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Troubleshooting Guide
There are a number of things that can go wrong in a grinding operation. They generally fall into one of six areas:
Surface integrity problems. Surface integrity is a term devised by Metcut, the organization that compiled the Machining Data Handbook, to describe all surface and subsurface conditions above and beyond surface finish, form and dimension. Surface integrity relates to surface cracks, sub-surface cracks, grain growth, surface tempering/hardening, precipitation of grain boundary carbides etc. etc.
Loss of tool life. The consumable tools in grinding are the grinding wheels and the dressing tools.
Grinding fluid problems. Fluid problems may relate to the fluid type, concentration, mixing, foam, residues, odors, water quality, misting, operator acceptance, dermatitis and environmental issues.
Machine tool problems. The machine and fixturing may suffer from mechanical issues with respect to vibration, lack of stiffness, stick/slip slideways and so on, as well as electrical and electronic problems in the areas of improper grounding, motor and pump controls and CNC control system irregularities.
Material problems. Often overlooked, incoming material may change in constituents and heat treatment to such an extent that it might appear that it is the grinding process that has become unstable.
Productivity. Companies generally look for the highest quality at the lowest piece part cost, some need to make their parts as fast as possible, at any cost, and others need to do the best they can with the tools they have. Optimizing productivity is therefore difficult as there are many thoughts and ideas on what is truly optimum.
Click on the subjects below for interest and answers to some of the most common problems. If you can't find a solution e-mail Dr. Salmon.