Document kDzDNJ92kON65BQmKXx7Qw500

CIMFORM GRINDING WHEEL APPLICATION GUIDE ABRASIVES RESIN BONDED , ABRASIVES i PLAINTIFF'S EXHIBIT CGI-IS CIMFORM . - iMSS ^Centerless Grinding Microcentric and . 0^nW/iype Grinding t Chucking Grinders Flute Grinding Thread Grinding Grinding '}$? ForM)fe^Snaggiri^h I'> Creepfeed Grinding :S; i Superabmsiyes ^m^m^lLGtMihgr Tool Room Grinding -^Griritfmg']0ieef^ &Mm Wheels^Recommendations V^s/ -*n> m WiH'R'stlOTSS' MIL 000022 Introduction Cincinnati iVInacrc-' seads the metalworking industry in developing superior solutions to grinding and metalworking applications. The Consumable Products Division uses a total systems approach to bring application expertise to its complete line ot metalworking products. The information that you will find in this Application Guide will help remove the curtain of mystery that surrounds many grinding applications. Types of grinding are highlighted in this guide, ranging from sharpening carbide tipped cutters to snag grinding huge billets. Generally each grinding section contains starting grade recommendations, machine data, wheel sizes, and trouble shooting. Your daily use of this publication will quickly familiarize you with Cincinnati Milacron products, and shed some light on solving problems you may face every day. MIL 000023 Mission Statement The Consumable Products Division of Cincinnati Milacron will be the recognized global leader in the development, manufacture and marketing of abrasive and metalworking fluid products and services for the metalworking industry. Using the core strategy of leadership we will endeavor to establish an environment of mutual respect and trust between our employees, customers and suppliers. We will use the principles of innovation and continuous improvement to consistently exceed customer expectations, and be the global supplier of choice. We will reach for growth and profitability in our business while providing growth and opportunity for each of our employees. MIL 000024 Table of Contents 1 General Information Product Availability (Grains) Bushings, Blotters, Metric Conversions Bonds, Vitrified, Resinoid Product Availability -- VQC, VFM, VRW, B90, VA, VSA, VFP, VFQ, VSC Metric Conversions of Wheel Sizes Variable Density Product Line Accessories and Supportive Services Shape Types of Grinding Wheels Average Particle Size -- Surface Finishes Grading Wheels Treatments 'Marking Chart . 1 (Competitive Grains & Bonds "Superabrasives CMSAII Weights of Grinding Wheels Rockwell Hardness Chart 2 Safety Wheel Speed Chart Safety Guide Torque Pressure -- Mounting Broken Wheel Report 3 Cimcool Cimcool Cutting & Grinding Fluids 4 Centerless Grinding RK350-20 Twingrip Starting Grade Recommendations Centerless Wheels in Stock Typical Machines RK220-8 Centerless Machine Data Regulating Wheels "G" Ratio Centerless Basic Principles "Top Up" Thrufeed Rates Typical Applications Fintech Products Trouble Shooting 5 Centertype Grinding 480 Series Step Grinder Starting Grade Recommendations Machine Data Basic Principles Troubleshooting Camshaft Grinding Crankshaft Grinding 6 Precision Roll Grinding Basics of Roll Grinding Applications Trouble Shooting Optimizing Roll Grinding Fintech Products 7 Disc Grinding Starting Grade Recommendations Sizes and Bolt Patterns Applications Troubleshooting 8 Internal Grinding Starting Grade Recommendations Wheel Size & Wheel Speed Basic Principles Trouble Shooting 9 Microcentric and Chucking Grinders RK Series 220-HS Checker Starting Grade Recommendations m 1-2 1-5 1-6 1 -7 1-13 1-15 1-16 1 -17 1 -25 1-30 1-31 1-35 ' 1-36 1-37 1-38 1-40 1-42 1 -43 2-1 2-2 2-8 2-9 3-1 4-1 4-3 4-4 4-5 4-10 4-12 4-13 4-14 4-15 4-21 4-22 4-24 4-24 4-26 5-1 5-3 5-7 5-9 5-13 5-15 5-17 6-2 6-8 6-9 6-10 6-10 7-2 7-3 7-8 7-10 8-2 8-3 8-4 8-9 9-1 9-3 Bearing Grinding Basic Principles 10 Surface Grinding Recommended Starting Grades Machine Data Segments Test Form Basic Principles "G" Ratio in Surface Grinding 11 Creepfeed Grinding ELB's Cam-Master Machine What is Creepfeed Grinding? Test Form VCR Availability Down Cut vs. Up Cut 12 Tool Room Grinding Starting Grade Recommendations Toolmaster Diamond and CBN Monoset Cutter and Tool Grinder General Recommendations CMSA II Conversions Tool & Cutter Grinders Wheel Shapes Sizes and Grades in Stock Spiropoint Grinding Wheels Projectoform and Easy Mount Gear Grinding Wheels Maag Gear and Drill Pointing Tool Room Applications Gleason Wheels Machine Data Troubleshooting 13 Mounted Grinding Wheels Starting Grade Recommendations Shapes Specifications Availability 14 Abrasive Cut-Off Wheels Starting Grade Recommendations Dimensional Limits Hot Press and Cold Press Rubber Bond Bond Types and Abrasives Reinforcement Code Rough Sides General Information Machine Data Arbor Holes Principles of Cutoff Trouble Shooting - 15 Flute Grinding Starting Grade Recommendations Machine Data Applications Troubleshooting 16 Snagging Wheels Snagging Wheel Portable Snagging Wheel Cups, Cones & Plugs 17 Type 27 & 28 Super Speed Portable Super Speed Wheel 18 Thread Grinding Starting Grade Recommendations . . Threads Per Inch Versus Grain Size Threads Per Inch Versus Diameter Basic Principles Troubleshooting 19 Diamond & CBN Superabrasives 20 Grinding Wheel Recommendations g.5 9.7 10-1 10-4 10-14 10-15 10-20 10-21 11 -1 11 -2 11 -3 11 -4 11 -5 12-2 12-3 12-4 12-5 12-6 12-7 12-8 12-9 12-10 12-11 12-12 12-13 12-14 12-15 12-16 12-21 13-1 13-2 13-4 13-7 14-1 14-4 14-5 14-6 14-7 14-8 14-8 14-9 14-11 14-13 14-15 14-17 15-1 15-2 15-4 15-6 16-1 16-1 16-1 17-1 18-1 18-2 18-3 18-4 18-5 19-1 20-1 MIL 000025 i& T MIL 000026 1-1 Product Availability In most grinding wheel specifications, there are only five items needed for a complete grinding wheel grade, j These are: j 1. Abrasive 2. Size of abrasive (grit size) 3. Hardness 4. Structure 5. Bond (vitrified, resinoid, and special). These will i be discussed in depth in the subsequent section. ! Abrasive The abrasive used for an operation is usually determined by the material to be ground. There are four general cat egories of abrasives: A. Aluminum Oxide B. Silicon Carbide C. Diamond D. Cubic Boron Nitride (CBN) Aluminum oxide is used to grind high tensile strength material such as carbon steel, alloy steel, annealed mal leable iron, etc. Silicon Carbide is used to grind low tensile strength materials such as gray iron, chilled iron, bronze, aluminum, copper, etc. Aluminum oxide and silicon car bide are considered conventional abrasives. Diamond is used to grind extremely hard non-ferrous material such as tungsten carbide and ceramics. CBN is used to grind hardened tool steels such as M series or T series. Diamond and CBN are considered superabrasives. To understand the remainder of this section, a knowl edge of the term of "friability" is needed. "Friability" is the ability of an abrasive grain to fracture under grinding stress. More friable abrasives are more easily fractured during grinding and thus cut cooler, but wheels made of these abrasives generally do not last as long. A. Aluminum Oxide Abrasive 2A - Tough aluminum oxide grain with a titanium impurity to impart toughness; used for heavy duty work (blue color). 4A - Semi-friable grain - has a sodium impurity to impart special fracture capabilities (pinkish beige color). 12A - Semi-friable grain - has a chromium impurity to impart special fracture capabilities (pink color). Recommended for some heat sensitive steel alloys, special alloys, and high chrome alloys. 9A - Pure aluminum oxide, very friable grain (white color). This abrasive is recommended for tool steels and other heat sensitive steels. 97A - A combination of 2A and 9A to form a semi-friable wheel used for more heat sensitive steels, or where burn with 2A abrasive is a problem. 2A and 97A are by far the most popular abrasives for most precision grinding applications. 29A - A higher friability mixture of 2A-9A (light gray). WA - White friable aluminum oxide JA - A blend of one friable and one semi-friable alu minum oxide. LA - Similar to JA. FA - Tough aluminum oxide. 13A - Pink semi-friable aluminum oxide. HA - Semi-tough - same as 97A. See page 1-31 for Ceramic Abrasive designations. B. Silicon Carbide 6C - Black silicon carbide - used for grinding non-ferrous materials and gray or cast irons. 5C - Green silicon carbide - used for heat-sensitive, nonferrous materials. 7C - Combination of 5C and 6C. 6C is the most popular grain used for silicon carbide applications. Combination aluminum oxide and silicon carbide - combina tion grains C2A, C4A, and C12A - are available in resinbonded wheels. These combinations of abrasive types are used for special alloys and materials. C. Diamond MD - Uncoated medium friability diamond for general heat sensitive carbides. CMD - Nickel coated medium friability diamond for gen eral uses. AMD - Copper coated medium friability diamond for day grinding applications. DMD - Nickel coated tough diamond for carbide-steel combinations. EMD - Nickel coated friable diamond for carbide grinding (no steel). D. Cubic Boron Nitride 1 BN - Nickel coated CBN used in resin bonds. 2BN - Uncoated CBN used in vitrified wheels. MIL 000027 1-2 Product Availability (cont.) Grit Size Conventional abrasives are available from coarse grit 24 to fine grit 220 mesh. Superabrasives are generally avail able from 60 grit to 1000 grit. Grades The grade of the wheel specifies the relative amount of bond in the wheel. An M grade wheel has more bond than an I grade (M will act harder). Soft grades are used on: 1. Large stock removal operations, (i.e., surface grind). 2. Large area of contact. 3. hard materials. Hard grades are used on: 1. Low stock removal operations (finish). 2. Small areas of contact. 3. Soft materials. Bonds There are two generic types of bonds for precision grind ing: resinoid and vitrified. Resinoid bonds are grinding wheel bonds comprised of a plastic bonding system. Vitrified bonds are grinding wheel bonds comprised of glass-like materials. Though there are no clear-cut dis tinctions between where resinoid and vitrified wheels are used, resinoid wheels are generally used when the wheel has to absorb some shock or the operation requires that no dressing is desired throughout the use ful life of the wheel. Vitrified bonds are used for form holding and high precision operations. Resinoid Bonds The breakdown of resin wheels in grinding is primarily from heat. Apparently the breakdown from pressure plays only a minor role in resins; however, pressure is a major factor in vitrified breakdown. This (in part, at least) explains why these bonds do not act the same in grind ing grade for grade, and why the grade patterns cannot be compared one with the other. To further the confu sion, competitive resinoid grading systems and our own agree less among "themselves than they do in vitrified. For this reason it is seldom wise to rely too heavily on competitive gradings. Although we do not agree with competition, we do have a regular progression in hard ness from grade to grade which is not generally common with other manufacturers. Resin bonds in general have a much higher resistance to thermal shock than do vitrified and are therefore to be 1-3 used on all dry, high stock removal operations to the exclusion of vitrified bond. Resin bonds are better able to absorb mechanical vibr tions and are for this reason preferred in many finishin operations where fine grain wheels are used (120 and finer). The coarser grain sizes are usually avoided in fit ishing because of the tendency of resins to "fish tail", leaving deep scratches in the surface. There is another important difference between resin ar vitrified bonds in application. It is usually easy to deter mine the hard or soft action of a vitrified wheel; howevr this is not always true of resin. A resin wheel will often act soft when it is in fact too hard. This stems from the fact that resins break down from heat. The harder the wheel, the more heat developed - and hence more breakdown. There is no easy way to analyze this type c problem except to say that if several wheels have been tried, each harder in grade than the preceding wheel, and ail act soft, it is often wise to try grades softer than the softest grade tried. Unlike vitrified bond wheels, resin bond wheels cannot be checked for cracks by ringing them with a mallet.AII resin wheels should be given a careful visual inspectior before mounting. Wet or Dry Grinding Resin bond wheels give best results when the bond is selected for either wet or dry grinding. This is important because resins are not waterproof. Some have better moisture resistance; others have better heat resistance. Precision Cincinnati resins B2, B80, B90 and BWK should be used wet. B2 - General purpose resinoid bond system used in moderate to light operations. Usually used for wet grinding, this bond has high moisture but low heat resistance and should be used on applications where any kind of cutting fluid is used. B80 - General purpose resinoid bond used in mode ate to heavy grinding activity. B80 is also designed for wet grinding where there is high stock removal and high feed rates. Usually recommended in the higher grade range - P6, Q6, R6, S6, etc. B90 - Another general purpose resin bond recom mended for both heavy duty and precision grinding. Although somewhat more resilient than B80, usually produces higher "G" rations and better reproducibility BWK - Special purpose resinoid bond. MIL 000028 Vitrified Bonds VFM - General purpose bond system for precision grinding. Used with aluminum oxide only. VRW - General purpose bond system for precision grinding with excellent form holding capabilities. Used with aluminum oxide abrasive only. VQC - General purpose bond system for high pro duction centerless, large centertype, and microcen tric (available in 2A and 97A abrasives only). VA - A slightly softer acting vitrified bond used in grinding large diameter, thin wall, face grinding, and flat parts. V4, VC, VF - Additional vitrified bonds used in creepfeed products and some surface grinding applications. VC2 and VF2 - The "2" indicates the wheel is 1/2 grade harder than standard. VL - Bond system for surface grinding. Used with aluminum oxide abrasive only. VSC - Bond used with silicon carbide abrasive. Diamond Bond B - General purpose bond system designed for MD, CMD, and EMD type diamond. B5 - Dry grinding bond system designed for AMD type diamond. B6 - Special bond system designed for DMD type diamond for carbide steel application. BY - A high quality resin bond used in grinding nonferrous materials. CBN Bonds B4 - General purpose grinding bond designed for 1 BN abrasive. B7 - Toolroom grinding system designed for 1 BN abrasive. Marathon Products VHA - Vitrified bond system designed for internal and notch grinding where aluminum oxide would nor mally be used. VHC - Vitrified bond system designed for internal or notch grinding where silicon carbide abrasive would normally be used. VMA, VEA - Vitrified bonds used in the open struc ture Marathon products. How To Make A Wheel Act Differently Harder Softer Decrease infeed rate Decrease traverse speed Decrease work speed Decrease thrufeed rate Increase infeed rate Increase traverse speed Increase work speed Increase thrufeed rate Additional information for superabrasives is in Section 12. MIL 000029 1-4 General Information. Plastic Bushing Bushing Designation Thickness NBt (1) NB2 NB3 1/2* 3/4" r SB4 (2) SB5 SB6 SB7 SB8 SB9 SB10 SB11 SB12 '/." and thicker 7." and thicker 7." and thicker '/' and thicker 7." and thicker 7." and thicker 7.' and thicker 7/ and thicker 7/ and thicker ID (inches) 1,3/4,S/8 1,3/4,5/8 1,3/4,5/8 1 1 1 1 17. 17. 17. 17. 17. Reduced 10 Sizes (inches) 3/4,5/8,1/2 3/4.5/8.1/2 3/4.5/8.1/2 3/8 1/2 5/8 3/4 1/2 5/8 3/4 7/8 1 Metric and Decimal Equivalents of Common Fractions Fractions of an Inch 1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 1/64 3/64 5/64 7/64 9/64 11/64 13/64 15/64 17/64 19/64 21/64 23/64 25/64 27/64 29/64 31/64 Decimals of an Inch .0156 .0313 .0469 .0625 .0781 .0938 .1094 .1250 .1406 .1563 .1719 .1875 .2031 .2188 .2344 .2500 .2656 .2813 .2969 .3135 .3281 .3438 .3594 .3750 3906 .4063 .4219 .4375 .4531 .4688 ;4844 .5000 Milli meters 0.397 0.794 1.919 1 588 1.985 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.937 8.334 8.731 9.126 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700 Fractions of an Inch 17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4 25/32 13/16 27/32 7/8 29/32 15/16 31/32 1 33/64 35/64 37/64 39/64 41/64 43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64 Decimals of an inch .5158 .5313 .5469 .5625 .5781 .5938 .6094 .6250 .6406 .6563 .6719 .6875 .7031 .7188 .7344 .7500 .7645 .7813 .7969 .8125 .8281 .8438 .8594 .8750 .8906 .9063 .9219 .9375 .9531 .9688 .9844 1.0000 Milli meters 13.097 13.494 13.891 14.287 14.684 15.081 15.478 15.875 16.272 16.688 17.085 17.462 17.859 18.256 18.653 19.050 19.447 19.843 20.240 20.637 21.034 21.430 21.827 22.224 22.621 23.018 23.415 23.812 24.209 24.606 25.003 25.400 Plastic Blotter Availability 4061J 4496G 4061L 44247 4061M 4494B 4061G 4061N 6447J 4817R 7280R 5281G 81181 5166N DIAMETER 87/ 14V," 14V," 17" 17" 17V 20V 20V 87," 11V," 247," 12V," 137," 13" HOLE 677 127," 127." 127," 127." 12.090 1677 1677 57,' 87," 207." 107.' 1077 10" THICKNESS .020 .014 .020 .014 020 .020 .014 .020 .020 020 015 020 020 .020 INVENTORY YES NO YES NO YES NO NO YES YES YES NO NO NO MINIMUM ORDER QTY 100 PCS too PCS 50 PCS too PCS 50 PCS 100 PCS 100 PCS 50 PCS 100 PCS 100 PCS 100 PCS 100 PCS 100 PCS 100 PCS NET CONSUMER SELL PER PC .86 3.16 1.84 5 20 3.76 3 84 6.02 4.43 86 3.16 4 92 91 91 91 1-5 Metric Conversions MM to inches MM Inches 3 6 8 10 13 16 20 25 32 40 50 63 80 100 125 150 180 200 230 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1300 1500 1800 .118 .236 .315 .393 .511 .629 .787 .984 1.259 1.574 1.968 2.480 3.149 3.937 4.921 5.905 7.086 7.874 9.055 9.842 11.811 13.779 15.748 17.716 19.685 21.653 23.622 25.590 27.559 29.527 31.496 33.464 35.433 37.401 39.371 41.339 43.308 45.276 47.254 51.182 59.056 70.867 Inches to MM ~~ Inches MM 1/8 1/4 5/16 3/8 1/2 5/8 3/4 1-1/4 1-1/2 2 2-1/2 3 4 5 6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 60 70 3.17 6.35 7.94 9.52 12.70 15.87 19.05 25.40 31.75 38.10 50.80 63.50 76.20 101.60 127.00 152.39 177.79 203.19 228.59 253.99 304.79 355.59 406.38 457.18 507.98 558.78 609.58 680.37 711.17 761 97 812.77 863.57 914.36 965.16 1015.96 1066.76 1117.56 1168.35 1219.15 1269.95 1523.94 1777 93 Metric Conversions SFPM to M/Sec SFPM M/Sec M/Sec to SFPM M/Sec SFPM 1000 2000 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 10000 10500 11000 11500 . 