coolant volume or pressure

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Problem

Grinding ability decreased

Solution

  • Decrease the wheel speed (reduce V/v)
  • Decrease the stock removal
  • Increase dressing amount and traverse feed rate
  • Increase Coolant volume or pressure

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Problem

The grinding ratio is being decreased

Solution

  • Increase the wheel speed (increase V/v)
  • Decrease the stock removal
  • Decrease the infeed rate and traverse feed rate
  • Increase dresser's setting angle
  • Decrease the dressing amount and traverse feed rate
  • Increase Coolant volume or pressure

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Problem

Grinding burns appear

Solution

  • Decrease the wheel speed (reduce V/v)
  • Decrease the stock removal
  • Decrease the dressing amount and traverse feed rate
  • Increase Coolant volume or pressure
  • Use coolat with good lubricity-penetration

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Problem

Warping occurs (for surface grinders)

Solution

  • Decrease the stock removal
  • Increase Coolant volume or pressure
  • Use coolant with good lubricity-penetration

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Problem

Poor surface roughness

Solution

  • Increase the wheel speed (increase V/v)
  • Decrease the stock removal
  • Decrease the infeed rate and traverse feed rate
  • Do frequent dressing
  • Increase dresser's setting angle
  • Decrease the dressing amount and traverse feed rate
  • Raise the concentration of coolant
  • Rebalance the wheel carefuly

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Problem

Poor workpiece tolerance

Solution

  • Decrease the wheel speed (increase V/v)
  • Decrease the stock removal
  • Decrease the infeed rate and traverse feed rate

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Problem

Roundness is poor

Solution

  • Change the grinding cycle
  • Correct the center hole by grinding it
  • Replace the dresser with a new one

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Problem

Cylindricity is poor

Solution

  • Modify the stabilizer position
  • Adjust the over-run amount in the processing surface end
  • Adjust the table swivel
  • Modify to a dressaer with large diamond

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Problem

Scratches appear irregularly

Solution

  • Increase the dresser's setting angle
  • Decrease the infeed rate and traverse feed rate
  • Clean around the Coolant

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Problem

Screw-like scratches appear

Solution

  • Fix the dresser securely
  • Chamfer the grinding wheel immediately after dressing

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Problem

Isolated scratches appear

Solution

  • Increase the wheel speed (increase V/v)
  • Decrease the stock removal
  • Decrease the dressing amount and traverse feed rate
  • Increase Coolant volume or pressure
  • Change toa dresser with sharp point

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Problem

Chattering occurs at regular intervals

Solution

  • Decrease the stock removal
  • Do dressing frequently
  • Fix the dresser securely
  • Chamfer the grinding wheel immediately after dressing
  • Raise the concentration of Coolant
  • Increase Coolant volume or pressure
  • Rebalance the wheel carefuly
  • Fix the grinding wheel to the flange securely

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Problem

Uniformly distributed chattering occurs

Solution

  • Decrease the vibrations of the outside, machine, ..etc
  • Rebalance the wheel carefuly
  • Decrease the wheel speed (reduce V/v)
  • Decrease the stock removal
  • Decrease the infeed rate and traverse feed rate
  • Decrease the dressing amount and traverse feed rate
  • Increase Coolant volume or pressure

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Problem

Chattering occurs irregularly

Solution

  • Decrease the infeed rate and traverse feed rate
  • Clean around the Coolant

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