“Centerless grinding is one of the best techniques applied by operators and manufacturers in running high volume production of bars and materials for the machining industry.”Centerless grinding is one of the best techniques applied by operators and manufacturers in running high volume production of bars and materials for the machining industry. It paves way for more opportunities and new applications in the machining world.
Why centerless?The centerless grinder has no centers which the name “centerless” has implied. With proper set-up, the operation can achieve excellent roundness and surface finish. The “centerless” set-up enables the machine to even grind and cut out-of-round workpieces. It’s a method of three-point positioning which includes the proper adjustment of the grinding wheel, the regulating wheel, and the workblade. The set-up itself is critical to the outer surface of the materials and for the successful result of the process.
Easy set-upCenterless grinding, among all other operations, has the easiest set-up process. But first, proper automation must be set-up for a continuous and consistent flow. To get the operation started, a firm support (workblade) of the workpiece between the wheels and its height must be held in place. This plays significantly in the rounding action which determines the accuracy and consistency of the parts’ roundness and diameter tolerance. The set-up operation for centerless grinding is not that daunting and complicated to other machining operations – and has less time consuming exercise! But it takes all the proper understanding of basic fundamentals to achieve the best results.
TypesThe centerless grinding machine is able to perform multiple tasks particularly center-type which can be done in two ways: plunge grinding and through-feed grinding. If the workpiece is pulled past the grinding wheel by the regulating wheel, it is called through-feed grinding which is relatively used in machining long round bars and even thin rods which are made of brittle steels and metals. If the challenge is to machine relatively complicated parts, the plunge grinding (in-feed) is highly recommended. The plunge grinding is used to machine parts as complex as camshafts, crankshafts, and gear shafts. Eminently, the in-feed grinding is mostly used for automotive applications.
Superabrasive wheels for super-high precision and dimensional toleranceThe wheels used for grinding are constantly dressed with abrasive teeth. These teeth are sharp grains made of either diamond and/or cubic boron nitride. This is the method behind why the centerless machine is able to perform abrasive cutting and excessive removal of unnecessary parts of the workpiece. With the abrasiveness of the grains, the grinding wheel itself in the machine is also able to perform multiple significant tasks such as polishing, roughing, and cleaning. Centerless grinders are also used oftentimes by operators for recycling old bars and restoring its outer surface and appearance through the continuous grinding process.
The abrasive grains and the consistent gap between the wheels are keys on achieving that super-high precision roundness and tight dimensional tolerance among bars and part components. Centerless grinding is efficiently applied to different application and manufacturing of parts ranging from simple tube bars to relatively complex shafts.