1200 12500 13000 13500 14000 14500 15000 15500 16000 5.080 10.159 15.239 17.779 20.319 22.859 25.399 27.938 30.478 33.018 35.558 38 098 40.638 43.177 45.717 50.797 53.337 55.877 58.417 .60.956 63.496 66.036 68.576 71.116 73.656 76.196 78.735 81.275 10 12 15 20 22 25 28 30 33 35 38 40 43 45 48 60 63 80 100 1969 2362 2953 3937 4331 4922 5512 5906 6496 6890 7481 7874 8465 8859 9449 11812 12402 15749 19686 MIL 000030 Availability of Permanent Type Bushings 1. Lead bushings are no longer available except as spe cial order on the A80-R2-R regulating wheels. 2. Current I.D. treatments are as follows: Sized hole (S.H.) - a special precision tool coats the hole with a liquid plastic which hardens to a tough, precise hole. Vitrobond bush - a proprietary blend of fillers, molten sul fur and fiberglass is cast into the I.D. This forms a tough, very smooth I.D. Ground hole - I.D. ground to size. Vitrified Bonds VQC - our latest development in vitrified bonds designed as a non-premium bond for improving part quality. VRW - high performance bond for aluminum oxide grain designed for durability in high production applications. VFM - general purpose bond for aluminum oxide grain; designed for form holding. VSC - general purpose bond for silicon carbide abra sives. VA -a slightly softer acting vitrified bond used in grinding large diameter, thin wall, face grinding, and flat parts. V, VC, VF - additional vitrified bonds used in creepfeed products and some surface grinding applications. VC2 and VF2 - the "2" indicates the wheel is 1/2 grade harder than standard. VL - bond for aluminum oxide segments and surface grinding wheels. V5, V6, V7, VI0 - bond for valve seat wheels and mount ed wheels. VFME1 - a vitrified bond for use in special regulating wheel applications. VSA - A high quality vitrified bond developed for use with MSB abrasives. V8 - Additional vitrified bond for use with silicon carbide grain. 3. Wheel bushing availability A. For small holes up to 4" - first preference is sized hole (S.H.) - ground hole is not desirable but can be made available For cup wheels the first choice is sized hole B. For larger I.D.'s over 4" - the vitrobond bush is available for 5", 12", and 20" I.D. holes. Most (but not all) wheel O.D. sizes and thicknesses can be vitrobond bushed. Minimum wheel thickness is generally 2".. Resin Bonds B2 - general purpose bond for wet grinding and cutoff wheels. B80 - a high strength resin bond developed mainly for high stock removal. BB - bond for mounted wheels. B8 - warm pressed bond for severe cutoff operations. BF9 - reinforced bond for cutoff wheels. Special Resilient Bonds BR - special rubber-resin bond for regulating wheels. BWK - special purpose bond.. B90 - another general purpose resin bond recommend ed for both heavy duty and precision grinding. Although somewhat more resilient than B80 usually produces higher "G" rations and better reproducibility. BA, BC, BF, BH - General purpose resin bonds for use in Grades F-S. B254 - Higher strength bonds used in both precision and snagging operations. B320 - Developed for roll grinding and cut-off. B9 - Cold presed cut-off bond. BL3206 - Hot pressed resin bond. E - Shellac bond used in roll grinding. Rubber Bonds R - general purpose rubber bond. CIMFORM GRINDING WHEELS MARKING CHART ON PAGE 1-36 mil 000031 l I 1-6 II VQC Product Availability Diameter 14 16 18 20 22 24 26 30 36 42 Thickness Min. Max. 3/8 4 3/8 4 3/8 4 3/8 10 1/2 4 1/2 20 3/4 8 3/4 10 7/8 10 7/8 6 Grain Types - 2A, 29A, 97A, 12A Grit Size - 46, 54, 60, 70, 80, 90, 100, and 120 Grades -1 through N Structure - None Shapes All I.D. 5'' 8" 9" 10" 12" 16" 18" 20" XX XXXX XX XX XX XXX XX XXXX XXXX XX Not Available - Multigrades, Bias Wheels Standard Maximum Operating Speed - 6500 SFPM for Types 1, 5 and 7. Higher operating speeds should be noted on wheel orders. If approved an "E" will be added to the wheel grade to indicate overspeed operation. VFM CIMFORM Wheel Availability Aluminum Oxide Vitrified Wheels and Segments I Grit Sizes Structure 4 (dense) structure 6 (medium) structure 10 (open) structure 2A 36-220 24-120 24-100 4A 36-220 24-120 24-100 9A 36-220 24-120 24-100 12A 36-220 - 24-120 24-100 97A 36-220 24-120 24-100 29A 36-220 24-120 24-100 Grades Structure and wheel size 4 structure 1/4" to 30" 00 36" 00 42" 00 6 structure wheels & segments 1/4" to 42" wheel 00 10 structure wheels & segments Min. wheel 00 6" Coarse 24 30 Grit Size Medium Fine 54 70 90 120 36 46 to to to to 180 60 80 100 150 H-R H-R G-R G-S F-S F-S F-R H-R H-R G-R * G-S F-R F-Q F-P H-R H-R G-R G-S F-Q F-P F-0 220 F-R F-P F-0 120 H-N G-N G-N G-N F-N F-N F-M F-M E-K D-K D-K D-K D-K D-K D-K `Standard Maximum Wheel Speeds GRIT SIZE & WHEEL GRADE MIL 000032 46 & Coarser 54 & Finer D E F & Harder E & Softer F G & Harder Wheel Type SFPM SFPM 6 & 11 2 other 4500 5000 5500 5000 5500 6000 6000 6000 6500 4500 5000 5500 5000 5500 6000 6000 6000 6500 'See special operating speed section for exceptions. 1-7 VRW SUPER CIMFORM Wheel Availability VRW is available in 2A, 4A, 9A, 12A , 29A and 97A grain types, 4 and 6 structures in wheels only, 1/4' OD and up to 42' OD. 4 STRUCTURE 6 STRUCTURE** GRAIN SIZE GRADES GRAIN SIZE GRADES 36-46 H-S 36 H-M 54-80 G-S 46 G-M * 90-120 F-Q * 54 -120 F-M *150 - 220 F-N *90 grit & finer, 4 structure wheels over 15 inches thick must be ordered in two sections. **6 structure MAXIMUM THICKNESS is 10'//' in one piece. NOTE: D2 treatment only If type 7 web thickness is less than 40%, use speed for type 6 & add "E" for overspeed. Wheel type 6 & 11 2 other Grit size and wheel grade 36 & Finer E& softer F-G H& harder SFPM 4500 5000 6000 5000 5500 5500 6000 6000 6500 `See Special Operating Speed section for exceptions. Resinoid Wheel - B90 Bond Availability Grades: F - T Structure: 6-9-11-13-15 Grain Sizes: 36-150 Variable Densities: 6/4 - 9/5 Grain Types: 2A, 4A, 9A, 12A, 29A, 97A, 5C, 6C, C2A, C4A, C12A Max. Operating Speed: *9500 SFPM *L Grade and softer, 36 grit size = 8000 SFPM Max. Maximum thickness 10' for all grades Resinoid Wheels B2 Bond - General Purpose (Except Cut-Off) Abrasive Type 2A. 4A. 9A. 12A *97A 5C 6C *7C CA C2A. C4A, C9A, C12A 29A, MSB Abrasive Grit Size 24-220 24-220 24-220 24-220 24-220 24-36 24-220 24-220 `97A, 29A and 7C grain available in "1" grain combination only Additional Resin Bonds For Precision and Non-Precision Grinding Bond BA BC BF BH B254 B5 B320 Usage Range F'-N L-Q O-R Q-S P-W R-W F-P B9 BL6823 BL3206 BZ243 BL1830 E N-X X Purpose General Purpose Range From A to H (Hard) High strength bonds used for both precision and snagging operations Coolant resistant bond. Used for roll grinding & soft grade cut-off Basic cold-pressed cut-off bond Softest hot-pressed bond to Hardest Shellac bond MIL 000033 i- VRW Product Availability Abrasive Types: 9A, 4A, 12A, 29A, 97A, 2A Abrasive Sizes: 36-220. See Table for Grade Availability Wheel Thickness: 4 Structure -15" Maximum 6 Structure -10'/2" Maximum 10 Structure - 6" Maximum Structure and Wheel Size 4 Structure 1/4" Through 42" 0.0. 6 Structure 1/4" through 42" O.D. 10 Structure 4"through 30" 36 46 H-S H-S H-M G-M E-K E-K 54-80 G-S F-M E-K Grain Size go.iao F-Q F-M E-K 120 F-Q F-M "Standard Maximum Wheel Speeds -- SFPM Wheel Type E & Softer Grit Size and Wheel Grade 36 and Finer F. G H & Harder 6 & 11 4500 5000 6000 2 5000 5500 6000 Other 5500 6000 6500 'Higher operating speeds must be noted on wheel orders. If approved an "E" will be added to the wheel grade to indicate "overspeed operation." Example: 2A60-H6-VRWE 150-220 F-N VA Product Availability Abrasive Types: 9A, 4A, 12A, 29A, 97A, 2A, Abrasive Sizes: 24-220. See Table for Grade Availability Wheel Thickness: 4 Structure - 24" Diameter Maximum 6 Structure - 10V2" Maximum 8 Structure - 8" Maximum 10 Structure - 6" Maximum Structure Grain Size and Wheel Size 24 30 36,46 54, 60 70, 80 4 Structure 1/4" Through 30" 0 D. 36" O.D. 42" O.D. H-R G-R G-S H-R G-R G-S H-R G-R G-S 6 Structure Segments and Wheels 1/4" thru 42" O.D H-N G-N G-N F-N F-N 8 Structure Segments and Wheels 1/4" through 42" O.D. F-M F-M E-M E-M 10 Structure Segments and Wheels 3" through 30" O.D| E-K D-K D-K D-K 0-K "Standard Maximum Wheel Speeds -- Refer to VFM Speed Table 90,100 F-S F-R F-Q F-M E-L D-K 1-9 120 150 180. 220 F-S F-R F-R F-Q F-P F-P F-P F-0 F-0 F-M " ** MIL 000034 VFM Product Availability Abrasive Types: 9A, 4A, 12A, 29A, 97A, 2A, 32A Abrasive Sizes: 24-220. See Table I for Grade Availability Maximum Wheel Thickness: 4 Structure - 22" Maximum 6 Structure -10'A" Maximum 10 Structure - 6" Maximum Structure and Wheel Size Grain Size 24 30 36. 46 54. 60 70.80 90.100 4 Structure 1/4" Through 30" 0.0. 36" 0.0. 42" O.D. H-R G-R G-S F-S H-R G-R G-S F-R H-R G-R G-S F-Q 6 Structure Segments and Wheels 1/4" thru 42" O.D. H-N G-N G-N F-N F-N F-M 10 Structure Segments and Wheels 3" through 30" O.D| E-K D-K 0-K 0-K 0-K 0-K "Standard Maximum Wheel Speeds -- SFPM Wheel Type Grit Size and Wheel Grade 46 and Coarser 54 and Finer DE F & Harder E & Softer F 6 & 11 4500 5000 6000 4500 5000 2 5000 5500 6000 5000 5500 Other 5500 6000 6500 5500 6000 "See special speed chart tor overspeed applications G & Harder 6000 6000 6500 120 F-S F-Q F-P F-M 150 180, 220 F-R F-R F-P F-P F-0 F-0 VSA Product Availability Abrasive Types: MSB, 1MSB, 3MSB, 5MSB, 7MSB Abrasive Sizes: 24-220. See Table for Grade Availability Wheel Thickness: 8" Maximum Structure and Wheel Size 4 Structure 0 Through 30 0.0. Over 3" thru 42". 6 Structure 0 thru 3" O.D. Over 3"thru 42" 8 Structure 0 thru 3" 0.0, Over 3" thru 42" 10 Structure Segments and Wheels Over 3" thru 30" O.D 24, 46 H-S H-S G-M G-M E-L E-L 54, 60 G-S G-P F-N F-N E-L E-L 80 G-S G-P F-N F-N E-L E-L 0-K 0-K 0-K Grain Size 100 120 . F-Q F-Q F-0 F-0 F-M F-M F-M F-M E-K E-K E-K E-K 150 F-Q F-0 F-M F-M E-K 180, 220 F-N F-N -- -- O-K Wheel Grade G & Softer H & Harder 1-8" O.D. 1/2 3/8 Minimum Wheel Thickness - Inches 10"-14" O.D. 16"-20*O.D. 24" 0.0. 5/8 3/4 1 7/16 1/2 1/2 "Standard Maximum Wheel Speeds -- Refer to VFM Speed Table 30" 0.0. 1-1/2 3/4 36"-42" O.D. 2 7/8 MIL 000035 1-10 VFP Product Availability (Engineered Grain Spacing) Abrasive Types: 9A, 4A, 12A, 29A, 97A, 2A Abrasive Sizes: 30-150 Grit. See Table Wheel Thickness: 6" Maximum, 1/2" Minimum Structure and Wheel Size 42 Structure 4" thru 30" O.D.. 62 Structure 4" thru 30" O.D. 82 Structure 4" thru 30" O.D. 30, 36, 46 l-Q G-N F-M 54, 60 H-Q F-N E-M Grain Size 70, 80 H-R F-N E-M go, ioo G-R F-M E-L 120,150 F-R F-M E-L Standard Maximum Wheel Speeds -- Refer to VFM Speed Chart VFQ Product Availability (Engineered Grain Spacing) Abrasive Types: 9A, 4A, 12A, 29A, 97A, 2A Abrasive Sizes: 30-150 Wheel Thickness: 10" Maximum, 1/2" Minimum Structure and Wheel Size 42 Structure 4" thru 42" O.D.. 62 Structure 4" thru 42" O.D. 82 Structure 4" thru 42" O.D. 30, 36, 46 l-Q G-N F-M 54,60 H-Q F-N E-M Grain Size 70,80 H-R F-N E-M 90,100 G-R F-M E-L Standard Maximum Wheel Speeds -- Refer to VFM Speed Chart 120,150 F-R F-M E-L See page 1-23 for definition of Engineered Grain Spacing i-ii MIL 000036 Silicon Carbide Vitrified Wheels - VSC VSC Product Availability I Abrasive Types: 5C, 6C, 7C Abrasive Sizes: 24-220. See Table for Grade Availability Wheel Thickness: Maximum, See Table Structure and Wheel Size 4 Structure, 1/4 through 42" O.D. 8" Maximum Thickness 6" Maximum Thickness 4" Maximum Thickness 2" Maximum Thickness Sticks 6 Structure, 1/4 Through 42 O.D. 8" Maximum Thickness 6" Maximum Thickness 4" Maximum Thickness 2" Maximum Thickness Sticks 10 Structure Segments and Wheels 3" through 30" O.D. 8" Maximum Thickness *24, 30, 36 P-Q P-R P-S P-T P-U G-Q G-R G-S G-T G-U F-N and smaller O.D. wheels are net available in 24, 30 or 36 grit. 46 0-Q 0-R 0-S 0-T 0-U F-Q F-R F-S F-T F-U F-M 54. 60 0-Q 0-R 0-S 0-T 0-U F-Q F-R F-S F-T F-U Grain Size 70, 80, 90 N-Q N-R N-S N-T N-U E-Q E-R E-S E-T E-U 100 M-P M-Q M-R M-T M-U E-P E-Q E-R E-T E-U D-L 0-L D-L NOTE: Wheels larger than 16" thru 20" thick will be made in 3 equal sections. Example: a 20" thick wheel will be made in 3-6.667" sections. Thickness tolerance for each section will be +.020, -.000. 120 150,180, 220 M-0 M-N M-P M-0 M-R M-Q M-T M-S M-U M-T E-0 E-N E-P E-0 E-R E-Q E-T E-S E-U E-T D-L VSC - Silicon Carbide "Standard Maximum Operating Speeds -- SFPM Grit Size and Wheel Grade Wheel Type 24 Grit and Finer GH 6 & 11 4500 5000 2 5000 5500 Other 5500 6000 1 & Harder 6000 6000 6500 'Higher wheel speeds must be noted on wheel orders. An "E" will be added to the wheel grade to indicate "overspeed operation." Example: 6C60-H6-VSCE Available Grades for Operating Speeds up to and including 8500 SFPM 1. All 4 structure VSC wheels. 2. 6 structure VSC wheels listed below. NOTE: I.D. must not exceed 60% of O.D. Grit Size 24-36 46 54-60 70-90 100-120 150-180 220 Bond VSC VSC VSC VSC VSC VSC VSC Available Grades K6-U6 H6-U6 " G6-U6 E6-U6 E6-U6 E6-T6 E6-T6 MIL 000037 1-12 Resinoid Wheels B90 Bond - General Purpose Availability Abrasive Types: Aluminum Oxide - 9A, 4A, 12A, 29A, 97A, 2A Silicon Carbide - 5C, 6C, 7C Mixtures of Aluminum Oxide & Silicon Carbide - C9A, C4A, C12A, C2A Abrasive Sizes: 24-220 Grit. 5C Available in 36-220 Grit Only Wheel Thickness: 14" Maximum Dependent on Available Tooling Grit Size 24 30 36-80 90-100 120 150-220 Segments 6 Structure -- -- K-T K-T -- -- -- Wheel Size 42" O.D. And Smaller 9, 11 Structure 13 Structure E-R -- D-R E-R D-R E-R 0-R E-R D-R E-R D-R -- 0-R -- 15 Structure -- E-R E-R -- -- -- -- "Standard Maximum Wheel Speeds -- SFPM Grit Size and Wheel Grade Wheel Type 24 Grit and Finer 36 Grit and Finer F and Softer G-L M and Harder F and Softer G-K L and Harder IN, IP 5000 7000 8500 5000 7000 8500 2, 2N, 2P 5000 6000 7000 5000 6000 7000 6,11 5500 7500 8500 5500 7500 8500 Others 6000 8000 9500 6000 8000 9500 `Higher wheel speeds must be noted on wheel orders. If approved an "E" will be added to the wheel grade to indicate "overspeed operation." Example: 2A60-L9-B90E Metric Conversion of Some Standard Size Grinding Wheels Size 6" x: x IV," 7 x V." x IV," 7 x %" x IV," 7 x V." x 1V." 8" x: V," x 1 '/<" 8" x; 7," x 17," 8" x' Xi% x 1V," 8" x: 7," x 17," 10" x r" x 3" 12" x v. x 3" 12" x r x 3" 12" X3/.," x 5" 12" x r" x 5" 14" x r" x 5" 14" X 1 x 5" 16" x 2 " x 5" 18" x Vs" x 9" 20" x 1 "x 12" 20" x 2" x 12" Metric 152.4 X 12.7x31.75 '177.8 X 6.35x31.75 177.8 X 12.7 x 31.75 177.8 X 19.05 x 31.75 203.2 X 6.35x31.75 203.2 X 6.35 x 31.75 203.2 X 12.7x31.75 203.2 X 19.05 x 31.75 254 x 25.4 x 76.2 304.8 X 19.05 x 76.2 304.8 X 25.4 x 76.2 304.8 X 19.05 x 127 304.8 X 25.4 x 127 355.6 X 25.4 x 127 355.6 X 38.1 x 127 406.4 X 50.8 x 127 457.2 X 9.53 x 228.6 508 x 25.4 x 304.8 508 x 50.8 x 304.8 Size 20" X 3" X 12" 20" X 4" X 12" 20" X 6" X 12" 24" X 1" X 12" 24" X 2" X 12" 24" X 4" X 12" 24" X 6" X 12" 24" X 8" X 12" 24" X 10":x 12" 30" X 1" X 12" 30" X 2" X 12" 30" X 3" X 12" 36" X 1" X 12" 36" X 2" X 12" 36" X 3" X 12" 42" X 1" X 12" 42" X 17," x 12" 42" X 2" X 12" Metric 508 x 76.2 x 304.8 508 x T01.6 x 304.8 508 x 152.4 x 304.8 609.6 x 25.4 x 304.8 609.6 x 50.8 x 304.8 609.6 x 101.6 x 304.8 609.6 x 152.4x304.8 609.6 x 203.2 x 304.8 609.6 x 254 x 304.8 762 x 25.4 x 304.8 762 x 50.8 x 304.8 762 x 76.2 x 304.8 914.4 x 25.4 x 304.8 914.4 x 50.8 x 304.8 914.4 x 76.2 x 304.8 1066.13 x 25.4 x 304.8 1066.13 x 38.1 x 304.8 1066.13 x 50.8 x 304.8 For other metric size availability call Cincinnati Milacron Customer Service 1-513-841-8721. 1-13 MIL 000038 4 I Grade Limits -- B90 Excalibur Structure Grain Size 24 30-54 60 70 80 90-100 120 150-180 220 30" & Smaller 97 Wheel Size 36" 97 42" 97 Segments 9 E-R S-Z E-R S-Z D-R D-R D-R S S-Z S-X S-Y S-Y S-W S-U S-V S-Y S-U S-X S-U E-P E-P E-P E-P E-P E-P Use 6 or 9 structure for B90 Bond When converting from Vitrified to Resin Bonded wheels, go 5 grades harder, i.e. 29A801-K6-VFM to 29A801-P6-B90. Grade And Grit Size Limits For Multigrade Wheels Underlined grades and grit sizes indicate the maximum spread permitted for multigrade wheels. *Grit Sizes 26 46 54 60 70 46 54 60 70 80 54 69 70 80 90 0 70 80 90 100 ZQ 80 90 100 120 80 90 100 120 150 90 100 120 150 180 100 120 150 180 220 H 1 J K L M N O Grades 1 J K 'L J K LM K LMN LMNO MNOP NOPQ O PQR P Q R S, 'Availability also governed by grade and grit size restrictions in vitrified and resin sections. NOTE: Structure number must be the same for all portions of the wheel. For example, 97A1201-L4-VFM hardside is not available on a 97A801-J6-VFM wheel. NOTE: If grades are the same and only the grit size is varied, the finer side is considered to be the hard side. NOTE: It is very difficult to differentiate between the hard and soft sides in the finished product for identification purposes. A small vitrified wheel (ceramic button) is placed in the soft side of multigrade wheel at molding near the wheel I.D, This button will be white (9A) in blue wheels (2A) and blue (2A) in white wheels (9A). MIL 000039 1-14 Variable Density Wheels Variable density wheels are made so that the density varies from the periphery toward the center. Described as Denser Harder Portion at Hardness is Specified by Multiple Typical Specifications Wheel, OD, Minimum Centerless et al Variable Density ID Wheel Type Structure Numbers 6C36-K9/5-B2 2A60-M6/4-VFM 20" Discs Zoned OD Grade Letters '2A46-H/G/F13-B2 12" Type 1 wheel sizes available With the provision that maximum thickness limit must be used in conjunction with the available tooling. "No change can be made in grain type or size Variable Density Type 1 Wheel 29A601-K6/4-VFM EXAMPLE Outer Diameter 6 Structure Wheel Size Maximum OD ID Thickness (Nominal) 0 12 6 24 12 10 30 12 10 36 12 to 20 10 42 12 to 20 10 Minimum Thickness 1 1 2 2 2 Inner Diameter 4 Structure Disc Wheel ill K Grade J Grade --Hi 11 29A541-K/J9-B90 EXAMPLE Disc Wheel IV'-viN1-rV.'f*?.** J Grade Grade iT-'bCV! \ I'&'i ''rZ'.'tt A.if- t 29A541-J/K9-B90 EXAMPLE 1-15 Standard Treatments For Vitrified Bonded Products "B" Treatment - Sulfur Impregnation "D" Treatment - Wax Impregnation "D2" Treatment - Special Impregnation "R" Treatment - Resin Impregnation For Mounted Points "S" - Wax Impregnation For Mounted Points Treatment Availability Segments, Wheels, and Mounted Points "B" <18" O.O., <3" Thick Wheels Not Available in VRW. VQC or VSA Wheels "D" S6" O.C., <4" Thick Wheels >6" O.D., <2" Thick Wheels Not Available in VRW, VQC or VSA "D2" Wheels <30" O.D., <3" Thick Wheels 46 & Fine'r, 4"& 6 Structure "R" & "S" Mounted Points Note: Treatments not available for plate mounted or nut Inserted disc wheels. 