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Choosing The Right Grinding Wheel

Understanding grinding wheel fundamentals will help you find the right wheel for the job.

Article
From:
12/15/2000
Modern Machine Shop, Joe
Sullivan

Click Image to Enlarge

The grinding wheel is a cutting tool. It's an abrasive cutting tool.

In
a grinding wheel, the abrasive performs the same function as the
teeth in a saw. But unlike a saw, which has teeth only on its edge, the

grinding wheel has abrasive grains distributed throughout the wheel.

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Thousands of these hard, tough grains move against the workpiece to

cut away tiny chips of material.
Abrasive suppliers offer a wide array of products for a wide array of

These CBN wheels for

double-disc grinding are
used on hard-to-grind
materials in gear, pump,
bearing and automotive
component

manufacturing.

grinding applications in metalworking. Choosing the wrong product can

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cost the shop time and money. This article presents some of the

Grinding Machines & Equipment

fundamentals of selecting the best grinding wheel for the job.

AbrasivesGrits and Grains

Grinding
wheels and other bonded abrasives have two major
components-the abrasive grains that do the actual cutting and the
bond that holds the grains together and supports them while they cut.
The percentages of grain and bond and their spacing in the wheel
determine the wheel's structure.
The particular abrasive used in a wheel is chosen based on the way it
will interact with the work material. The ideal abrasive has the ability

Grinding wheels are

generally labeled with a
maximum safe operating
speed. Don't exceed this
speed limit. The safest
course is not
even to
mount a given wheel on
any grinder fast enough to
exceed this limit.

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to stay sharp with minimal point dulling. When dulling begins, the
abrasive fractures, creating new cutting points.
Each abrasive type is unique with distinct properties for hardness,
strength, fracture toughness and resistance to impact.
Aluminum
oxide is the most common abrasive used in grinding wheels.
It is usually the abrasive chosen for grinding carbon steel, alloy steel,
high
speed steel, annealed malleable iron, wrought iron, and bronzes
and similar metals. There are many different types of aluminum oxide

abrasives, each specially made and blended for particular types of

grinding jobs. Each abrasive type carries its own designation-usually a combination of a letter and a
number. These designations vary by manufacturer.
Zirconia alumina is another family of abrasives, each one made from a different percentage of
aluminum oxide and zirconium oxide. The combination results in a tough, durable abrasive that
works well in rough grinding applications, such as cut-off operations, on a broad range of steels and
steel alloys. As with aluminum oxide, there are several different types of zirconia alumina from
which to choose.
Silicon carbide is an abrasive used for grinding gray iron, chilled iron, brass, soft bronze and
aluminum, as well as stone, rubber and other non-ferrous materials.
Ceramic aluminum oxide is the newest major development in abrasives. This is a high-purity grain
manufactured in a gel sintering process. The result is
an abrasive with the ability to fracture at a
controlled rate at the sub-micron level, constantly creating thousands of new cutting points. This
abrasive is exceptionally hard and strong. It is primarily used for
precision grinding in demanding
applications on steels and alloys that are the most difficult to grind. The abrasive is normally
blended in various percentages with other abrasives to optimize its performance for
different
applications and materials.
Once the grain is known,
the next question relates to grit size. Every grinding wheel has a number

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Choosing The Right Grinding Wheel : Modern Machine Shop

designating this characteristic. Grit size is the size of individual abrasive grains in the wheel. It
corresponds to the number of
openings per linear inch in the final screen size used to size the

grain. In other words, higher numbers translate to smaller openings in the screen the grains pass
through. Lower numbers (such as 10, 16 or 24)
denote a wheel with coarse grain. The coarser the
grain, the larger the
size of the material removed. Coarse grains are used for rapid stock removal
where finish is not important. Higher numbers (such as 70, 100 and 180) are fine grit wheels. They
are suitable for imparting fine finishes, for small areas of contact, and for use with hard, brittle

materials.

Buying Bonds
To allow the abrasive in the
wheel to cut efficiently, the wheel must contain the proper bond. The

bond is the material that holds the abrasive grains together so they can
cut effectively. The bond
must also wear away as the abrasive grains wear and are expelled so new sharp grains are exposed.
There are three principal types of bonds used in conventional grinding wheels.
Each type is capable

