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Creep-feed grinding is best described as a high stock removal rate process very much like milling, but using a grinding wheel in place of the milling cutter. The advantages gained over the large chip processes of milling, broaching and even turning, are that with creep-feed grinding the surface finish is far superior. Both form and dimensional accuracy are extremely high and there are virtually no burrs, additionally the workpiece can be finished machined, from solid, in its fully hardened state. In fact, it is a general rule that it is best to grind hard than soft material. Creep-feed grinding that uses very open structure vitrified aluminum oxide and silicon carbide wheels, that are dressed intermittently, using a single point diamond, crush roll or diamond roll dresser, is termed conventional creep-feed grinding (CFG). If a vitrified or resin bonded cBN or a diamond wheel is used, with intermittent dressing, it may be called superabrasive creep-feed grinding. When a plated superabrasive grinding wheel is used then the grinding wheel speed may be significantly increased. This takes us into the realm of high-speed creep-feed grinding or High-Efficiency Deep Grinding (HEDG.) CDCF peripheral wheel speeds run in the range 10 to 30m/s (2,000 to 6,000 sfm) and for CFG, in the range 25 to 45 m/s (5,000 to 9,000 sfm) whereas HEDG runs from 45m/s to 250m/s (9,000 to 50,000 sfm.)
Dr. Salmon wrote a training video for Brown and Sharpe, produced by Charles Shaw & Associates, Providence, RI, USA, in which he used a slow motion film clip, courtesy of DeBeers Industrial Diamond Division, to illustrate the principles of creep-feed grinding and how they differ from conventional reciprocating grinding. Click on the e6 - element six logo below, (DeBeers Industrial Division's new name) and a QuickTime video should run automatically. If you have difficulties please e-mail me and I'll see what I can do.
Creep-Feed Grinding