000040 I Product Line i i i Your Future Grinding When you buy CIMFORM* grinding wheels you're assured of new and improved products. Cincinnati Milacron has many new product development research laboratories, plus numerous other testing and customer service laboratories, and over 10% of company employ ees work in research, development and engineering. First there's basic research. We investigate basics like wheel hardness as a performance characteristic in terms of resistance to wear, tendency to cause metallur gical damage and tendency to create high power demand. One basic research project was a comparison of theoretical predictions of the effects of wheel speed with laboratory results on commercial parts ground at speeds of 12,000 sfpm to 20,000 sfpm. In our Abrasive Development Laboratory, engineers and technicians develop new bonding systems and products for grinding applications. VQC was developed to meet the need for increased part quality without increased costs. The Abrasive Development Laboratory also devel ops new processes to manufacture grinding wheels more efficiently. Here, in addition to developing new products, we check all incoming materials for quality, constantly run value analysis checks in competitive products, and work to improve existing products. The complex structure of grinding wheels requires scien tific knowledge in areas of organic and inorganic chem istry, and ceramics. Cincinnati Milacron's research into the grinding wheel field has brought wheels with improved bonding materials, and entirely new additives to aid the grinding process. The development of our CIMFORM line of wheels is a prime example. CIMFORM Grinding Wheels were developed to offer superior solutions to a wide range of challenging grinding and metalworking applications. CIMFORM products include Vitrified Bonded Abrasives, Resin Bonded Abrasives, Diamond/CBN Superabrasives and a range of Accessories and Supportive Services. For additional information on the full line of CIMFORM products, see accompanying chart. In our Products Testing laboratory we test new and improved product developed by our Abrasive Develop ment Laboratory in actual use in machines. Technicians with machine tool backgrounds use the latest scientific equipment to evaluate grinding wheels on performance factors like wheel life, number of pieces per dress, cubic inches of metal removed per cubic inch of wheel wear (grinding ratio), rate of stock removal, power consumed, finish, pounds of metal removed per hour and pressure required. This work is done in close coordination with our CIMCOOL Metalworking Fluid division and with other divi sions of Cincinnati Milacron. We test new machines to find the best machine-wheel-fluid combination. The work of the Products Testing Laboratory in the prac tical application of wheels is not the last stop in testing abrasive products in use. CIMFORM Grinding Wheels are also tested in many Cincinnati Milacron plants. These plants are among our toughest customers. We then field test on selected customer applications before actual market release. One thing is certain -- you never get a CIMFORM Grinding Wheel until it is thoroughly production proved. The Consumable Products Division of Cincinnati Milacron makes all the popular sizes, shapes and grad ings of precision grinding wheels. Aluminum oxide, sili con carbide, diamond, cubic boron nitride or mixed grain abrasive wheels are supplied with vitrified, resin, rubber and various other bonds. CIMFORM Grinding Wheels are made from 1/4" to 42" in diameter, and from 1/32" to 2T' in thickness. Internal wheels of 1/4" diameter grind the inside diameter of miniature bearing races. Wheels of 42" diameter grind bearing surfaces on automotive crankshafts. Wheels have been made, in sections, of 5' and more in diameter (for lapping- transmission parts) and 6' wide (for grinding limestone slabs.) Our wheels range from tiny points the size of a dentist's drill to wheels weighing more than 1/4 ton. CIMFORM Grinding Wheels have contributed to the higher speeds required of the new grinding machines. We now manufacture wheels to operate at 16,000 sfpm. Wheels for even higher speeds are in the offing. Precision centertype wheels Precision centerless wheels Centerless regulating wheels Surface grinding wheels Creep-Feed grinding wheels Cylinder wheels Segments Internal grinding wheels Cutter grinding wheels Diamond wheels Cubic boron nitride wheels Roll grinding wheels Disc (plate mounted) wheels' Nut-inserted wheels Cutoff wheels Mounted wheels Valve Seat grinding wheels ' MIL 000041 A complete line of foundry snagging, resin, non-preci sion and off hand (portable) grinding wheels 1-16 Product Line (cont.) CIMFORM Brands Vitrified Bonded Abrasives Super CMSA CMSA II Fintech Resin Bonded Abrasives Precision Excalibur Snagging/Portable/Cut- Off (SPC) Apex 2000 Crusader SuperLancer CIMFORM Predict-A-Grind 130 This innovative software is yet another part of the unique program offered by Cincinnati Milacron's "Grinding Systems Engineering" (GSE) Team. This Team has been using an analytical approach to improving their customers' grinding processes since the depart ment was founded in 1988. Ease-of-use and range of applications are additional substantial advantages of CIMFORM PREDICT-AGRIND 130TM. Virtually anyone involved in grinding can use the software's numerous features, with significant return for process improvements. CIMFORM PREDICTA-GRIND 130TM can be used in both DOS and Windows versions. Unique features of CIMFORM PREDICT-A-GRIND 130TM include: Allows metric/inch input of information (or combination of both) Recommendations based on actual grinding process data Provides data necessary to make grinding cycle and process improvements Diamond/CBN Superabrasives Marathon Marathon 2 VIDA Toolmaster Accessories and Supportive Services Abrasive Engineering CIMFORM Predict-A- Grind 130 Neverdull GSE Training Defines process limitations and lists constraints for machine, part and measurements Determines production rates Allows for cycle design for various abrasives and bonding Instantaneous response of calculations User friendly prompting for 25-35 necessary items of input data Listing of important output data; machine set-up para meters and settings Identifies force levels, both normal and tangential Additional programs for machine static stiffness test and calculations Defines optimum wheel speed and wheel width Features "Help Key" for immediate on-line assistance Software provides all the outputs required for grinding process improvements and has been tested under production conditions Contact your Cincinnati Milacron Representative to learn more about these and other programs Milacron has to offer. TYPE 1 STRAIGHT WHEELS TYPE 7 DOUBLE RECESSED WHEELS O TYPE 2 CYLINDER WHEELS TYPE 5 RECESSED ONE SIDE WHEELS TYPE 12 DISH WHEELS .OAOim0 1-17 T\ PE *. >1KAIOH f CLP WHEELS * .I *r*. /J*.-... i *' . A-' - K -- ---W-- -1 Hr- `."C't. ___ L TYPE 13 SAUCER WHEELS MIL 000042 ice ling to Type 20 -- Relieved One Side 1*l~ f~~ f--rsl --1-- -l-- T1 | Type 21 -- Relieved Two Sides Type 24 -- Relieved and Recessed One Side, Recessed Other Side Type 22 -- Relieved One Side. Recessed Other Side GT i-- D ------------K-- - 1 T1 | Type 23 -- Relieved and Recessed Same Side u P --H -- Type 25 -- Relieved and Recessed One Side, Relieved Other Side Type 26 -- Relieved and Recessed Both Sides -Afin v r \ ------ G -- H -- ) MIL 000043 1-18 Product Line (cont.) Meaning Of Markings Wheel Grade Factors to consider when grading a wheel for a particular application are abrasive type, grit size, hardness, structure and bond type. Abrasive type Grinding wheels are made with one of the basic abrasives or a mixture of them. Selection of the correct abra sive for a particular job is dependent on such factors as the type and hardness of the material ground, the finish desired and the production rate required. Often the final selec tion can be made only by trial on the job. (See Two Components -- Thousands of Variations on page 6 for more details on abrasives.) Usually one of the following basic abrasives will meet the needs of the job. Basic Abrasives A -- Tough, brown aluminum oxide -- usually for rough grinding applications 2A -- Blue or brown aluminum oxide -- general purpose, most fre quently recommended 4A -- Off white aluminum oxide -- production & tool grinding 9A -- White aluminum oxide -- tool grinding 12A -- Pink aluminum oxide -- pro duction and tool grinding; particularly suited to hard, heat sensitive materials 13A -- Another pink semi-friable abrasive suited for grinding chrome or materials high in chrome. W5A -- Steel foundries snagging 15A -- Same only more durable 18A -- Same only slightly softer W5C -- Cast iron foundry snagging 15C -- Same only more durable 18C -- Same only slightly softer AZ -- Foundry (Steel and Cast Iron) portable snagging 5C -- (green), 6C (black) -- Silicon carbide -- general purpose; 1-1Q rough grinding tungsten car bide MD -- Diamond -- wet and dry grinding (mostly carbide) AMD -- Copper coated diamond -- dry grinding (carbide) CMD -- Nickel coated diamond -- wet grinding (mostly carbide) EMD -- Nickel coated friable diamond -- wet grinding (carbide) DMD -- Blocky diamond for grinding combinations of steel & carbide 1 BN -- Nickel coated cubic boron nitride -- grinding hardened high speed steel, tool steel and die steel 2BN -- Uncoated cubic boron nitride for production grinding operations Resin Bond System CA -- Mixed aluminum oxide and silicon carbide -- 6C and A C2A -- Mixed aluminum oxide and silicon carbide -- 6C and 2A C4A -- Mixed aluminum oxide and silicon caroide -- 6C and 4A C9A -- Mixed aluminum oxide and silicon carbide -- 6C and 9A C12A -- Mixed aluminum oxide and silicon carbide 6Cand12A Mixed Abrasives On some applications mixtures of abrasives are preferred. Vitrified and resin bond system 97A -- Mixed 2A and 9A aluminum oxide (gray) 29A -- A higher friability mixture of 2A-9A (light gray) 7C -- Mixed silicon carbide 6C and 5C Abrasive grain size The size of individual abrasive grits influences the stock removal rate, chip clearance in the wheel, and corner holding ability. Abrasive grain size is determined by the size of the screen through which the grits will pass. The number of the nominal size indicates the size of the opening in the screen. A low number of grain size indicates a large grain, and a high number denotes a fine grain. Although the problem of screen ing grain sizes is complicated because of the unsymmetrical shapes of the grits, some idea of the grain sizes in inches can be gained by knowing the size of the square open ing between the wires through which the grain will not quite pass: 30 grit 60 grit 120 grit .0232" square hole .0098" square hole .0035" square hole The grit size number may also indi cate a combination of two or more adjacent sizes. Combinations are often found to provide a more efficient grinding action than single sizes. Grain size varies from 8 (very coarse) to 800 (very fine). Choice of grain size for a given operation depends on stock removal rate, surface finish desired and workpiece material. The coarsest grit sizes (8 through 20) are used for billet conditioning and snagging, where the purpose is to rapidly remove large amounts of excess or impure material with little concern about surface roughness or geometry of the part. Ceramic Grains 1MSB 1WB 3MSB 3WB 4WB 5MSB WB -6WB MSB BG DA (usually resin) 10% Ceramic 30% Ceramic 40% Ceramic 50% Ceramic 100% Ceramic 25% Ceramic mil 000044 rawwiMw- ain, ne creen Sizes 24 through 46 are also nor mally used in high stock removal hapes operations where geometry is impor tin tant and some control of surface fin / ish is required on soft materials. >pen- Finish depends upon several wheel /hich characteristics. Fine surface finishes may often be attained with the use of lole a fine grain wheel. However, surface ole finish is also dependent upon the ole glaze of the wheel (flatness of the grain) so that a properly dressed coarse grain wheel may also yield fine surface finishes. Other variables in producing fine surface finishes are bond type, wheel hardness and stock removal rate. di- cient irse) size 20) i d Finer grit sizes do help significantly in grinding hardened work. Here there is less tendency for the wheel to load (metal in the wheel face) than in grinding softer work; and the fine grain has better penetrating abil ity on the hard workpiece. On stock removal operations fine grain gener ates more heat, so steps should be taken to quench the additional heat. On softer materials, where the ten dency to load is greater (large duc tile chips), the coarser grain sizes are more efficient (more pieces per dress or higher metal removal rate) because of the greater chip clear ance between the grains. e Wheel hardness or The grade of a grinding wheel is a measure of the strength of the bond ing holding the individual grains in ic the wheel -- the major factor being ic the average diameter of the individ ic ual bond posts. Grade letters range ic from A to Z in the order of increasing bond content (Marking Chart page nic 36, Section 1). ic if the bond post is not strong enough to withstand the forces imposed on it, fracture occurs and grain is dis charged from the wheel. The wheel is then said to be "soft acting." If this does not take place at a toorapid rate, it becomes an ideal condi tion for rough grinding. However, pre cise control of this breakdown is quite difficult and rarely is accom plished in industry. A greater degree of control may be had for roughing by using a wheel having a somewhat larger-diameter bond post (higher-inthe-alphabet grade letter) and free SHARP GRAIN Fast Diamond Traverse or Crushing DIRECTION --------* OF MOTION INFGGD low , FORCE DULL GRAIN Slow Diamond Traverse DIRECTION OF MOTION ' , INFEED FORCE HIGH High accuracy High culling efficiency Poor finish Low heat Low accuracy Low cutting efficiency Good finish High heat running mechanical roll dresser such as a Desmond. When surface finish is important the bond post diameter must be large enough (grade letter high enough in the alphabet) to prevent the grain from being lost from the wheel face during grinding. The wheel is now said to be "hard acting". The wheel is dressed slowly with a diamond; the flat surfaces left on the grain will develop a good surface finish. See Wheel Dressing, page 24 for more information on dressing. Figure above shows conditions associated with grain condition (sharp grain -- dull grain). MIL 000045 1-2 Product Line (cont.) A grinding wheel consists of only two ingredients: the abrasive grain and the bonding material that holds the grains. But it is far from being a sim ple product. With differences in type of grain and bond, and their propor tions, about one-quarter of a million different standard size, shape and grading variations are possible. Except for diamond, manufactured abrasives have almost completely replaced natural abrasives such as emery and the quartzite used in sandpaper. Even with diamond, the manufactured abrasive has increas ingly supplanted the natural product. The three prime characteristics of abrasives that govern grinding per formance are hardness, toughness and reactivity with work materials. Because of the complexity of the grinding process, including the nature of abrasive wear, guidelines for selecting abrasive type are based on accumulated experience. Aluminum oxide Aluminum oxide is made by refining bauxite ores in an electric furnace. The bauxite is first heated to drive off moisture, and then mixed with coke and iron borings to form the furnace charge. After the mixture has been fused and cooled, the resulting rock-like mass is crushed and screened into the various grain sizes. The color and the toughness of the abrasive is determined by the amount of impurities (iron oxide, tita nium oxide and silica), toughness is also strongly affected by additives. Aluminum oxide, the most popular abrasive by a wide margin, is usually recommended for grinding most steels, annealed malleable and duc tile iron, and nonferrous cast alloys. Specialized aluminas include fused mixtures of zirconium oxide and alu minum oxide for high production snagging, and sintered alumina, which is extremely tough, for billet 1-21 conditioning and other very high stock removal snagging. Aluminum oxide -- chromium oxide alloy is used to combine the cool, low stress grinding action of high purity aluminum with low abrasive wear. The result is Cincinnati's famous pink grinding abrasive, which is particularly well suited for abrasive resistant, heat sensitive tool steels. Silicon carbide Silicon carbide (SiC) is made by mix ing pure white quartz (sand) and fine petroleum coke, plus some salt and sawdust, in an electric furnace. This process is one of synthesizing or combining the sand and coke, in contrast to refining bauxite into alu minum oxide. Again the resulting crystalline mass is crushed and graded by particle size. Silicon carbide is sometimes used for grinding gray iron and unan nealed malleable iron, nonferrous metals like copper, brass, aluminum and magnesium, and nonmetallics, including gem stones. MSB (Ceramic) MSB is a non-seeded ceramic alu minum oxide abrasive that is an extremely tough and durable abra sive in all grades. This grain is chem ically quite pure and of uniform quali ty. It is comprised of a complex poly crystalline microstructure. When used in a grinding wheel it is blend ed, in varied percentages, with a more friable conventional aluminum oxide. A grinding wheel such as this has a much longer and more productive life. The MSB abrasive stays much sharper longer and breaks down ir smaller increments. The act of redressing the wheel is accomplished in smaller incremem for it is no longer necessary to krc out entire grains, or parts of grains simply retouch the face of the MSf wheel .0005 to .0010" deep (In me cases a new diamond dressing to needs to be installed, especially if the present one is dull or flat.). Diamond Diamond is the hardest known sut stance. Until recently use of diamc abrasive was generally limited to hard and dense materials like cemented carbides, marble granite glass and other ceramics. Howeve recent developments in manufac tured diamonds leading to control! crystal configurations and surface coatings have expanded its use in the grinding of other metals in sor specialized