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of giving distinct characteristics to the grinding

action of the wheel. The type of bond selected
depends on such factors as the wheel operating speed, the type of grinding operation, the precision
required and the material to be ground.
Most grinding
wheels are made with vitrified bonds, which consist of a mixture of carefully selected
clays. At the high temperatures produced in the kilns
where grinding wheels are made, the clays
and the abrasive grain fuse into a molten glass condition. During cooling, the glass forms a span

that attaches each grain to its neighbor and supports the grains while they grind.
Grinding wheels made with vitrified bonds are very rigid, strong and porous. They remove stock
material at high rates and grind to precise requirements. They are not affected by water, acid, oils
or variations in temperature.
Vitrified bonds are very hard, but at the same time they are brittle like glass. They are broken down
by the pressure of grinding.
Some bonds are made of organic substances. These bonds soften under the heat of grinding. The

most common organic bond type is the resinoid bond, which is made from synthetic resin. Wheels
with resinoid bonds are good choices for applications that require rapid stock removal, as well as
those where better finishes are needed. They are designed to operate at higher speeds, and they
are often used for wheels in fabrication shops, foundries, billet shops, and for saw sharpening and
gumming.
Another
type of organic bond is rubber. Wheels made with rubber bonds offer a smooth grinding
action. Rubber bonds are often found in wheels used where a high quality of finish is required, such
as ball bearing and roller bearing races. They are also frequently used for cut-off wheels where
burr and burn must be held to a minimum.
The strength of a
bond is designated in the grade of the grinding wheel. The bond is said
to have a
hard grade if the spans between each abrasive grain are very strong and retain the grains well
against the grinding forces tending to
pry them loose. A wheel is said to have a soft grade if only a
small force is needed to release the grains. It is the relative amount of bond
in the wheel that
determines its grade or hardness.
Hard grade
wheels are used for longer wheel life, for jobs on high-horsepower machines, and for
jobs with small or narrow areas of contact. Soft grade
wheels are used for rapid stock removal, for
jobs with large areas of contact, and for hard materials such as tool steels and carbides.

Wheel Shapes
The
wheel itself comes in a variety of shapes. The product typically pictured when one thinks of a
grinding wheel is the straight wheel. The grinding facethe part of the wheel that addresses the

workis on the periphery of a straight wheel. A common variation of the straight wheel design is
the recessed wheel, so called because the center of the wheel is recessed to allow it to fit on a
machine spindle flange assembly.
On some wheels, the cutting face is on
the side of the wheel. These wheels are usually named for
their distinctive shapes, as in cylinder wheels, cup wheels and dish wheels. Sometimes bonded
abrasive sections of various shapes are assembled to form a continuous or intermittent side grinding
wheel. These products are called segments. Wheels with cutting faces on their sides are often used

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Choosing The Right Grinding Wheel : Modern Machine Shop

to grind the teeth of cutting tools and other hard-to-reach surfaces.

Mounted wheels are small grinding wheels with special
shapes, such as cones or plugs, that are
permanently mounted on a steel
mandrel. They are used for a variety of off-hand and precision
internal
grinding jobs.

Tying It All Together

A number of factors must be considered in order to select the best grinding wheel for the job at
hand. The first consideration is the material to be ground. This determines the kind of abrasive you
will need in the wheel.
For example, aluminum oxide or zirconia alumina should be used for

grinding steels and steel alloys. For grinding cast iron, non-ferrous metals and non-metallic
materials, select a silicon carbide abrasive.
Hard,
brittle materials generally require a wheel with a fine grit size and a
softer grade. Hard
materials resist the penetration of abrasive grains and cause them to dull quickly. Therefore, the
combination of finer grit
and softer grade lets abrasive grains break away as they become dull,

exposing fresh, sharp cutting points. On the other hand, wheels with the
coarse grit and hard grade
should be chosen for materials that are soft, ductile and easily penetrated.
The amount of stock to be removed is also a consideration. Coarser grits give rapid stock removal

since they are capable of greater penetration and heavier cuts. However,
if the work material is
hard to penetrate, a slightly finer grit wheel will cut faster since there are more cutting points to
do the work.
Wheels
with vitrified bonds provide fast cutting. Resin, rubber or shellac bonds should be chosen if a
smaller amount of stock is to be removed, or
if the finish requirements are higher.
Another factor that affects the choice of wheel bond is the wheel speed in operation. Usually
vitrified wheels are used at speeds less than 6,500 surface feet
per minute. At higher speeds, the
vitrified bond may break. Organic bond wheels are generally the choice between 6,500 and 9,500
surface feet per minute. Working at higher speeds usually requires specially designed wheels for
high speed grinding.
In any case, do not exceed the safe operating speed shown on the wheel or its blotter. This might
be specified in either rpm or sfm.
The next factor to consider is the area of grinding contact between the wheel and the workpiece.
For a broad area of contact, use a wheel with coarser grit and softer grade. This ensures a free,
cool cutting action under the heavier load imposed by the size of the surface to be ground. Smaller

areas of grinding contact require wheels with finer grits and harder grades to withstand the greater
unit pressure.
Next, consider the severity of the grinding action. This is defined as the pressure under which the
grinding wheel and the workpiece are brought and held together. Some abrasives have been
designed to withstand severe grinding
conditions when grinding steel and steel alloys.
Grinding machine horsepower must also be considered. In general, harder grade wheels should be
used on machines with higher horsepower. If horsepower is less than wheel diameter, a softer
grade wheel should be used. If horsepower is greater than wheel diameter, choose a harder grade
wheel.