cases. Cubic boron nitride This newest manufactured abrasi'. has a hardness second only to dir mond and is 2.5 times as hard as aluminum oxide. It can withstand temperature of 2500F, whereas di mond begins to burn around 130C In its metal-coated form, cubic bo1 nitride has proved generally supe1 to both manufactured diamond an aluminum oxide in grinding superhard high speed steel, tool steel c die steel. It does not, however, co pete with diamond in grinding tunsten carbide MIL 000046 i nuch wn in el is The abrasive grains are the cutting nents, tools of a grinding wheel. They are * knocfcj held in position by one of several 'ains: j bonds. The three major bond types MSB I are organic, ceramic or vitrified, and CBN Grain Vitrified bonds Ceramic or vitrified bonds are strong, rigid and retain high strength sub- ! at elevated temperatures, but their imond lower shock resistance inhibits their to application where mechanical impact or large temperature differentials are nite, likely to occur. Power demand, grindaver, ing pressure, workpiece temperature ,c- and geometry variation are nearly rolled always lower with vitrified wheels, ce Vitrified bonds are also practically i into unaffected by exposure to watersome and oil-based grinding fluids. Vitrify means to change into glass by heat and fusion. A vitrified bond is sive glass-like. Various ceramic materials, dia- such as clay, feldspar, or frit, are as mixed with the abrasive grains and d heated slowly and carefully to dia- around 2300F. At this temperature OOF. the ceramic materials are fused, or soron melted, and when cooled they form >erior a glass-like, porous structure in and which the abrasive grains are held. 3r' Organic bonds I and The organic bonds (resin, rubber ,om- and shellac) have better mechanical in9~ and thermal shock resistance than other bonds. It is also the predomi nant choice for diamond when used in metalworking. Rubber-resin bond is used for centerless grinder regu lating wheels and for cutoff wheels where the piece being cut must be cut to close limits and where the fin ish of a cut is important. The amount of heat generated in some high stock removal operations even with grinding fluid creates large temperature differences in the grind ing wheel. Therefore organic bonds are required to withstand the thermal stresses. Organic bonds being more resilient or yielding tend to generate smoother surface finishes and to tol erate more variation in machine setups. However the resiliency also tends to cause higher power demand, more heat generation with possible workpiece burn and poorer geometry control. Resin bonds are _ likely to be softened by prolonged exposure to water based grinding fluids. Powdered phenol formaldehyde resin and abrasive grains are mixed together to form resin wheels. At the relatively low temperature of 350F the plastic resin flows around the abrasive grains and undergoes an irreversible chemical change. When cooled, the resulting wheel is less brittle and more resistant to thermal stress than a vitrified wheel. Metal bonds Compared to vitrified and organic bonds, the uses of metal bonds are limited. The major use of metal bonds is with diamond abrasive for grinding under harsh conditions. The metal bond diamond wheel removes material slowly and frequently with high heat generation, but in many applications such as certain glass grinding, abra sive wheel shaping, and concrete or stone sawing, the long life outweighs these disadvantages. Metal bonds are also used with alu minum oxide or diamond abrasive to provide conductive wheels for elec trolytic grinding. MIL 000047 1-22 Product Line (cont.) f Wheel structure The structure number in the wheel grading following the grade letter is in reality a number indicating a den sity chart (in a 0 to 15 range a low structure number indicates a close compaction, a high one less com paction). Generally a change in structure has little effect on grinding. In some coarse grain surface grind ing wheels it is desirable that the wheel have more porosity than nor mal. this is done by using a granular material as part of the abrasive mix. After molding,-this granular material will leave the mix as a gas before or during firing. The additional voids left in the mix through the use of the granular material are known as induced porosity and may be desig nated by a high structure number, an additional bond symbol, or both. Concentration in diamond and cubic boron nitride wheels is akin to struc ture in other abrasive wheels in that it is a measure of abrasive per unit volume of grinding wheel. However, the total stock that can be removed with a diamond or cubic boron nitride wheel is usually directly proportional to the amount of diamond or cubic boron nitride it contains. Therefore, 1-23 concentration is a much more impor tant characteristic in diamond and cubic boron nitride wheels than is structure in other abrasive wheels. As with structure and grade, there is no published standard that estab lished quantitative values to designa tions. However, most diamond wheel producers have adopted the conven tion in which 100 concentration des ignates 72 carats of diamond per cubic inch of wheel and smaller con centration numbers refer to the frac tional part of 100 concentration in the wheel; that is, 50 concentration designates 36 carats per cubic inch. The cubic boron nitride wheel con vention is similar but, rather than 100 concentration designating 72 carats, 100 concentration designates 25 vol ume percent of the rim structure. The difference is academic as far as the density is concerned 100 concentra tion in a cubic boron nitride wheel designates exactly the same volume of abrasive as 100 concentration in a diamond wheel. Bond Just as a lathe has a tool post to hold the bit, so a grinding wheel has a bond to hold the grits in cutting position, the bond itself does-not remove metal; its main function is to hold the grains in the cut with vary ing degrees of strength (grade). The first bond symbol, such as V, denotes the general type of bond (vitrified, resin, etc.) and is the same for all manufacturers. The second symbol, consisting of one or more letters or digits, such as S, is the manufacturer's code for a particular modification of the bond, and also for such features as induced porosity, special treatment or reinforced wheels. This second symbol is optional. Engineered Grain Spacing For some applications it may be nec essary to use an induced porosity we call engineered grain spacing. Engineered grain spacing is a con cept of optimized bonding of abra sive grains where the optimum strength of bonding is obtained with minimum of bond content. The high er porosity of the grinding wheel is engineered to be distributed in such a way that the optimum strength of the bonding system is achieved with out addition of bonding material. MIL 000048 _ Standard Shapes of Grinding Wheel Faces For lace N, dimensions V. X and T are specified by Ihe user. N T is the narrower wheel face 30 Angular Grinder. V=60 45 Angular Grinder. Y=45' MIL 000049 1-24 Shape Types of Grinding Wheels Type 1 - Straight wheel. Peripheral grinding wheel having a diameter, thickness and hole. Type 2 - Cylinder wheel. Side grinding wheel having a diameter, thickness and wall wheel is mounted on the diameter, or a similar wheel mounted in a chuck or on a plate. *Type 5 - Wheel, recessed one side. Peripheral grinding wheel having one side straight or flat and the opposite side recessed. A recessed wheel allows wider faced grinding wheel to be used when the available mounting thickness (E) is less than the required overall thickness (T). The recess allows grinding clearance for the nut and flange. - W-- ' A r T E _______f t --*J h* L-- *Type 6 - Straight-cup wheel. Side grinding wheel having a diameter, thickness and hoh with one side straight or flat and the opposite side recessed. This type, however, differs from Type 5 in that tl grinding is performed by the wall (W). The wall dimension (W) takes precedence over the diameter of the recess as an essential intermediate dimension to describe this shap type. 1-25 "Type 7 - Wheel, recessed two sides. Peripheral grinding wheel having both sides recessed to allow grinding clearance for both flanges or recessed so that an unusually wide faced wheel may be mounted whe the available mounting thickness (E) is less than the over thickness (T). ` Note: Arrows indicate grinding surface. 'Recess shall be at least 1/3 the wheel diameter. "E" 5500 SFPM max. MIL 000050 Type 11 - Flaring-cup wheel. (Print Required) .Side grinding wheel having a wall flared or tapered out ward from the back. Wall thickness at the back is normally greater than at the grinding face (W). Type 12 - Dish wheel. (Print Required) Side grinding wheel known as a dish, differing from a Type 11 in that Type 12 always has a (U) dimension. The (W) dimension of a Type 11 becomes the (A) dimension of a Type 12. The grinding may be performed by the (U) face. Type 13 - Saucer wheel. (Print Required) Peripheral grinding wheel known as a saucer, differing from a Type 12 in that the cross-section is equal throughout (U=E). The face is always half-round with R= A z Type 16 - Cone, curved side Type 17 - Cone, straight side, square tip Type 18 - Plug, square end MIL 000051 1-26 Shape Types of Grinding Wheels Type 18R - Plug, round end Type 19 - Plugs, cnonical end, square tip Dished and/or Recessed Wheels A dished side is a depression in the side of a wheel which is tapered from a radial flat at the periphery (A) to an inside flat (K) or recess diameter (P). 1-^ r r E - O--------- ;-------------- ** i*1 ! MStBIS <- i T H U-- 1 *Type 20 - Wheel, dished one side. Peripheral grinding wheel having one side straight or flat and-the other side dished to a flat. ' .. r~ u-*ia| i--1---- crumr u <- T *Type 21 - Wheel, dished two sides. Peripheral grinding wheel having both sides dished to a flat. "Type 22 - Wheel, dished one side, recessed other side. Peripheral grinding wheel having one side recessed and the other side dished to a flat. MIL 000052 1-27 Type 27 - Depressed center snagging wheel Used on hand-held grinders. Type 28 - Dished, depressed center snagging wheel Used on hand-held grinders. . _ MIL 000053 1-28 How to Specify the Following Shapes: NOTE: The words RELIEVED and CONCAVE are often used instead of "Dish" in the description of types 20 through 26. tV TYPE 20 Example: 20 x 2 x 12 - Grading Rec 1/S 14-1/2 x 1/2 Dish 1/2 TYPE 21 Example: 20 x 2 x 12 - Grading Rec 2/S 14-1/2 x 1/2 Dish 2/S 1/2 TYPE 22 Example: 20 x 2 x 12 - Grading Rec 2/S 14-1/2 x 1/2 Dish 1/S 1/2 TYPE 23 Example: 20 x 2 x 12 - Grading Rec 2/S 14-1/2 x 1 Dishl/2 TYPE 24 Example: 20 x 2 x 12 - Grading Rec 2/S 14-1/2 x 1/2 Dish 1/S 1/4 TYPE 26 Example: 20 x 2 x 12 - Grading Rec-2/S 14-1/2 x 1/2 Dish 2/S 1/4 TYPE 25 Example: 20 x 2 x 12 - Grading Rec 1/S 14-1/2 x 1/2 0/S 14-1/2 x 1/4 Dish 2/S 1/4 Example: 20 x 1 x 12 - Grading 15" Raised Hub 1/S-1/2" Face Si Example: 20 x 1 x 12 - Grading Rec 1/S 1/4 to 15" Hub Example: 20 x 1 x 12 - Grading Rec 2/S 1/4 to 15" Hub n on Example: 20 x 1 x 12 - Grading 15" Raised Hub 2/S-1/2" Face I- __ '90 r-i^ y/v 30 Angular Grinder - V = 60 45 Angular Grinder - V = 45 Example: 20 x 1 x 12 - Grading N Face X = 1/4 V = 45 MIL 000054 Availability for C-10 & C-11 Stones 20 Charts c-io thickness MAX. MIN. WIDTH-W LENGTH-L 1/2 1 3/4 !2 2 1 2 1 1-1/4 1/8 1 3/8 3/4 1 2 2 7/16 1/2 3 4 4 4 4 4 6 6 1-1/4 2 1-1/8 1-1/4 1-1/4 3/16 1 2 1-1/2 1 2 6 6 7 8 8 2 28 2 38 2 48 1 58 C-11 3/4 3/16 4 8 ] Surface Finish Comparisons Current USA *Ra D (or AA or CLA) English Metric Micro Micro- inches meters (or microns) = 60 = 45 i 0.5 1 2 4 8 16 21 63 125 250 500 1000 2000 0 012 0.025 0 050 010 0 20 0 40 0 80 1 60 32 63 12.5 25 50 Older USA RMS+Rq Micro inches 1 W. German CH Number (orVDI It) 2 Approx, ff 0 55 1.11 22 44 89 6 178 12 35 5 18 70 24 140 30 275 36 550 42 1100 2200 1 Soviet Class It Ra micro meters 14 13 12 11 10 9 8 7 6 5 4 3 2 Average Particle Size of Abrasive Grain This chart may be used to determine the grit size which must be specified in order to maintain a specified radius in a workpiece. If a certain radius is required, find the particle size which is the same as the radius required and specify the corresponding grit size or the next finer grit size. For example, if a .010 radius is required, specify 80 or 90 grit; or if a .003 radius is required, specify a 180 or 220 grit. Swiss N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 Nil N12 French 9 10 11 12 13 14 15 16 17 18 19 Grit Size Aluminum Oxide Silicon Carbide 4 6 8 10 12 14 16 20 24 30 36 46 54 60 70 80 90 100 120 150 180 220 240 280 320 400 500 600 900 Levigated Alumina Average Inches .2577 .2117 .1817 .1366 .1003 .0830 .0655 .0528 .0408 .0365 .0280 .0200 .0170 .0160 .0131 .0105 .0085 .0068 .0056 .0048 0034 .0026 .00248 ,00175 .00128 00090 .00065 .00033 00024 ,000118 Particle Size Microns 6848 5630 4620 3460 2550 2100 1660 1340 1035 930 710 508 430 406 328 266 216 173 142 122 86 66 63 44 32 23 16 8 6 3 German Micro meters 0.012 0.025 0 050 0 10 0 20 0.40 0 80 1.60 32 63 12.5 25 30 Japan Microns 0012 0.025 0 050 010 0.20 0.40 0 80 1 60 3.2 6.3 12.5 25 50 Ra is now the universal sym bol for the parameter that was called AA (Arithmetic Average) in the United States and CLA (Centre Line Average) in England. `Also same values for Dutch RU. 1RMS 1.11 x Ra Ra to Microns} (Ra x .02541 = MICRONS RMS to Ra} RMS Ra 1.1 Microns to Ra} MICRONS=Ra .0254 Ra to RMS} Ra x 1 1 RMS MIL 000055 1-30 Grading Cincinnati Wheels J The five variables to be considered in grading a wheel are: 1. Abrasive type 2. Abrasive size 3. Hardness 4. Structure 5. Bond Grade changes and a resultant change in grinding action can be made by variations in one or more of these com ponents. these factors, especially Grain Type and Bond Type, will be discussed in greater depth in this section. Abrasive Selection of the correct abrasive for a particular job is dependent on such factors as the type and hardness of the material ground, the finish desired and the produc tion rate required. Often, the final selection can be made only by trial on the job. A. Conventional Aluminum Oxide Abrasives 2A --Tough aluminum oxide grain with a titanium impurity to impart toughness, used for heavy duty work (blue color). 4A -- Semi-friable grain -- has a sodium impurity to impart special fracture capabilities (pinkish beige color). Production and tool grinding. 12A -- Semi-friable grain -- has a chromium impurity to impart special fracture capabilities (pink color). Recommended for some heat sensitive steel alloys, special alloys and high chrome alloys. 9A -- Pure aluminum oxide, very friable grain (white color). This abrasive is recommended for tool steels, and other heat sensitive steels. 32A -- A unique single crystal aluminum oxide abra sive particularly suited for broad contact area grinding of heat sensitive alloy steels (beige in color) used extensively in tool room wheels. Only used with VFM Bond. B. Ceramic (MSB) Aluminum Oxide Abrasive Conventional aluminum oxide abrasives are manufac tured by using an electric furnace for fusing raw materi als into a large ingot, this ingot is then crushed and screened to obtain various grit sizes. Ceramic aluminum oxide (new generation abrasive) is manufactured by a sintering process. The sintered abrasive wears more uni formly and breaks down by losing smaller particles of abrasive. Significantly longer life, more parts per dress and lower power demand can be obtained with the ceramic grain. All MSB products are manufactured with a 1-31 I single grain size. Example: 5MSB601,3MSB601, etc. IMSB -- A mixture of 10% ceramic (MSB) with 90% of a friable conventional abrasive (9A). Used mostly j internal wheels for I.D. grinding (light color, tinge of blue). 3MSB -- A mixture of 30% ceramic (MSB) and 70% of a friable conventional abrasive (9A). For relatively low stock removal operations and relatively soft parts (light bluish color). 5MSB -- A mixture of 50% ceramic (MSB) and 50% of a friable conventional abrasive (9A). For more severe operations, form holding and harder parts (blue In color). 7MSB -- A mixture of 70% ceramic (MSB) and 30% j of a friable conventional abrasive (9A). For operations where improvement can be obtained with a higher percentage of MSB (blue in color). MSB -- 100% ceramic abrasive. Rarely recommend ed. For deep slots, intricate forms, hard parts and heavy stock removal (blue in color). C. Silicon Carbide 6C -- Black silicon carbide -- used for grinding nonferrous materials and gray or cast irons. 5C -- Green silicon carbide -- used for heat sensitive non-ferrous materials. 7C -- A 50/50 mixture of 5C and 6C. D. Abrasive Mixtures - Conventional For some applications, mixtures of abrasives are pre ferred. Mixtures of abrasives can be used to get perfor mance-characteristics intermediate between the individ-i ual abrasives. j Mixtures for Vitrified and Resin Bond Systems < 97A -- A semi-friable mixture of 2A and 9A aluminurr. oxide abrasives (grayish in color). 29A Higher friability mixture of 2A and 9A (light gray color). 7C -- A mixture of 6C and 5C silicon carbide abra sives (greenish-black in color). MIL 000056 I etc. Mixtures for Resin Bond Systems Only 90% C2A -- Mixture of aluminum oxide and silicon carbide ostly - 2A and 6C. e of C4A -- Mixture of aluminum oxide and silicon carbide - 4A and 6C. I 70% tively t parts C12A -- Mixture of aluminum oxide and silicon car bide - 12A and 6C. C9A -- Mixture of aluminum oxide and silicon carbide -- 9A and 6C. J COO/ NOTE: Various blends of ceramic grains are also avail- e able for use with the resin bond system, i.e. 3MSB, ts 3MSBC2A, 3MSB29A, 3MSB97A, 3MSB2A. _ E. Diamond 30% rations -- Uncoated medium friability diamond for gener ic i al heat sensitive carbides - wet and dry grinding. i CMD -- Nickel coated diamond - wet grinding (mostly nend-' carbide). nd AMD -- Copper coated diamond - dry grinding of car bide. I nonpositive DMD -- Nickel coated blocky diamond for carbide- steel corr|binations. EMD -- Nickel coated friable diamond for carbide 9rindin9 (no steel) - wet. NCD -- Nickel coated diamond for difficult to grind non-ferrous materials (i.e. carbide, ceramic, glass, etc.) F. Cubic Boron Nitride erfor- *N -- Nickel coated CBN used in resin wheels. idivid- BN -- Nickel coated CBN used in resin bonded wheels for the toolmaster program. 2BN -- Uncoated CBN used in vitrified wheels. minum^r`f Size Conventional abrasives are available from coarse grit t arav * *'ne 9r'* (^20) mesh. The grain size in a Cincinnati wheel grade is usually a mixture of 1/3 nominal size, 1/3 next finer and 1/3 next coarser size. Example: a 60 grit ra* wheel contains 1/3 each 54, 60 & 70 grit. Exceptions are 7C, 29A, 97A, IMSB, 3MSB. 5MSB and 7MSB. A single Qrit size (nominal) is used in wheels made with these abrasives. The single grit size is indicated by a 1 suffix. Example: 29A601. Superabrasives are generally avail able from 60 thru 320 grit. Grades The grade of the wheel specifies the relative amount of bond in the wheel. An M grade will has more bond than an I grade (M will act harder). Soft grades are used on: 1. Large stock removal operations, (i.e., surface grind). 2. Large area of contact. Hard grades are used on: 1. Low stock removal operations (finish). 2. Small areas of contact. 3. Soft materials. Bonds There are two generic types of bonds for precision grind ing: resinoid and vitrified. Resinoid bonds are grinding wheel bonds comprised of a plastic bonding system. Vitrified bonds are grinding wheel bonds comprised of glass-like materials. Though there are no clear-cut dis tinctions between where resinoid and vitrified wheels are used, resinoid wheels are generally used when the wheel has to absorb some shock or operation requires that no dressing is desired throughout the useful life of the wheel. Vitrified bonds are used for form holding and high precision operations. Resinoid Bonds The breakdown of resin wheels in grinding is primarily from heat. Apparently the breakdown from pressure plays only a minor role in resins; however, pressure is a major factor in vitrified breakdown. This (in part, at least) explains why these bonds do not act the same in grind ing grade for grade, and why the grade pattern cannot be compared one with the other. To further the confu sion, competitive resinoid grading systems and our own agree less among themselves that they do vitrified. For this reason itjs seldom wise to rely too heavily on com petitive gradings. Although we do not agree with compe tition, we do have a regular progression in hardness from grade to grade which is not generally common with other manufacturers. Resin bonds in general have a much higher resistance to thermal shock than do vitrified and are therefore to be used on all dry. high stock removal operations to the exclusion of vitrified bond. Resin bonds are better able to absorb mechanical vibra tions and are for this reason preferred in many finishing operations where fine grain wheel? are used (120 and finer). The coarser grain sizes are usually avoided in fin ishing because of the tendency of resins to "fish tail", leaving deep scratches in the surface. MIL 000057 1-32 There is another important difference between resin and vitrified bonds in application. It is usually easy to deter mine the hard or soft action of a vitrified wheel; however, this is not always true of resin. A resin wheel will often act soft when it is in fact too hard. This stems from the fact that resins break down from heat. The harder the wheel, the more heat developed - and hence more breakdown. There is no easy way to analyze this type of problem except to say that if several wheels have been tried, each harder in grade than the preceding wheel, and all act soft, it is often wise to try grades softer than the softest grade tried. Unlike vitrified bond wheels, resin bond wheels cannot be checked for cracks by ringing them with a mallet. All resin wheels should be given a careful visual inspection before mounting. Wet or Dry Grinding Resin bonds give best results when the bond is designed for either wet or dry grinding. Some resins have better wet strength, others better heat resistance. Precision grinding with rare exceptions is always done wet. Resin bonds used in precision grinding are designed to resist breakdown from the various coolants which can be used. Cut-off operations can be done either wet or dry. B2 -- General purpose bond used mostly in precision grinding operations. Can also be used in cut-off appli cations, wet or dry where a soft acting bond is required -- especially useful on heat sensitive materials. B90 -- A recently developed (Excalibur) general pur pose bond which has proven to be more consistent in precision grinding applications with longer wheel life compared with similar wheels made with B2. Competes with Norton's B17. B5 -- Bond system specifically designed for flute grinding. BHT -- Bond system specifically designed for thread grinding. B8 -- Warm pressed bond system used in nonreinforced cut-off wheels. Harder acting compared to B2. BF9 -- A bond system designed for use in reinforced cut-off wheels. BPN -- Bond system for use in an economy line of non-reinforced cut-off wheels. SPY -- Bond system for use in an economy line of reinforced cut-off wheels. B9 -- Cold press cut-off. 1-33 B2 -- Hot press cut-off. BB -- Bond system designed for use in mounted points. BX -- Resin bond system used for deburring and veq light stock removal. Very limited availability. Some A, E and W shape mounted wheels and some small diam eter Type 1 wheels. Cotton fiber reinforced. BXP -- Softer and more resilient bond than BX. Best suited for polishing. Also very limited availability. Cotton fiber reinforced. Special Resilient Bonds BWK -- Resin modified bond used in light stock removal, precision grinding applications. BR -- Resin modified bond designed for use in regu lating wheels. Rubber Bonds R -- General purpose rubber bond for cut-off wheels where burr and burn free parts are essential, regulat- i ing wheels and mounted points Vitrified Bonds VFM -- General purpose bond system for precision grinding. Used with aluminum oxide only. j VFMEI -- VFM bond used in special regulating whee!< applications (lappers). 1 VRW -- General purpose bond system for precision grinding with excellent form holding capabilities. Used with aluminum oxide only. \ VQC -- General purpose bond system designed for : high production centerless, large centertype and i microcentrics (available with 2A, 29A, 97A and 12A abrasives). VL -- Surface grinding bond. General use would be inj segments and larger wheels (20" x 24" O.D.). Used > only with aluminum oxide abrasive. j VA -- Bond system used where softer, cooler cutting ! action is required, e.g. burn sensitive, thin wall parts, j large parts. Works extremely well with 29A abrasive. | VSA -- Bond system specifically designed for MSB j abrasive and mixtures of abrasives containing a por- : tion of MSB _ ' VCR -- Bond system specifically designed for use in ; creepfeed grinding wheels. Used with both aluminum ! oxide and silicon carbide abrasives. MIL 000058 ad nd ver ne A, f : diam-j Best' i. k regu- /heels jgulat- ision wheel :ision . Used id for id 12A d be if sed V4 -- A low temperature bond used largely in creepfeed and surface grinding applications. VC -- A very similar bond to be used when grain size is 54 and finer. VF -- Similar to VC. To be used when grain size is 60 and finer. VCO -- Bond system used exclusively for segments. Limited availability. AA-1, CD universal, NO Universal and HM14 styles only. 2A, 97A, 9A and 12A abrasives only. VFP -- Bond used in products with engineered grain spacing. Pores are generated by burn out during firing of an organic material which is uniformly distributed in the wheel. Use only with aluminum oxide abrasives. VFQ -- Another bond used in products with engi neered grain spacing. Unlike VFP products, the pore inducer does not burn out, but is a soft material uni formly dispersed in the wheel which crushes easily during grinding creating the effect of porosity. Use only with aluminum oxide abrasives. VE0615 -- Bond symbol for VFM wheels for operation at 16000 SFPM. VE0685 -- Bond symbol for VRW wheels for opera tion at 16000 SFPM. VSC -- General purpose bond used only with silicon carbide abrasives. V5 --Tough mounted point bond used with aluminum oxide abrasives. V6 -- Glossy mounted point bond used in precision operations with aluminum oxide abrasives. Ml -- General purpose bond for use in mounted points with silicon carbide abrasives. utting Darts, isive. i/lSB t por- jse in linum MIL 000059 1-34 Grinding Wheel Treatments Availability I For certain purposes grinding wheels are impregnated with material designed to aid or improve the grinding action. This is called "treating" the wheel. Treatment will improve the grinding action by: 1) Reducing loading. Loading is buildup of metal on the abrasive surface resulting from working soft and ductile metals such as aluminum, soft bronze, brass, magnesium, etc. The use of special treatment fills the pores and helps to prevent swarf buildup. 2) Improving cutting action and life. On heavy duty operations sufficient heat is generated to soften the treatment so that it flows and has lubricating action. 3) Changing the grinding action. This means increas ing wear resistance without affecting the rate of cut or burning the work. 4) Helping to maintain and hold form on shaped wheels. Filling the pores adds support to the abrasive grains. 5) Sealing the pores - or waterproofing bonded abrasive products. How to Order Treated Wheels Treatment designation is shown in the marking as follows: 14 x 2 x 1 'U - 97A601-K6-VFMD2 1 x 1 x 3/8 - 9A80-M4-VRWD2 D - Wax B - Sulphur D2 - Special Impregnation Basically there are three types of treatments being applied to CINCINNATI Grinding Wheels today. These are: D - Wax B - Sulphur and a special impregnation called D2 Contact your Cincinnati Milacron Marketing Company, Territory Manager or Application Engineer to determine the exact sizes and specifications for which these treat ments are available. WAX - D Treatment includes parafins, and stearates. This type of treatment is used on applications to retard wheel loading. SULPHUR - B Treatment is by far the most widely used It finds extensive use in the bearing industry on highproduction, fast stock removal, internal grinding opera tions. The automotive industry also uses sulphur treatec wheels. As much as 70-80% of all honing sticks are sul phur treated. Most vitrified bonded cutlery grinding wheels are sulphur treated. Sulphur treatment is not available in organic bonds. Better surface finishes can be produced with sulphur treated wheels than with wheels having no treatment. D2 Treatment (proprietary) - Another popular treatment used largely in the bearing industry on high-production bore and race grinding operations. It does not have the stain and odor characteristics found in sulphur, but doe: add cooling and lubrication to the grind. Prices The prices of treated wheels are 5 to 15 percent highe' than those of the same wheels untreated. Sulphur treat ment is not available in VRW or VQC bond. Standard Treatments for Vitrified Bonded Products For VFM, VL and VSC Only Exception: D2 is available in VRW and VQC "B"Treatment - Sulfur Impregnation "D" Treatment - Wax Impregnation "D2"Treatment - Special Impregnation "R" Treatment - Resin Impregnation for Mounted Wheels "S" Treatment - Wax Impregnation for Mounted Wheels Treatment "B" "D" "02" Availability Wheels 18" O.D. and Smaller, 3" Thick and Thinner 70 Grit and Finer, H Grade and Harder NOT AVAILABLE IN VRW. VSA Wheels 6" O.D. and Smaller. 4" Thick and Thinner Over 6" thru 30" O.D., 2" Thick and Thinner NOT AVAILABLE IN VRW. VSA Wheels 30" O.D. and Smaller, 3" Thick and Thinner 46 Grit and Finer. 4 and 6 Structure NOTE: Treatments are not available for plate mounted and o. inserted disc wheels MIL 000060 ig hese pany, ermine 9 treat ies, retard y use lighiperatreatei ire sut '9 ds. ihur -lent. itment uction ve the ut does higherf ir treat- t :ed d and nut MIL 000061 1-36 Typical Marking: CIMFORM GRINDING WHEELS CINCINNATI GRAIN TYPES MFG CINCINNATI MILACRON Premium Zirconia .Alumina AZ Zirconia Alumina 18A. W5A I5A Acme Allison Abrasives Bay Stale Buckeye Carborundum Colonial Gardner Hanson Jowtrt Rodgers MWA National Norton NZ. NZC Pacific Radac Red Hill Sterling Tyrolit Winterthur A 28A 3XT, 2XT, 8XT 27A, 33A ZR. ZRA, ZRC AZA. VA ZA 24A.ZA ZF 3ZF ZS 4ZF. 5ZF 19A. 20A. 21A YA. YB YD ZA, XA VA.VA2 21A Regula A AK FA Semi Friable Friable While 2A 9A 10A WA 10AK Pink 12A 82A 13A Off White/ Tan AO Mixture 32A 29A. 97A 11A H5A. 2A, HA, LA. JA. HSAK A, FA A.TA. TDA A 3A A. FA WA 9A WA 17A 19A WA W4A 8A, 2A, 16A MA SC/AO Mixture CA C2A. C4A C9A.C12A E5A. R5A. R5AK CA, CIA. C2A CA SC Heavy Duty 15C, 18C W5C SC Regular Black 6C C CK C c GC Friable Green 5C GC GC SC Mixture 7C FC RC Synthttle1 WSbTImsbT] 3MSe, SMS8, ZMSB. 3MSB2A 3MS829A jS 3MSB97a] $ 3MSBC2A i 3MSB6C 3 DA.WB.3Wr' ------ --* CA. MA CA 7C HC C C 1C 3C IGA. 3GA, j 5GA. GA i GC -- < A. GA A TA AA 20A A. 84A, 82A TA. 8A G. A 1A. 8A 2A A. PA A. 76A 57A. U57A A 35A 80A WA W 29A SA 38A 50A A. TA, 9A,WA RA. WRA BA A, FA A A A WA KA 31A WA 89A 9A,53A BA. PA 51A. 24A. 25A DA 5TA, IOTA. I5TA.22TA. 26A 13A.88A.8SA CA 5TAC 10TAC AC RA SFA.SflA WA BA 25A.64A. 32A 86A 49A 47A AT OA "88A 57A, 68A HA 90A. 91A HA. W2A AW 8AC.11AC MA. HA 16A, I9A 23A,53A 40A. 42A, 45A, 46A 9RA.WAA, 97A. RFA, RAA. 7RA. 43A,45A AC ZA. EA. PA 61 A, 64A. 67A CA. AC AX C CA. CKA AC 69A. 70A. 71A.72A 73A CA 41C. 42C JA AC TC 3C c C c c c X 7C c 37C 75C C GC C tc c GC RC GC CGC GC SC 1 GC 4C GC 1 ] 1 GC RC ! 39C 74C 1SG.3SG. | 5SG SG 1 80C 77C GC 8C 1GA.3GA, j 5GA J GC SC C 50C 97A HC I CINCINNATI BOND COMPARISONS CINCINNATI MILACRON VL Acme Allison Abrasives VFM V6.VK VC. VF. V9 voc VRW VCR V3 VKP VP3 VA V.V9 Bay State Carborundum Colonial V10 V22, V52. VA2 V76 V76 KOOLPORE V52KS V62 VHP. VTP V14.V20 VT V30 V40 V60 VS. VS01 VSP Gardner MWA National Norton acitc Radiac Sterling V VC VRC V3 VI VF V6W VBE VA3 VS5 V VA V25 V VI V3 V8 VW VH3 V6 VFIP VMM VBE VI27. VCF V128 VOS VP V2P Tyrotit Winterthur V V 1-37 VSC VSA VS V, VC. VF V * V32 V89 VR, VUF V VO. VGC VSLV12C VS. VBS Vv V VKM) VS8 V9 VD6 VM VC VS VOS V8 V B2 B9 81, B4, 86.86A B24.BO 8P2 B5SW 8SRW BSL1. BSL2 8C? B B17 -824 B3 830 936 8. 8FC 8T BT8 8 B B80 B90. BA BWK 6238 BC. BF B291 3320 BH. B254 84A.86A BJ2 B. 85.B11 BA2, BC2 BSL3 BSL4 B. BK. BW BEX BB B25 B25W BX BH -- ee BB2 BFM 8F 824 8AF 85 BZ j BHF 8G2 BRSAA . BT 8T 9FC . - BX354 0NC __ __ 3F _. MIL 000062 CIMFORM GRINDING WHEELS SUPERABRASIVE MARKING CHARTS ynthetlc l&QSfV| (MSB. 5MSB, 3MSB2A 29A. )7A, /2A >C B.3WB --- ga] .A BESIN bond diamond wheels grit-------- type md Uncoated rMD AMD DM0 EMD NCD Nickel Coated Copper Coated Nickel Coated Nickel Coated Nickel Coated GRIT SIZES 46 thru 600 46 Thru 320 46 thru 320 60 thru 320 60 thru 320 100,150, 220 GRADES Soft-J-L-N-P-R-Hard J-L-N-P-R J-L-N-P-R J-L-N-P-P J-L-N-P-R P-R CONCENTRATIONS Low-50-75-100-High 50-75-100 50-75-100 50-75-100 60-75-100 75-100 RESIN BOND CBN WHEELS GRIT TYPE 1BN Nickel Coated GRIT SIZES 46 thru 320 46 thru 320 SG. G BN Nickel Coated 100,150, 220 SA. VITRIFIED BOND DIAMOND WHEELS GRIT TYPE RD GRIT SIZES 60-320 GRADES Solt-M-O-Q-S-U-Har Q - Light Duty T - General Purpose W - Heavy Duty Q - Light Duty T - General Purpose W - Heavy Duty GRADES M-N-0 CONCENTRATIONS Low-80-100-High Q=44 T=66 W=88 Q=44 T=66 W=88 CONCENTRATIONS 50-75-100 BOND B, BY B, BY B5, B5Y B6, B6Y B, BY BDL DEPTH OF DIAMOND **** BONO B4, B4Y 87 DEPTH OF DIAMOND BBL BOND VDA DEPTH OF DIAMOND .... VITRIFIED BOND CBN WHEELS GRIT TYPE 2BN 2BN Uncoated Uncoated GRIT SIZES 60 thru 320 60 thru 320 GRADES P-R-T-U P-R C VITRIFIED BOND OPEN STRUCTURE CBN WHEELS GRIT TYPE 2BN .2BN I2BN 2BN 28N '2BN Uncoated Uncoated Uncoated Uncoated Uncoated Uncoated GRIT SIZES 60 thru 320 60 thru 240 60 thru 320 60 thru 240 60 thru 240 60 thru 240 GRADES M-N-O-P M-N-0 IM-N-O-P M-N-0 M-N M-N-0 CONCENTRATIONS 100-125-150 100-125-150 BOND VHA VHC DEPTH OF DIAMOND .... CONCENTRATIONS 80-100-125-150 100-125-150 164 100-125-150 100-125-150 164 BOND VEA VEC ' VEB VMA VMC VMB DEPTH OF DIAMOND .... MIL 000063 1-38 CIMFORM GRINDING WHEELS SUPERABRASIVE CONVERSION CHART CINCINNATI MILACRON Abrasive Technology Accurate Diamond Tool Bay State Ceram Citco Clipper Construction Diamond Products Continental Diamond Tool Corp. Diamond Productions Inc. Diamond Technology Products Ltd. Elgin Engis Fantastic General Industrial Diamond Co. Jacgues Kennametal National/U.S. Diamond Noritake Norton Pacific Permattach Precision Radiac J.K Smit Superabrasives, Inc. Supercut Tyrolit Union Dia-Tek Univel Universal (Radiac) U.S. Diamond (See National) Waltham Wheel Trueing Wickman MD S D, MD D, 6D DU SD MD MD MD D, MD MD D, MD D, MD SD GD S SD D, MD SD SD MD PDM,PDN MD D, MD 6, 6D D, MD E SD D, ID E MD CMD, NCD SN NCD D, 4D, 7D DN, DX 5SD MDN ND NDC ND CMD CD NMD CD CGD SN CD MDC, WD SDC ASD NMD PBB ND NCD, WD, 1WD PD MDN C, H SDM 2D G WD MD WD, WMD SD ND WCMD XDN AMD SC CCD 3D DC 9SD MDC CD CCD CD CDC CMD CGBD SC CCD DD, MDK ASDC CMD CD CCD, DD PDC MDC D SDC 3D K DD CD SCD DMD 9D 6SD CSGD AGB XD CDX DSC, MD4C AMD XD SD F SDX 5D H DXD EMD 4SD NC8D CDP 8WD A2D 4D PDN I I 1 Superabrasive Conversion Chart -- CBN CINCINNATI MILACRON Abrasive Technology Accurate Diamond Tool Amplex Bay State Carborundum Ceram Citco Clipper Construction Diamond Products Continental Diamond Tool Corp. Diamond Products Inc. Diamond Technology Products Ltd. Elgin Engis 2BN CB 1B.GSS CB BZ BN B 1BN CBN BN CB 2B, B, KSS CB CB CB CB CB CB CBN, BZN 1-39 General Industrial Diamond Co. National/U.S. Diamond Norton Permattach Radiac Regal Diamond Superabrasives, Inc. Supercut Tyrolit Ultra Diamond Union Dia-Tek Univel Universal (See Radiac) U.S. Diamond (See National) Waltham B CBN CB B, CB CB PBM BZ B, BB BN B BM 2CBN CB B BN MIL 000064 CMSA H Synthetic Abrasives CMSA II synthetic abrasive grinding wheels consistently outperform other wheels in productivity, cost efficiency and versatility- Performance generated by CMSA II on nost grinding operations exceeds Milacron standards by as much as 30% to 40%. CMSA II is as versatile as it is nnovative; the ideal, high performance grinding wheel for jasic and precision grinding applications. Grinding System Engineers Dur Grinding System Engineers are ready to help you optimize your grinding operation utilizing the complete ine of Milacron abrasives and CIMCOOL metalworking fluids. After reviewing your total grinding operation our GSE will recommend and apply the products designed to achieve greater productivity and higher efficiency. We guarantee that CMSA II will deliver many advantages to [your grinding applications, including superior quality on fyour finished parts. [CMSA II Grinding Application Advantage ^ More pieces per dress [ Less diamond wasted '* Cooler cutting [Better part to part consistency Less chatter ^ Better geometry Less downtime * Better finishes \ Faster cycles * Free cutting Less bum ? Broader range of applications [ Better form holding purrent Status of CMSA II |BI 1. In general, MSB Wheels perform very well. i, CB ~] A. 30% MSB outperforms 50% SG wheel. B. 30% MSB outperforms a conventional wheel up to BM j 65 times. :Z ~ ~2. MSB Segments perform well on hard materials. 