Care And Feeding

Grinding wheels must be handled, mounted and used with the right amount of precaution and
protection.
They
should always be stored so they are protected from banging and gouging.
The storage room
should not be subjected to extreme variations in temperature and humidity because these can
damage the bonds in some wheels.
Immediately after unpacking, all new wheels should be closely inspected to be sure they have not
been damaged in transit. All used wheels returned to the storage room should also be inspected.
Wheels
should be handled carefully to avoid dropping and bumping, since this may lead to damage
or cracks. Wheels should be carried to the job, not rolled. If the wheel is too heavy to be carried
safely by hand, use a hand truck, wagon or forklift truck with cushioning provided to avoid damage.

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Choosing The Right Grinding Wheel : Modern Machine Shop

Before mounting a vitrified wheel, ring test it as explained in the American National Standards
Institute's B7.1 Safety Code for the Use, Care and Protection of Grinding Wheels. The ring test is
designed to detect any cracks in a wheel. Never use a cracked wheel.
A
wise precaution is to be sure the spindle rpm of the machine you're using doesn't exceed the
maximum safe speed of the grinding wheel.
Always
use a wheel with a center hole size that fits snugly yet freely on the spindle without forcing
it. Never attempt to alter the center hole. Use a
matched pair of clean, recessed flanges at least
one-third the diameter
of the wheel. Flange bearing surfaces must be flat and free of any burrs or
dirt buildup.
Tighten the spindle nut only enough to hold the wheel firmly without over-tightening. If mounting a
directional
wheel, look for the arrow marked on the wheel itself and be sure it points in the
direction of spindle rotation.
Always make sure that all wheel and machine guards are in place, and that all covers are tightly
closed before operating the machine. After the wheel is securely
mounted and the guards are in
place, turn on the machine, step back out
of the way and let it run for at least one minute at
operating speed before starting to grind.
Grind only on the face of a straight wheel. Grind only on the side of a cylinder, cup or segment
wheel. Make grinding contact gently, without bumping or gouging. Never force grinding so that the
motor slows noticeably or the work gets hot. The machine ampmeter can be a good indicator of
correct performance.
If
a wheel breaks during use, make a careful inspection of the machine to be sure that protective
hoods and guards have not been damaged. Also, check the flanges, spindle and mounting nuts to be
sure they are not bent, sprung or otherwise damaged.

System Analysis
The
grinding wheel is one component in an engineered system consisting of wheel, machine tool,
work material and operational factors. Each factor affects all the others. Accordingly, the shop
that wants to optimize grinding performance will choose the grinding wheel best suited to all of
these other components of the process.
About the author: Joe Sullivan is senior product manager for Norton Company, Worcester,
Massachusetts.

What Are Superabrasives?

Superabrasives
make up a special category of bonded abrasives designed for grinding the
hardest, most challenging work materials.
Because carbides,
high speed steels, PCD, PCBN, ceramics and some other materials used to
make cutting tools can be nearly as hard as conventional abrasives, the
job of sharpening them
falls to a special class of abrasives-diamond and the CBN, the superabrasives.
These materials offer extreme hardness, but they are more expensive than conventional
abrasives (silicon carbide and aluminum oxide). Therefore, superabrasive grinding wheels have
a different construction than conventional abrasive wheels. Where a conventional abrasive
product is made up of abrasive all the way
through, superabrasive wheels have abrasive on the
cutting edge of the wheel that is bonded to a core material, which forms the shape of the

wheel and contributes to the grinding action.

Superabrasive wheels are supplied in the same standard grit range as conventional wheels
(typically 46 through 2,000 grit). Like other types of wheels, they can be made in a range of
grades and concentrations (the amount of diamond in the bond) to fit the operation.
There are four types
of bond used in superabrasive wheels. Resinoid bond wheels are

exceptionally fast and cool cutting. They are well-suited to sharpening multi-tooth cutters and
reamers, and for all precision grinding operations. Resin is the "workhorse" bond, most
commonly used and most forgiving. Vitrified bond wheels combine fast cutting with a resistance
to wear. They are often used in high-volume production operations. Metal
bond wheels are used
for grinding and cutting non-metallic materials, such as stone, reinforced plastics and
semiconductor materials that cannot be machined by other cutting tools. Single-layer plated
wheels are used when the operation requires both fast stock removal and the generation of a
complex form.

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Choosing The Right Grinding Wheel : Modern Machine Shop

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