88 3. Creepfeed-Grade MSB Wheels are successful on !N | aerospace materials. Highspeed MSB Wheels (16,000 SFPM) demonstrate CBN outstanding grinding performance and wheel life. :B Patents Related With CMSA II 5---------- A- MSB Grain ------------ U.S. Patent No. 4,881,951. 11/21/89, 3M Co. ---------- - U.S. Patent No. 5,282,875, 2/1/94, 3M Co./Cincinnati _____ _ Milacron B. Organic Pore Inducer U.S. Patent No. 5,037,452, 8/6/91, Cincinnati Milacron C. Inorganic Pore Inducer U.S. Patent No. 5,094,672, 3/10/92, Cincinnati Milacron Comparison -- Aluminum Oxide Abrasives 1. Manufacturing Process 2. Crystal Size (um) 3. No. of Crystals/60 Grit 4. Reinforcing Structure FUSED ALUMINA Fusion -200 -1 No SOL-GEL ALUMINA SG GRAIN MSB GRAIN Sol-Gel Sol-Gel -0.2 -0.05 --1 Billion --64 Billion No Yes A. Fusion Process CRUSHING and SEPARATING (FUSED ALUMINA) 3.9'/ MIL 000065 1-40 CMSA II Synthetic Abrasives (B) Sol-Gel Process Valve Manufacturer 3MSB601-N 4/2 VSAE 9581 24 x 1 x 12 Engine Valve XA706-P6-VH2 PPD Increased 5 times 20% shorter cycle Automotive Engine 5MSB541 K6 VSAE 15 Cranks PD 42 X 1.880 X 12.050 53A54 M VSB Crank Pin 53A 2 cranks per dress 7.5 times better Transmission Parts 3MSB 801A-J6-VSAE 100 PPD @ .0004 24 X 1.388 X 12 97A801-J-VQC 7 PPD @ .0008 29 times better MSB Case Histories Diesel Engine Parts 2MSB461 L6 VSA 42 x 2.130 x 12 29A461-M6-V72 BS Crank Pins 3PPD MSB AT .00125 1PPD 29A AT .00250 - Overall 6 times better Engine Builder 3MSB801 N4 VSAE 36.024 x .925 x 12 9A70 04 VFME 9PPD MSB Crank Pin 2PPD 9A 4.5 times better Engine Builder 3MSB601-N6/3MSB601-K6VSAE 42 X 2.002 X 12.050 57A54-L-VSB Better finish; 4 times better life 1-41 mil 000066 , 1 UetrHTS OF ALUMINUM OXIDE* GRINDING WHEELS WITHOUT HOLES VlS-----:..r I Thickness (InchesT* - 1 234567 viT~-- Res. Rub. Vll* Rub. Rub. Rub. Vit Res. Rub. Vit. Res. Rub. Vit. Res. Rub. Vit. Res. Rub. 1 1 1 11/2 11/2 11/2 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 .07 .08 .09 .15 .17 .20 .28 .31 .34 .60 .69 .76 1.1 1.2 1.4 1.7 1.9 2.1 2.4 2.8 3.1 3.3 3.8 4.2 .13 .16 .17 .30 .34 ..40 .56 .62 .68 1.2 1.4 1.5 2.1 2.5 2.7 3.3 3.9 4.2 4.8 5.5 6.1 6.5 7.6 8.3 .20 .23 .26 .45 .51 .60 .84 .93 1.0 1.8 2.1 2.3 3.2 3.7 4.1 4.9 5.8 6.4 7.2 8.3 9.2 9.8 11.4 12.5 .27 .31 .34 .60 .68 .80 1.1 1.2 1,4 2.4 2.8 3.1 4.3 4.9 5.4 6.6 7.7 8.5 9.6 11.1 12.2 13.1 15.3 16.6 .33 .39 .43 .75 .85 1.0 1.4 1.6 1.7 3.0 3.5 3.8 5.4 6.2 6.8 8.3 9.7 10.6 12.0 13.9 15.3 16.3 18.9 20.8 .40 .47 .51 .90 1.0 1.2 1.7 1.9 2.0 3.6 4.2 4.6 6.4 7.4 8.2 10.0 11.6 12.7 14.4 16.6 18.3 19.6 22.7 25 .47 .55 .60 1.2 1.2 1.4 2.0 2.2 2.4 4.2 4.9 5.3 7.5 8.6 9.5 11.6 13.5 14.8 16.8 19.4 21.4 22.8 26.5 29.1 Vit. 8 4.3 8.5 12.8 17.1 21.3 26 30 Res. 8 4.9 9.9 14.8 19.9 24.7 30 35 Rub. 8 5.4 10.9 16.3 21.7 27 33 38 Vit. 9 5.4 11 16.2 21.6 27 32 38 Res. 9 6.2 12.5 18.7 25 31 37 44 Rub. 9 6.9 13.7 20.6 27 34 41 48 Vit. 10 8.3 13.3 20 27 33 40 47 Res. 10 9.7 15.6 23.3 31 39 47 54 Rub. 10 10.6 17.0 25 34 -42 51 59 Vit. Res. Rub. [yit. [Res. |Rub. Ivit. [Res. [Rub. 12 12 19.2 29 12 13.9 22.2 33 12 15.2 24.4 37 14 13.1 26.1 39 14 15.2 30.4 46 14 16.6 33.2 50 16 17.1 34.1 51 16 19.7 39 59 16 21.7 43 65 38 48 58 67 44 55 67 78 49 61 73 86 52 65 78 91 61 76 91 106 67 83 100 116 68 85 102 119 ' 79 99 118 138 87 109 130 152 ya[Ftes. [pub. b [Hes. [Rub. IVit. [Pes. |Rub. lyit. |Res. |Pub. f/it. |Res. |Rub. Ivit. |Res. Rub, Vit. Res. Rub. Vn Res. Rub 18 21.6 43 18 25 50 18 27 55 65 86 108 130 151 75 100 125 150 175 83 110 138 165 192 20 27 . 53 80 107 133 160 187 20 31 62 92 123 154 185 216 20 34 68 102 136 170 204 238 22 32 22 38 22 41 65 97 129 162 194 226 75 112 149 187 224 261 82 123 164 205 246 297 24 36 24 45 24 49 77 115 164 192 230 269 91 136 182 227 272 318 98 147 195 244 293 342 26 45 91 135 180. 255 270 315 26 52 104 156 208 260 312 364 26 57 115 172 229 286 344 401 28 52 105 157 209 261 314 356 28 62 123 184 246 307 368 429 28 66 133 199 266 332 399 465 30 60 120 180 240 300 360 420 30 70 141 211 282 351 422 492 30 76 153 239 305 380 458 534 36 86 173 259 345 432 518 604 36 99 200 300 400 500 600 700 36 109 220 330 439 549 659 768 8 .54 .62 .67 1.2 1.4 1.6 2.2 2.5 2.7 4.8 5.6 6.1 8.6 9.9 10.6 13.3 15.5 17.0 19.2 22 24 26 30 33 34 39 43 43 50 55 53 62 68 77 89 98 105 122 133 136 158 174 173 200 220 214. 247 272 248 298 328 307 363 380 360 416 457 418 491 531 480 563 610 690 800 878 deduct 10-15% for silicon carbide wheels HOW TO USE THIS CHART A table of grinding wheel weights can only be approximate due to the many variations of abrasives, grains and grades and bonding processes. This table may be used in estimat ing net weights of wheels for shipping or ordering purposes, or for calculating approxi mated floor loads. As the chart covers wheels without holes, net weights shown for a wheel equivalent to the hole diameter and thickness should be deducted e.g. 1 - 20 x 2 -12 Alum. vit. 20 x 2 = 53 lbs. 12x2 (hole) = 19.2 Net Weight = 33.8 lbs. to find the total weight of a package add 20% to the net weight of the quantity involved. In the above example for 1 - 20 x 12 wheel weighing 33.8 lbs. net add 20% or 6.76 lbs. for packing material and container resulting in a gross weight of 40'A lbs. When wheels are recessed on one or both sides the weight of a wheel equivalent to the diameter and thickness of each recess should also be deducted. For example: 1 - 14 x 8 x 5 Alum. Vit. Rec. 1/S 8 x 1 'A Rec. 0/S 8x2 14 x 8 105 lbs. 5x8 (hole) 13.3 91.7 lbs. Recess 1/S rA" Thick Recess 0/S 2" Thick Equiv. to single recess 1/S8 x 3'A x 5` 9.2 deduct Total 82.5 lbs. In figuring weights on intermediate thick nesses, proportion fractional thicknesses based on the 1" scale. Each recessed side may be calculated separately eg.8x 1'A x 5 and 8 x 2 x 5 or the two thicknesses can be added together as we have done making one deduction for an 8 x 37? x 5 recess. 8 x 37.. = 12 8 lbs. (7; ol 8x1) = 2.15 lbs or 14 95 lbs 5 X 37; = 4.9 lbs. (V; ol 5x) = .85 lbs. or 5.75 deduct Total deduction 9.2 lbs. NOTE: When using this weight chart to calcu late the weight of an order for purposes of meeting the Freight Allowed Requirements, do not add the weight of packaging. NOTE: A 3800Y A80R2R regulating wheel weighs 290 lbs. A 42 x 1 x 12 vitrified wneel weighs 92 lbs. MIL 000067 I 1.0.0 Equivalent Hardness Numbers For Rockwell C Hardness Numbers Rockwell C-Scale Hardness No. Diamond Pyramid Hardness No. Vickers Brinnell Hardness No. 10-mm Ball. 3000-kg Load Standard Hultgren Tungsten Ball Ball Carbide Ball Rockwell Hardness No. A-Scale 60-kg Load, Brale Penetrator B-Scale 100-kg Load, 1/16 in. Dia. Ball D-Scale 100-kg Load, Brale Penetrator CBN 68 67 66 65 64 63 9A 62 61 60 59 58 57 56 55 29A 54 53 52 51 940 -- -- -- 900 -- -- -- 865 -- -- -- 832 __ __ 739 800 -- -- 722 772 -- -- 705 746 -- -- 688 720 -- -- 670 697 __ 613 654 674 -- 559 634 653 -- 587 615 633 -- 575 595 613 -- 561 577 595 __ 546 560 577 -- 534 543 560 -- 519 525 544 500 508 512 528 487 494 496 85.6 85.0 84.5 83.9 83.4 82.8 82.3 81.8 81.2 80.7 80.1 79.6 79.0 78.5 78.0 77.4 46.8 76.3 -- -- -- -- -- -- -- " -- -- -- -- -- -- -- -- -- -- 76.9 76.1 75.4 74.5 73.8 73.0 72.2 71.5 70.7 69.9 69.2 68.5 67.7 66.9 66.1 65.4 64.6 63.8 50 49 48 47 46 45 44 43 42 97A 41 513 475 481 481- 75.9 498 464 469 469 75.2 484 451 455 455 74.7 471 442 443 443 74.1 458 432 432 432 73.6 446 421 421 421 434 409 409 409 423 400 400 400 412 390 390 390 402 381 381 381 73.1 72.5 72.0 71.5 70.9 -- -- -- -- -- -- -- -- -- -- 63.1 62.1 61.4 60.8 60.0 59.2 58.5 57.7 56.9 56.2 40 392 371 371 371 70.4 -- 55.4 39 382 362 362 362 69.9 - -- 54.6 38 372 353 353 353 69.4 -- 53.8 37 363 344 344 344 68.9 -- 53.1 36 354 336 336 336 68.4 (109.0) 52.3 35 345 327 327 327 67.9 (108.5) 51.5 34 336 319 319 319 67.4 (108.0) 50.8 33 327 311 311 311 66.8 (107.5) 50.0 32 318 301 301 301 66.3 (107.0) 49.2 31 310 294 294 294 56.8 (106.0) 48.4 30 302 286 286 286 65.3 (105.5) 47.7 29 294 279 279 279 64.7 (104.5) 47.0 '28 286 271 271 271 64.3 (104J)) 46.1 27 279 264 264 264 63 8 (103.0) 45.2 26 272 258 258 258 63.3 (102.5) 44.6 25 266 253 153 153 62.8 (101.5) 43.8 24 260 247 247 247 62.4 (100.5) 43.1 23 254 243 243 243 62.0 100.0 42.1 22 248 237 237 237 61.5 99.0 41.6 21 243 231 231 231 61.0 98.5 40.9 2A 20 238 226 226 226 60.5 97.8 40.1 (18) 230 1219 219 219 -- 96.7 -- (16) 222 212 212 212 -- 95.5 -- (14) 213 203 203 203 -- 93.9 -- (12) 204 194 194 194 -- 92.3 -- (10) 196 187 187 187 -- 90.7 -- (8) 188 179 179 179 -- 89.5 -- (6) 180 171 171 171 -- 87.1 -- (4) 173 165 165 165 -- 85.5 -- (2) 166 158 158 158 -- 83.5 -- (0) 160 152 152 152 -- 81.7 -- Rockwell, Superficial Hardness No. Superficial Brale Penetrator 15-N Scale, 15-kg Load 3Q-N Scale, 30-kg Load 45-N Scale, 45-kg Load 93.2 92.9 92.5 92.2 91.8 91.4 91.1 90.7 90.2 89.8 89 3 88.9 88.3 87.9 87.4 86.9 86.4 85.9 85.5 85.0 84.5 83.9 83.5 83.0 82.5 82.0 81.5 80.9 80.4 79.9 79.4 78.8 78.3 77.7 77.2 76.6 76.1 75.6 75.0 74.5 73.9 73.3 72.8 72.2 71.6 71.0 70.5 69.9 69.4 -- -- -- -- -- ---- -- -- -- -- 84.4 83.6 82.8 81.9 81.1 80.1 79.3 78.4 77.5 76.6 75.7 74.8 73.9 73.0 72.0 71.2 70.2 69.4 68.5 67.6 66.7 65.8 64.8 64.0 63.1 62.2 61.3 60.4 59.5 58 6 57.7 56 8 55.9 55 0 54.2 53.3 52.1 51 3 50.4 49.5 48.6 47.7 46 8 45.9 45.0 44.0 43 2 42.3 41.5 -- -- -- -- -- -- -- -- -- -- 75.4 74.2 73.3 72.0 71.0 69.9 68.8 67.7 66.6 65 5 64.3 63.2 62.0 60.9 59.8 58.6 57.4 56.1 55.0 53.8 52.5 51.4 50.3 49.0 47.8 46.7 45.5 44.3 43.1 41.9 40 8 39.6 38 4 37 2 36.1 34.9 33.7 32 5 31.3 30.1 28 9 27 8 26 7 25 5 24.3 23.1 22.0 20.7 19 6 -- -- -- -- -- -- -- '----- -- -- Values in parentheses are beyond normal range and are given for information only. Shore Schleroscopi Hardness No. ; i 97 1 95 1 92 j 91 ] 88 j 87 85 83 81 80 78 76 75 74 72 71 69 68 67 66 64 63 62 60 48 57 56 55 54 52 51 50 49 48 47 46 44 43 42 4*. 4! 40 38 38 37 36 35 35 34 33 32 31 29 28 27 26 Jo 24 24 A .AO MIL 000068 Safety iV Ki-i " C fiiiriln g iil 1'im e," n-liu h is tin- /mrc llw t Irnth in m punv n y n rn lwt-1 ir hen in-erxpeecling. increases as the sipiaie o f the vehciis- ( f ilia l wheel. Far example, the centrifu g a l Ini I c at a II heel iw a ia ig ai 5,50(1 suifut c /eel per mimac is -19 /u r t cal gieaier than in the same wheel naming al -1.50(1 s k i face leeI pei minute, although the speed is actually oals 22 pet 1 cal giealei .2C g*, Cmog9J .-E- jf-- Q> TJ CD CD Cl Ct) 81 CD O 80 CO 78 t: 76 3 U) 75 74 C>D 72 0 71 (2 69 68 w 67 66 CD TJ CD 64 63 62 5> TJ O. </J > o 60 48 w TJ C <57 JC CD 56 55 o 54 (J.) 3 52 C 51 n E50 (2 49 c CL 48 oQ TJ 47 w cd 146 44 > 3 0 LL 43 c o 42 o u_ 41 41 40 38 3 38 C 37 36 35 Q. 35 34 33 cid o 32 31 29 o > 28 a: 27 26 25 24 24 r.ooo O' ri TT ft rn pi 'O'tW rmi, i---* m-- O O n tt m m r- vi O' G m Ooop piSS rj- p- m noon ri cv oo vo m, <n o o n- vo <n ri -- ri O' so p*` rj- co m 8.008 O' r- r- OT' ---- 0m0 ft -r \o nriri crnwrt.icn oc cc r* irtCt ocn O'-------m c n O' n -- n g oc in o O' O', P; rt ri ri ri n in rt vO ri ri 00 >q *t ri ri ri O' n O' -- G ri r*. -- o ri ri ri r~ G G ri m <0 C4TP G 1n ft t-- fnorni WGP* oOr.rr*t1j o in n pO 00 ---*r--t<n --* o o vO^r. v"TTofPnOV-rOti O' n \o rr-i nri o--o ri m m o n vG ---- 0o"C<n rirO,'Gn r*. r* C oc m -- -- O' co oc 00 (O' O' o r* G g r00i iinn 0O0' in o r-. O' r~. m ri m n. nw- O' O' -- rt O OO COO t vo ri ri -- -- GOPO' 0O O' go -r -- oc in n---- o oo o \o -t t vr, co rn O' O' c rt xn r^r-;0 p*' g vo* ~r o -r ri ri r'TV, ir,C<C (OCM tt, ri O r- cc m rc O O' C'XvC { ri ri ri ri g--m n O' m m ri ri O' o n Pnn ---------- G vo -- r-' oc cc O' m ri o--T O O' G r- O' co m -t n O' m O' coajr, G in n it, O' O p- r -- Oj -T n n O O' o r--xO'noc *t G G C rt m t m ri t Mr, O' rn CC ---------O 00 n. -- m O' O O O' O' G PC O' G P- G np-*1 ci/c", o--o CC TJ O' v,C"C m r- O' npic O' P* O' v-r, G-- G**, XQr, -t r~, O' n r* o cc r rn CC ri --j- r*. r\ O rn CC -- G C O' r- G m, m. O' n G O' O' oc *T p. gm P- G M V, O' C"0 Ov ------r o OP*' rmi m-- ri r- O' O' O' o tmc m, g m -r ri w*i -r r G rt O' none r~ n *T G O' CC n o G O' O' sc rC-OrOt>fT ri -- -- m, vo oc -- O' G m, o r~< -t ri O ri r-cc I-- m *T O ri O TCM c--c min mo n -rf rr O' T ri ri ri O' vo O *n xct vC-------- 1M ri ri --' O' n g Gf n-- mO' r- oo O' p. -- oo r.ov- -- O' ri w, n ri PTM o-ToWmO n oo r- -- P o -- O' ri O ri 00 n-, ri ri g m ri <ntn r* oc n. G O in PtiT, O G ri 0O0' Gin 0*n0 -- O O' O' 00 co r p* G -- in n O' O' -- -- n o in -- co " O' O' cooop pm. p~T- \OTfOr- <n T r- m vc 'Ten oonr O' cc rj O' T f riCf Ov G m O' r- w~, t -t m ri ri r*. oc -- r-~ m xpp G G r*. O P -- P- G G i5nC ir--i Op' r~, sC -- ri oc <n n m ri ri -- r- m vi -r rn rt~ oo n-t vcor, ri *n g-- pn' pr- n r-- G vC cc -r xnc O' m m, sc rr-i r--> trr G m pg g in r--, n m. ri in O' C o> sc P'rC'T -t O' n x r r~ _ ri -- -- oc n. r- G G rr--tnn co- r-xr. rTXnC-- I O' n. -r cc <n -- G _ m -t -- -- ri ri -- 3 n O' r'. o sc sc xr> tr*or- -- r- -r XT.C in. >n in WM *t rlw*,- -- g -r r*. o O', r j O O' oc p*' p- g so C'Cf'i ri ov -- r--to-r nO' v*. -- r- -r o rri ri -- 0C O' O' -- r- ir. O' r it r O oc G m -r -- G n r- n cc tn -t pi x v, ri rj n ri -- n 13 rirpr. : v.O' n n rxc SC PIP-- O O' x x p tpr, rr, G -- p'm o rtn G G G m n m. n in cc n r* o - sc cc *n o: n r r* g x -r n -- sc in - r, *r. r- sc G rj c 1-- n <" O' *n in ~r -r -t <-**. f l O' _OM<nT"T, m. r-, sc r* ri p ri sc cc -- rr*j cc r--i in. SC C -r in jC* -- oc r O n -r -- ri r j --' r O "T n T O o cc r- -- - ri MIL 000069 2-1 Safety Guide The grinding wheel, when carefully and correctly used, is a safe cutting tool. But if misused or abused, it does have a very dangerous potential. When we know that the rim of a wheel running at 6500 surface feet per minute is traveling at a rate of over 70 miles per hour, we can understand how dangerous any grinding wheel can be if it is broken by mishandling or misuse. Recommendations and rules to maintain the safety of grinding wheels are listed in the booklet "Safety Requirements for the Use, Care and Protection of Abrasive Wheels." This summarizes knowledge gained from decades of research and from literally thousands of man-years of practical experience with abrasive tools. It is by far the most comprehensive and authoritative docu ment on grinding safety in the English language. This booklet is highly recommended reading for people involved in the mounting or use of grinding wheels, seg ments, or mounted points. The American National Standards Institute (ANSI) standard B7.1 will be referred to here as the safety code. One requirement of the safety code is a prooftest: all sizeable grinding wheels must be overspeed tested by the wheel manufacturer before shipment. Typically, this test stresses each wheel to 2-1/4 times the rotational stress of its maximum usage speed. The test destroys any wheel of substandard strength, so it ensures that all surviving wheels are structurally sound. Hence, a preci sion wheel is perfectly safe to use immediately after its overspeed test. However, it can become very unsafe if it is cracked, chipped or gouged after that test. So there is good reason to say that grinding wheels don't break, they are broken. Listed below are some general precautions that should be observed in the use of abrasive wheels. More detailed information is in the safety code (ANSI B7.1 latest edition) available from: The Grinding Wheel Institute, 712 Lakewood Center, North Cleveland, Ohio 44107; American National Standards Institute Inc., 1430 Broadway, New York, NY 10018; or any grinding wheel manufacturer including Products Division/Cincinnati Milacron Marketing Company, 4701 Marburg Avenue, Cincinnati, Ohio 45209. Use the Right Wheel If the wheel was designed for grinding on its periphery, do not grind on its side. If it was designed for grinding c its side (Type 2 or Type 6 wheels, for instance) do not grind on the periphery. Maximum Speed The maximum operating speed (max RPM) is marked < : each wheel, its blotter, or (for small wheels) its contains :. This number and the outer diameter D1 (in inches) of ill new wheel establishes its maximum surface feet per It minute (max sfpm) by the formula: 1 max sfpm = 3.1416 D1 (max RPM)/12 On the adjacent page is a table, based on this formula, for converting wheel diameter and RPM to spfm and vii = versa. The max sofm of the new wheel sets the safe usage limit of that wheel. That is. as the wheel OP is r worn down, its RPM mav be increased as Iona as that max sfpm is never exceeded. To maintain the new-whe . sfpm as the OP wears, the following formula mav be : used: ! max RPM 2 = D1 over D2 (max RPM 1) where the numbers 1 and 2 refer to the original wheel and to the worn wheel respectively. Standard and Special Speeds ( Mismatching wheel and machine speeds can be dang* . ous. Recognizing this, wheel and machine manufacture have agreed over the years on certain standard speed* that both groups can design to. Table 24 of the safety I code defines these standard speeds. Although the typi* cal wheel user will have little use for this complex tabled he should be aware that it may affect the safety of his I operations. 1 A sure and direct way for the wheel user to avoid mis-| matching is to routinely specify the actual speed of hist machine on all orders for grinding wheels. This practicf | is strongly recommended by Cincinnati Milacron. In the | absence of a speed call-out on an order, Milacron will 1 supply a standard-speed product. The max RPM mark ing of the wheel alerts the user not to use the wheel if the machine speed exceeds that standard speed. If su a potential mismatch occurs, return the wheel along w1 a notation of the actual machine speed. To avoid speed mismatches, section 7 of the safety c& recommends that speed checks be made periodically: all grinding machines. Specific times to do this are cits there by machine type. MIL 000070 fety Guids (cont.) special" speed is, by definition, any speed that iDhe ftxceeds the appropriate standard speed listed in Table ndinai 20 of the safety code. To maintain safety at these higher lo not speeds, section 8 of the code places special require ments on the machine builder, the wheel manufacturer, jnd the wheel user. The chief responsibilities of the user ire to make certain that all guarding and other safety larked jevices supplied with the machine are used and main;ontain< ained in good working order, and that all safety precaues) of ( ions specified by the machine manufacturer are fol- t per owed. Cincinnati Milacron strongly recommends that users do lot attempt to increase the wheel speed of any grinder d la jeyond its original design value, nor alter its original and vi Juardin9- Any intended modification of other safety-relatsafe >d equipment should first be discussed with and ipproved by the machine manufacturer. as that nspection, Handling and Storage w-whe ^|| grincjjng wheels can be broken or damaged and ihould be handled as fragile items. The as-manufactured strength of wheels depends upon their bond type, grit size, grade, shape and size. However, careless storage, wheel landling, transport, mounting, or usage can degrade this jriginal strength by breaking or weakening the bonding naterial that holds the wheel together. nspection. Wheels should be visually inspected for ; dange^hips, cracks, or other indications of rough handling. This jfacture|hould be done when they are first removed from their speeds shipping container, or as soon as damage to the containaafety jr itself is noticed. Immediately discard or return to the he typi manufacturer any wheel showing such damage. It is )x table mportant that these wheels be segregated so they canof his )ot possibly be used. fandling, In-Plant Transport. All wheels are impact 'd mis- ensitive and should be protected from sudden shocks. i of his hey should not be moved or supported by metal practicejevices, e.g. lift truck forks or hoist hooks, unless the l. In thejpetal contact areas are covered by resilient material, on wiHny wheel that is dropped should be considered damA mar iged. Do not roll wheels on shop floors -- cover the path /heel i Jrith clean, staple-free cardboard. Do not lay wheels d. If sugjrectly on any metal, brick, or similar hard, rigid surface, .long w> ifety cd dically are cite Storage. Store wheels on resilient material and only in places that are dry and free from extremes of tempera ture and humidity. Water-soaking can gradually weaken resinoid wheels; telephone the manufacturer for advice if this happens. Both resinoid and vitrified wheels should be considered unsafe if they are wetted and then sub jected to freezing temperatures. A ring test should not be relied upon to detect the widely distributed damage due to freezing a damp wheel. iVlIL 000071 2-3 f Safety Guide (cont.) Mounting Grinding Wheels -- General History proves that grinding wheel breakage can result from many causes. However, for precision grinding wheels, one factor stands out. Careful analysis of many precision wheels broken during use shows that improper mounting is involved in more than 50% of all breakages. For this reason, each of the several methods of mount ing precision wheels are individually discussed in the fol lowing sections. In all cases, metal machine components must not press directly on abrasive surfaces. A blotter is to be used between the abrasive and any type of clamping flange or device. Similarly, when a spacer is used beside or between wheels, a blotter must be placed between each spacer and its mating abrasive surface. The spacer's clamping surface(s) must conform to the same geometric requirements that the safety code places on that machine's flanges. For example, for multi-screw flanged machines, any spacer used adjacent to a grinding wheel should be relieved near the bore, be the same OD as the flanges, and meet their flatness requirement. To detect possible damage during in-plant storage, han dling, or transport it is important that all wheels be thor oughly inspected immediately before mounting and at the mounting site. This means they should be inspected visually all over, despite any earlier visual inspections, and ring tested. Exceptions are segments, plate-mount ed and nut-inserted wheels, mounted points, and some small (e.g. less than 4") wheels; these are difficult or impossible to ring test. To ring test a wheel that is small enough to hold in one hand, the wheel should be suspended from the hole on a finger. If the wheel is too heavy, it can be supported by a hoist. If it is not possible to suspend the wheel free in the air, it can be rung while in a vertical position on a clean hard floor, the wheel should be dry and free from sawdust or other packing material. Tap the side of the wheel gently with a nonmetallic instrument (the handle of a screwdriver or a wooden hammer) about 45 degrees to one side of the vertical centerline and 1 or 2 inches inboard from the OD. Then rotate the wheel about 45 degrees in its suspension and tap again. A good vitrified wheel will have a clear metal lic ring. A resinoid wheel may not give a clear ring and must be visually examined for cracks. Large, thick wheels may be ring tested by striking the wheel on the periphery rather than the wheel side. If there is any reason whatsoever to suspect that a wheel has been damaged, do not mount it. But also do not use the ring test to "disprove" the suspected dam age. The ring test should be used to detect unknown 2-4 cracks but not to discount other evidence of damage it is not infallible. When damage is suspected, the only safe options are to destroy the wheel beyond further use, or return it to its manufacturer for re-inspection. Arbor-Mounted. New, clean blotters should be usedo both sides of the wheel. They assure even pressure on! the flanges around the arbor hole. Be careful not to wedge the blotter within the wheel bore. Flanges and spacers should be of equal diameter (inspect with a straightedge), flat and free of nicks. Nil and other protrusions should be carefully removed with; file and stone. The diameter of the flanges should be al least one-third the diameter of the wheel. See the safe! code for exceptions, flange dimensions and spindle diameters. The wheel should slide easily onto the arbor. If it doesii use another wheel; do not force the wheel or try to use larger, wide or narrower wheel than the size for which the machine was designed. If the wheel has the word "Top" or mount up on it, rotalf the wheel so that "Top" is at the 12 o'clock position wh the clamping nut is tightened. This will keep the hole clearance on the bottom, as it was when the wheel was] manufactured. This provides better concentricity and b; ance, and means less initial truing. The nut should be uniformly tightened only enough to keep the wheel from slipping; do not use a hammer because over-tightening can warp the flanges, putting high bore stresses in the wheel. The nut should tighten^ in the opposite direction from wheel rotation! ic o i-b P n n lie Collet and Flange. Follow all general instructions (see Mounting Grinding Wheels -- General above) and thoS~ for Arbor Mounted (above) down to tightening the nut. ^ MIL 000072 !r IE Safety Guide (cont.) 1396 ^First tighten the screws with slight finger pressure only. 9 only, j^gn tighten to 15 ft. lbs. with a torque wrench. Follow a (her crjSS-cro$s sequence of tightening the screws. Repeat ion' this tightening procedure at least three (3) times or more until all screws are pulled to the prescribed ft. lb. figure. Wider wheels may require more; the torque recommend ed by the machine manufacturer should be followed if it s other than 15 ft. lbs. Excessive tightening may spring the flange and collet. Warpage will reduce the contact area between the flanges and the wheel, and produce dangerously high . bore stresses. ised oi Additional precautions are necessary for mounting large ure on wheels on multi-screw flanges. These are covered in the to next section. Large Wheels, Including Centerless. No large, heavy *r wheel should be mounted manually. The lifting effort ;s. Nick required precludes accuracy of alignment and smooth ;d with mating of the wheel bore and spindle. Both of these are d be at essential to maintain the safety of the wheel. The initial e safet contact between the spindle and the bore is likely to be jle erky and can cause chipping or other damage to the ` wheel. Some cocking is almost unavoidable. A power lift d.oesri s,,hould be used to avoid th. ese problems, to use s0me *ar9e centerless grinders require removal of the vhich 5Pinc*'e ^rorn the machine to change wheels. The nachine manufacturer usually provides special fixtures o do this job. Power lifts for these fixtures are recom:, rotats^Qpujg^ chainfalls do not usually provide small enough on whe steps 0f vertical movement to allow accurate alignment, so cocking of the spindle is likely and this endangers the 2el was /vheel bore. Also, both spindle and wheel bore should be and bd lorizontal during mating. This allows the person mount- ng the wheel to feel any resistance to entry of the spingh to lie into the wheel bore, so he can avoid forcing or cockner ng. He does not have these factors under his control if utting mounting is done vertically -- the weight above the spinrighten lie or wheel is usually enough to chip or crack the vheel, and this is likely unless alignment is absolutely Perfect. Threaded hole wheels. Check that the direction of rotaion will tighten the wheel on the threaded arbor and not oosen it. Mounting rotation should be opposite to spindle otation. Be sure that the blotter is smooth and on the vheel. The threads of the arbor, or of the mounting bolts n the case of nut inserted discs, should not quite bottom P tfle threaded hole. Be certain that the back flange is is (see"01 recessed or relieved (threaded hole wheels only), id thos^'m'tations- Threaded hole cup wheel mounting should e nut. i10* usec* w'th wheels larger than 6" diameter. The maximum volume of cones and plugs should not be greater than 35 cu. in. (Example: a 3" OD by 5" long type (8 wheel. 3.1416 x R2 (1-52) H (5") = 35.3). Segments. The many segment chucks available have a variety of clamping methods. Detailed instructions can be obtained from the chuck manufacturer. Be sure clamping surfaces are clean and flat. Cylinders. Before mounting the wheel, suspend it and tap it with the end of a screwdriver or a wooden hammer. Resinoid wheels do not give the clear ring of a vitrified wheel, so they must be carefully inspected visually. Screw clamps should be tightened only enough to keep the wheel from slipping in the chuck. Vellumoid strips should be placed between the wheel and the clamps to serve as blotter cushions. Be sure the chuck is com pletely clean of old blotter and swarf before mounting a new wheel. Plate mounted wheels. Plates should be checked with a straightedge for flatness and wheel plate should be smooth and free of nicks. Mounting screws should not bottom in the threaded holes. Mounted wheels. The length of overhang of the wheel beyond the chuck has a bearing on the maximum safe speed. The safety code or the Grinding Wheel Institute's "Mounted Wheels - Safe and Efficient Operation" - latest edition, should be consulted to be certain maximum safe speed is not exceeded. MIL 000073 2-5 Safety Guide (cont.) Mounting Flanges -- ANSI B7.1 All abrasive wheels shall be mounted between flanges which shall not be less than one-third the diameter of the wheel. Both flanges, of any type, between which a wheel is mounted, shall be of the same diameter and have equal bearing surface. Guards Always use a guard. See that it is properly mounted and that all screws are in place and tight. If the wheel should be broken because of accident or neglect, make sure any damage to the guard is repaired or the guard is replaced. A damaged guard is not much protection. All guards should conform to Section 4 of the safety code (ANSI B7.1). Workrest Keep the workrest on a bench or stand grinder in repair and properly adjusted to no more than 1/8" away from the wheel. Starting the Wheel Stand to one side whenever you start a wheel. Allow new wheels to run at least one minute before grinding. VRWE SUPER CIMFORM Aluminum Oxide Vitrified Wheels 16,000 SFPM Operation The following SUPER CIMFORM wheel grades are available for 16,000 sfpm operation under the following conditions: 1. Grades as shown in the table below only. 2. 20" to 24" in diameter, 2'k" or less in thickness, 12" or smaller ID. (12.050 also) 3. For use only on machines approved by machine manufacturer. Available Grade Grit Hard Center* Non-hard Center Size 4 Structure 6 Structure 4 Structure 6 Structure 80 K-S K-M 90 K-Q K-M 100 K,L 120 K,L M-Q M J-Q K-M 150 J-N 180 J-N 220 J-N 'Wheel specifications must shown `VE0685 suffix code. Example: 2A80-K6-VE0685 Wheel Discard Size -- ANSI B7.1 The usable portion of an abrasive wheel shall be consi ered to be that portion which extends beyond the moun ing flanges. A wheel shall not be worn down to a size which would allow the mounting flange assembly to co tact the workpiece or workpiece holding fixture. Safety Glasses Protect your eyes when grinding. You can lose your saf ty glasses and get another pair but you will lose your eyesight only once. Grinding Fluid Turn on the grinding fluid only after the wheel has reached speed, and turn off the fluid before turning off the wheel. Running the fluid on a stopped wheel will cr ate a heavy side and out-of-balance condition. VFME CIMFORM Aluminum Oxide Vitrified Wheels 16,000 SFPM Operation The following SUPER CIMFORM wheel grades are availab! for 16,000 sfpm operation under the following conditions: 1. Grades as shown in the table below only. 2. 20"- to 24" diameter, 2'/2" or less in thickness, 12" or smaller ID. (12.050 also) 3. For use only on machines approved by machine manufacturer. Available Grade Grit Hard Center* Non-hard Center Size 4 Structure 6 Structure 4 Structure 6 Structure 80 K-N K-N 0-S 90 K, L K-M M-S 100 K.L M-S 120 K.L J-S M M 150 J-S 180 J-R 220 J-R 'Wheel specifications must shown "VE0815 suffix code. Example: 2A80-K6-VE0615 NOTE: The wheel size restrictions do not apply to nonhard center wheels. However, the I.D. must not exceed 60% of the wheel O.D. and all orders should show the operating speed. MIL 000074 irinding Wheel Safety Guide rinding wheels improperly used are dangerous, but ie consjjrininddiinngg is a safe operation if the few basic rules listed he mouMi elow are followed. These rules are based on material a size contained in the ANSI B7.1 Safety Requirements for the >ly to coj Use, Care and Protection of Abrasive Wheels." Storage , suitable racks, cradles and drawers should be provided your sa o store the various types of wheels used. The sketches e your^ ndicate a typical rack storing a range of wheels. 3o: Store wheels correctly supported. 2. Stack thin wheels flat. las 3. Ensure storage in dry conditions. ning off el will ci 3o Not: I. Store in damp or humid conditions. V Subject wheels to dramatic change in temperature. [j. Subject wheels to temperatures at or approaching freezing. Typical Storage Rack e availaH Mounting rrect mounting procedures are essential to the effi cient and safe operation of the wheel. It is important that |ersonnel performing the function are fully competent, o: Visually inspect all wheels before mounting for possible damage. zxample: Check machine speed against the established maximum safe operating speed marked on the wheel. Ring" wheel to determine if it is free from cracks, y to non-: ^se one c'e&n blotter on each side of wheel, tt eexxcceeeedd1' mounting flanges for equal and correct how the diameter) generally 1/3 diameter of wheel). Tighten multi-screw flanges uniformly to the machine manufacturer's suggested torque with a torque wrench. Do Not: 1. Mount a cracked wheel or one that has been dropped or has become damaged. 2. Use wheels whose maximum r.p.m. is less than the r.p.m. of the machine spindle. 3. Force a wheel onto the machine or alter the size of the mounting hole - if the wheel doesn't fit the machine, get one that will. 4. Use flanges of unequal diameter or relief, nor those which are not clean, flat or free of burrs. 5. Over-tighten flange retaining nuts. Use Given the correct wheel, mounted in accordance with approved procedure, safe operation depends largely on the treatment to which the wheel is subjected during use. Do: 1. Ensure that guards and workrests are properly adjusted and secure before starting machine. 2. Always use a safety guard covering at least one-half the grinding wheel. 3. Allow a newly mounted wheel to run at operating speed with guard in place at least one minute before starting to dress or grind. 4. Always wear protective glasses or some type of eye protection when grinding. 5. Always dress or make grinding contact gently. 6. Re-dress the wheel when necessary. 7. Turn off the coolant before stopping the wheel to avoid creating an out-of-balance condition. Do Not: 1. Ever exceed the maximum operating speed estab lished for the wheel. 2. Start the machine until the guard is in place. 3. Stand directly in front of the wheel when the machine is started. 4. Jam the work into the wheel, nor use excessive pressure or infeed. 5. Force grinding so that the motor slows noticeably or the work gets hot. 6. Grind on the side of the wheel (see ANSI B7.1 for exception). 7. Allow stationary wheels to rest in fluids. 8. Apply pressure to wheels to stop them. 9. Continuously use glazed wheels without dressing. 10. Use wheels for purposes other than those for which they are designed. MIL 000075 2-7 Proper Wheel Mounting Techniques and Appropriate Torque Pressures Tightening Sequence This is one of the many inspection stations in Cincinnati's plant. This machine can spin test wheels up to 42' diameter Shipped up to 5000 RPM. This machine is constructed of 1'A plate steel. MIL 000076 2-8 Pub No PG-305-6 CINCINNATI MILACRON ` GRINDING WHEELS Page 1 Date of Breakage BROKEN WHEEL REPORT Note: Because the careful handling and safe use of CINCINNATI MILACRON Grinding Wheels are beyond the control of Cincinnati Milacron, the company assumes no responsibility for damaged or broken wheels. Instructions 1. Submit for all wheels broken in operation on a machine. 2. Answer all questions. If you cannot get an answer, please so indicate. Use extra pages if necessary. 3. When the question is followed by the symbol (A), identify source of information if other than your own observation. Customer: Address: Wheel Size & Type: Wheel Spec, (grading): Whom did we bill and when? Purchase Order Number: Our M (mfg) Number: Date Wheel Shipped from Cincinnati: Date Broken:Time of Day:AM;PM Was anyone injured or sent home? Yes; No. If yes, describe on page 4 of this report. Max. RPM marked on wheel or blotter:RPM Damaged Wheel: Ship all pieces of damaged wheels, bushings, inserted nuts, blotters, etc. to Cincinnati Milacron, c/o Abrasive Product Manager. Damaged work parts, collets, centerless blades, and any other items involved in accident can also be helpful. All such material will be retained for a period of 5 years whenever m|ury was sustained in the accident. ameter, Shipped back via: Waybill No.: Date- MIL 000077 i 2-9 Page 2 GRINDING MACHINE: Manufacturer: Size & Type: Serial No.____ Customer No. Condition of machine & bearings (A): Good; Fair; Poor. Equipped with movable work rest? Yes; No. If so, how far was it from wheel just before accident? in. Can the operator vary the spindle R.P.M.? Yes_______ ; No_______ . Spindle R.P.M. at time of accident (by tachometer): Were any pieces of blotter from previous wheels or any other foreign material adhering to flanges or spindle? Yes; No. If yes, describe briefly: Number of prior breakages: this machine: similar machines nearby. MOUNTING: Spindle and flange pilots -- any burrs or high-pressure points? Yes; No. If yes, estimate of max. height:in. Diameter of: spindlein.; loose-flange pilotin. Flanges: Was spacer used between flange & wheel? Yes; No. If so, show data for spacer(s) rather than flange(s). Dimensions (measure with steel ruler): A (in.) B (in.) Loose Flange: _______ Fixed Flange: _______ _______ Blotter bearing surfaces -- measure out-of-flatness (e.g. with feeler gauges and straight edge): note max. value on appropriate line: Loose Flange Fixed Flange Concave? in. in. Convex? in. in. Wavy? in. in. Nicked? Gouged? Corroded? (Circle appropriate items.) How tight were flange screws? (A) (Check with torque wrench on similar machine nearby.) Mount loose flange on bare spindle (collet), using all original screws. Do flange faces puli' in to less than width"of this wheel7 Yes; No Do one or more screws 'bottom' before this critical spacing is reached? Yes_______ ; No_______ . If yes, how many7, Was wheel run before mounting? (A): Yes; No. MIL 000078 2-10 untlNTING (cont'd) Page 3 Thread condition, mounting nut or flange screws: Good; Poor. Blotters used? Yes; No. If so, mark blotter nearer driven end of spindle (fixed flange) and return both blotters with wheel. Hours wheel had been rotating since: Mounting: Last Start-up. Was wheel ever re-mounted? Yes; No. How many times?. GRINDING OPERATION: Sketch of part (show nominal dimensions, surfaces ground, & stock removal: Part Name & Material: Cutting fluid (circle appropriate one): Water soluble; Oil; Dry. Anything jammed between wheel and machine? (A) (Look for gouged part or tools in machine base or nearby scrap container; send to Cincinnati.) Wheel open to outside damage while running or while stopped, by cranes, trucks etc.? (A) Yes; No. Events leading up to breakage -- comments by operator, supervisor, witnesses, etc.' WHEEL STORAGE AND HANDLING: How are wheels inspected on receipt? (A) How are wheels stored? (A) How are wheels inspected before mounting? (A) Was this one? (A) Are wheels rolled on floor at any time? Yes; No Any other abusive handling? Yes; No I .. If so describe- MIL 000079 2-11 Page 4 REPORT OF INJURY: (If no injury or lost personnel time, so note on Page 1 and omit the following questions. However, sign report at bottom of this page.) Injured person's: Name: Address: Age: Length of service, this job:years. Was the person wearing: goggles; safety glasses; face shield: (Circle items pertinent to this injury.) Wheel guard in place: Before accident? Yes ; No After accident? Yes : No If not. briefly describe. leather apron; safety shoes? Was guard adjustable for wheel wear? Yes; No. If so, how far was movable member from wheel OD just prior to accident?in. (Look for fresh scrapes next to clamping screw or nut, re-position, and measure.) Name of employer's Workmen's Compensation Insurance carrier: Name of doctor or nurse attending: Address: Has injured person returned to work? Yes; No. How much lost time occurred?Is expected to occur?. If hospitalized, name and address of hospital: Extent of injury, and from whom did you get information. Witnesses: ________________ Name_______________ 1. 2. 3. ___________________________ Address 2-12 Signed____ Report date: MIL 000080 CIMCOOL utting and Grinding Fluids IMCOOL metalworking fluids were developed to meet jur application requirements, however demanding. The IMCOOL line consists of water-soluble synthetic, ;emi-synthetic and premium soluble oil products. Benefits include: excellent corrosion control high degree of lubricity for prolonged tool life pleasant to use . greater stability in hard water lower misting properties recyclable easy disposal tIMTECH Synthetic Metalworking Fluids teal for light- to heavy-duty operations, CIMTECH is ixtremely clean and has excellent corrosion control and )w misting characteristics. Ipplications include: automotive bearing farm implement construction equipment carbide grinding glass and mirror grinding IIMSTAR Semi-Synthetic Metalworking Fluids IIMSTAR brings users the best of both worlds: the benfits of oil content and the advantages of synthetic-type uids. It is well suited for individual machine and central ystem applications. IMPERIAL Soluble Oil Metalworking Fluids ^IMPERIAL products are designed for moderate- to eavy-duty cutting and grinding operations. Known for leir excellent rancidity control, many CIMPERIAL pro ducts also contain extreme pressure lubricant packages for enhanced machining and grinding performance in dif ficult applications. CIMCOOL Specialty Products Designed to complement CIMCOOL metalworking flu ids, these specialty products can help keep your opera tions running smoothly: CIMCLEAN Industrial Cleaners CIMTAP Tapping Compounds CIMGUARD Corrosion Preventives CENTERSAVER Waterproof Grease CIMCOOL ENVIROTREAT Ultrafiltration System A wastewater treatment system designed to treat oily wastewater for sewer discharge, Milacron's ENVIRO TREAT Ultrafiltration System can reduce the volume of oily wastewater by 90%. The unit processes fluid at a rate of 300 gallons per day. 100 Gallon CIMCOOL Recovery Unit The fast and efficient CIMCOOL Recovery Unit (CRU) is a portable industrial liquid vacuum cleaner designed to quickly clean out individual machine fluid reservoirs. The unique caster design enables the CRU to pivot for easy maneuvering in small areas and narrow shop aisles. CIMCOOL Oil Wheel The CIMCOOL Oil Wheel removes tramp oil from indi vidual machine reservoirs. CIMCOOL Mixmaster Proportioners Mixmaster Proportioners, available in either drum or reservoir models, are designed to mix the right amount of fluid concentrate with water. MATERIAL OPERATION Surface Cenlertvue/ Microcentric Centerless Internal i Form 1 f Thread/ Flute j Tool Room/ | General Purpose 1 Cast Iron CIMTECH 100 Carbon Steel CIMTECH 100 Alloy Steel CIMTECH 100 Aluminum Copper Not Applicable CIMTECH 410 CIMSTAR 40 CIMSTAR 60/60LF CIMTECH 410 CIMSTAR QUAL STAR/LF CIMTECH 100 CIMSTAR 40 CIMTECH 410 CIMSTAR 60/60LF CIMPERIAL 1011 CIMTECH 410 CIMSTAR 60/60LF CIMSTAR 40 CIMSTAR 60/60LF CIMPERIAL 1011 CIMTECH 410 CIMSTAR 40 CIMSTAR 60/60LF CIMTECH 410 CIMSTAR QUAL STAR/LF CIMTECH 410 CIMSTAR QUAL STAR/LF CIMSTAR 60/60LF CIMPERIAL 1011 CIMPERIAL 20 CIMTECH 410 CIMPERIAL 1011 CIMSTAR 40 CIMSTAR 60/60LF CIMPERIAL 1011 CIMTECH 410 CIMSTAR 60/60LF CIMPERIAL 1011 CIMTECH 410 CIMSTAR 60/60LF CIMTECH 410 CIMSTAR 60/60LF CIMSTAR 60/60LF CIMPERIAL 1011 CIMPERIAL 20 CIMTECH 410 CIMPERIAL 1011 CIMSTAR QUAL STAR/LF CIMSTAR 60/60LF CIMPERIAL 1011 CIMSTAR 40 CIMSTAR 60/60LF CIMPERIAL 1011 CIMSTAR 40 CIMSTAR 60/60LF CIMSTAR 40 CIMPERIAL 1011 CIMPERIAL 1010 CIMPERIAL 1011 ' CIMPERIAL 1011 CIMSTAR QUAL STAR/LF CIMSTAR 60/60LF CIMPERIAL 1011 Exotic Materials CIMTECH 100 CIMTECH 410 CIMTECH 410 CIMSTAR 60/60LF CIMPERIAL 1011 CIMPERIAL 1010 CIMPERIAL 1011 CIMSTAR 60/60LF CIMPERIAL1011 CIMPERIAL 1010 CIMPERIAL 1011 CIMPERIAL 1010 CIMPERIAL 1011 CIMSTAR 60/60LF CIMPERIAL 1010 CIMPERIAL 1011 MIL 000081 3-1 RK Centerless Grinder Brief Specifications Grinding Wheel Diameter maximum/minimum............................................24/17" (609/431 mm) Hole size...........................................................................................12" (304 mm) Regulating Wheel Diameter maximum/minimum............................................14/11" (355/279 mm) Hole size...........................................................................................6" (152 mm) Machine Capacities -- Standard Equipment Machine Size Work Diameter Grinding Regulating Main Drive Wheel Width Wheel Width Horsepower 220-8 1/16 to 4-1/2" 10" max. (1.6 to 114 mm) (254 mm) 10" max. (254 mm) 20 hp (15 kW) 230-12 1/2 to 6" 12" max. TWIN GRIP (12.7 to 152 mm) (304 mm) 14" max. (355 mm) 30 hp (22 kW) 350-20 1/2 to 6" 20" max. TWIN GRIP (12.7 to 152 mm) (508 mm) 20" max. (508 mm) 50 hp (37 kW) - MIL 000082 d-i rK Series Centerless Grinders Simply Productive The RK Series proves that outstanding precision is not out ot your price range. Simple modular build and mechanical design combine with advanced features to make these machines remarkably accurate and affordable. Cincinnati Milacron has reduced the number of parts in the RK Centerless by 42% while improving grinding per formance. Pneumatics have been removed and most hydraulics have been replaced by smooth running servo motor drives. Throughout the machine, automatic lubrication require ments have been eliminated by anti-friction slide-away systems. Complex computer programming has been replaced by simple state-of-the-art operator controls. Quick Setup and Easy Operation Mechanical design of the RK helps keep setup easy. The grinding wheel position is fixed, rigidly mounted to the machine bed. An upper/lower slide arrangement, under the regulating wheel and workrest, swivel together with a single adjustment for quick, accurate correction of taper or wheel contact. Precision Components RK machines are built on an epoxy granite base, select ed for its superior rigidity, vibration damping and thermal characteristics. RK centerless slides combine anti-friction ways, brush less AC servomotors, precision ballscrews and digital feedback. The result gives you two-way compensation with 0.000004" (0.1 micron) resolution. Standard RK truing units are a highly damped design. They provide anti-friction servomotor-driven traverse and cam-type profiling, the grinding wheel truing diamond axis is servomotor-driven, coupled with a precision ballscrew and a double pre-loaded nut. FILMATIC grinding wheel spindle bearings with hydrostatic lift provide long-lasting, hydrodynamic, self-centering sup port which is consistent under varying grinding loads. High dynamic and static rigidity provide 0.000004" (0.1 micron) rotational accuracy. The regulating wheel is rigidly support ed at both ends by special hydrodynamic bearings. Reliability Simple systems are easily maintained, have less poten tial for down-time and require fewer spare parts. With this in mind, Milacron's centerless experts ^searched our extensive library of designs, service records, run-off test results and customer reports. Incorporating such features as hydrostatic spindle lift and "S curve" slide acceleration to maximize ballscrew life, RK machines apply the latest technology in simple, durable, precision components. ONEfeed DMC Grinding Control One look at the RK's standard operator's station tells you a lot. It's a small unit with relatively few controls -- easy to learn, easy to set up and easy to operate -- yet packed with flexibility. RK machines are ONEfeed arranged, for infeed or thrufeed operation. Comprehensive diagnostics and cycle status display pro vide detailed operator information. The heart of the system is a multi-axis DMC (Dedicated Motion Controller). Its simple, direct controls give you the accuracy, speed and consistency of servo control with the common sense operation of a manual machine. Commonality and Support If you have Cincinnati centerless grinding machines, you'll be able to use most of your existing profile cams and work support tooling on the RK Series machines. Milacron has the machines, controls, wheels, fluids, training, service, parts and process expertise, providing a total support package that's second to none. Grinding Wheel Grades General Purpose: 97A601-K6-VFME Precision Finishing: 29A801-J4-VRWE Ceramic: 3MSB801-J6-VSAE (Larger diameter parts require slightly softer grades) Standard Machine Features Epoxy granite machine base Single screw swivel adjustment Anti-friction slide-way systems throughout ONEfeed arrangement for infeed or thrufeed operation 0.000004" (0.1 micron) machine resolution Servomotor regulating wheel drive Multi-axis servomotor machine motions FILMATIC grinding wheel spindle bearings Externally mounted grinding wheel motor Stand-alone machine hydraulics Machine mounted electrical cabinet Optional Equipment CNC grinding and regulating wheel truings Rotary diamond roll grinding wheel plunge dresser Variable frequency grinding wheel drive Automatic grinding wheel balancer Automatic gaging systems Coolant filtration and refrigeration equipment Autoloaders Various Programmable Controller alternatives MIL 000083 Recommended Starting Grades For Centerless Grinding This chart is graded for 20 inch and 24 inch diameter wheels. If a machine requires a smaller wheel, use a grade grade harder than grades shown in the chart. For Hi production with optimum setup use VRW 1 grade softer. For improved part quality with normal production and setup use VQC 1 grade softer. Material Operation Alnico Alnico Aluminum Alloys (Hard) Aluminum Alloys (Soft) Armature Shaft (Steel) Axles (Auto) Rough Axles (Auto) Finish Ball Bearings (Outer Ring) Bolts -- Steel-Forged or Machined Brass and 8ronze (Soft) Bronze (Hard) Bushings (Soft Steel) Bushings (Hardened Steel) Bushings (Cast Iron) Carbon Cast Iron (General Purpose) Ceramics (General Purpose) Copper Cylinder Liners Drills (Thru-Feed H.S.S.) Dowel Pins (Hardened) Glass -- Ground Joints, Stoppers) Glass -- Fine Finish Needles (Hypodermic) Nitralloy -- Bars Soft Nitralloy-- Bars Hard Paper -- Cardboard Tubes Pistons -- Aluminum Pistons -- Cast Iron Plastics -- Tubing & Bar Stock Roller Bearings Shafts -- Steel, Armature Thru-Feed In-Feed Pump Shaft -- Soft Pump Shaft -- Hard Shock Absorber -- Shaft Rough Shock Absorber -- Shaft Finish Steel (Soft) Thru-Feed Steel (General Purpose) Hot Rolled Bars -- General Purpose Cole Rolled Bars -- General Purpose Steel (High Speed) Steel (Drill Rod) Steel (Stainless) (Non-Free Machining) (Free Machining) Stellite Stoodite Thread -- Crush Dress 18 Pitch & Coarser Titanium -- Thru-Feed Bars Tubing -- Steel Rough Finish Tungsten -- Bars. Rods. Wire IMP Oiamond Roll Dress Crush Dress Valves (Automotive) Stems -- Rough Stems -- Finish Valve Guides -- Cast Iron Valve lifters -- Steel Chilled Iron Zirconium -- Bars Rough 8ars Finish Less than'//' Diameter 12A60-L4-VFM C12A601-P9-B90 97A601-J6-VFM 6C46-L6-VSC 97A601-L4-VFM -- -- 97A801-K4-VFM 97A601-N4-VFM 6C46-L6-VSC 97A601-J4-VFM 97A601-L4-VFM 97A801-K4-VFM 97A701-J4-VFM 6C46-N6- VSC 97A701-J4-VFM 6C80-L6-VSC 6C60-L6-VSCD -- 97A1201-N4-VFM 97A801-L4-VFM 6C60-N6-VSC 6C220-M6-VSC 97A1201-P4-VFM 97A601-M4-VFM 97A801-L4-VFM 6C36-K6-VSC 97A461-J6-VFM 97A241-J6-VFM 12A36-I6-VFM 97A801-L6-VFM ' 97A601-L4-VFM 97A601-L4-VFM 97A601-L4-VFM 97A801-L4-VFM 97A801 -V-BWK 97A1201-V-BWK 97A601-N6-890 97A601-M4-VFM C97A601-R9-B90 97A601-Q9-B90 97A801-K6-VFM 97A601-K6-VFM 6C60-M6-VSC 97A601-L6-VFM 97A601-M4-VFM 6C60-M6-VSC 12A220-04-VFM 6C60-R9-B90 97A461-J4-VFM 6C60-P9-B90 6C80-M6-VSC 97A801-04-VFM 97A1501-M4-VFM 97A601-N4-VFM 97A801-M4-VFM 97A701-M4-VFM 97A601-K4-VFM 97A601-N4-VFM 6C60-R9-B90 6C80-R9-B90 to 1 'll" Diameter 12A60-K4-VFM Cl2A461-09-B90 97A601-I6-VFM 6C46-K6-VSC 97A601-K4-VFM 97A601-M4-VFM 97A801-M4-VFM 97A801-J6-VFM 97A601-L4-VFM 6C46-K6-VSC 97A601-I4-VFM 97A601-K4-VFM 971801-J4-VFM 97A701 -16-VFM 6C36-M6-VSC 97A701-16-VFM 6C80-K6-VSC 6C46-L6-VSCD -- 971801-M4-VFM 97A801-J4-VFM 6C60-L6-VSC 6C220-L6-VSC -- 97A601-L4-VFM 97A801-K4-VFM 6C36-J6-VSC 97A461-16-VFM 97A461-16-VFM 6C60-J6-VSC 97A801-K6-VFM 97A601-L4-VFM 97A601-K4-VFM 97A601-L4-VFM 97A801-K4-VFM 97A801-L4-VFM 97A1201-V-BWK 97A601-N9-B90 97A601-K6-VFM C97A601-P9-B90 97A601-09-B90 12A801-J6-1?FM 97A601-J6-VFM 6C60-L6-VSC 12A60-K6-VFM 97A601-L4-VFM 6C60-L6-VSC 12A220-M4-VFM 6C60-Q9-B90 97A461-16-VFM 6C60-09-B90 6C60-L6-VSC 97A801-N4-VFM 97A1501-L4-VFM- 97A601-M4-VFM 97A801-L4-VFM 97A701-L4-VFM 97A601-J6-VFM 97A601-M4-VFM 6C60-P9-B90 6C80-P9-B90 VI," to 3" Diameter 12A60-J4-VFM Cl2A461-N9-B90 97A601-H6-VFM 6C46-J6-VSC 97A601-I4-VFM 97A601-L4-VFM 97A801-L4-VFM 97A801-16-VFM 97A601-J6-VFM 6C46-J6-VSC 97A601-H6-VFM 97A601-J6-VFM 97A801-16-VFM 97A701-H6-VFM 6C36-L6-VSC 6C70-J6-VSC 6C80-J6-VSC 6C60-K6-VSCD -- 97A801-J4-VFM 97A801-I4-VFM -- -- -- 97A601-K4-VFM 97A601-16-VFM 6C36-J6-VSC 6C36-J6-VSC 97A461-H6-VFM 6C46-I6-VSC 97A801-J6-VFM 97A601-K4-VFM 97A601-16-VFM --- -- -- -- 97A601-N9-B90 97 A601-16-VFM C97A601-09-B90 97A601-N9-B90 12A801-I6-VFM 97A601-16-VFM 6C60-J6-VSC 12A601-16-VFM 97A601-K4-VFM 6C60-K6-VSC _ 6C60-P9-890 97A461-H6-VFM 6C60-N9-B90 6C60-K6-VSC -- -- .- __ -- -- -- -- -- -- Over 3" Diameter 12A46-14-VA Cl2A461-M9-B90 29A601-G6-VA 6C46-I6-VSC 29A601-H4-VA -- -- 29A801-H6-VA -- 6C46-J6-VSC 29A601-H6-VA 29A601-I6-VA 29A801-H6-VA 29A701-G6-VA 6C36-K6-VSC 6C70-I6-VSC 6C46-I6-VSC 6C46-I6-VSCD 6C36-J6-VSC -- 29A801-G6-VA -- -- -- -- -- 6C36-I6-VSC 6C36-I6-VSC 29A461-H6-VA 6C36-H6-VSC 29A801-I6-VA -- -- -- -- -- -- 29A601-H6-VA C29A461-N9-B90 29A461-M9-B90 -- -- __ -- -- 6C60-J6-VSC _ -- 29A461-G6-VA 5C60-L9-B90 6C60-J6-VSC -- -- __ -- -- -- -- -- -- MIL 000084 JlJterless Wheels jjomrfionly In Stock In Various Grades de ong fcn-chfna E, t.. ; '" - ISrinding er3'' 1wheels meter 'A 11fc4x2crx 12" 9-B90 -VA 1|(t i pc. or 2-10" sections) C -1 |4*x18*x 12" -VA | |(1 pc. or 2-9" sections) -VA 1B4*X 12"X 12" :c 1 |4"x20"x 12" -VA 1 VA -VA 1 4 |4"x8"x12" -VA 1 ;c 1 |4'x6"x12" C1 C 1|4*x5*x12" CD -1 ;c | |4*x4"x 12" -VA 1|o*x8"x 12" Regulating Wheels 14" x 20" x 6" (2 pc.) 14" X 12" X 5" (2 pc.) 14" X 12" x 6" 14" x 10" x 6" 14" x 10" x5" 13" x 10"x 6" 13" x 10" x 6" 13" x 10" x 5" 12" x 8" x 5" |0*x6"x 12" 12" x 6" x 5" |0'x4"x 12" 12" x 4" x 5" t Regulating Wheel Recess Chart i-VA 19-890 9-B90 SC 5-VA 190 'SC Grinding Machines Application Data Machine: 440-20 TWIN GRIP Centerless Grinding Machine Part: Bearing Races Material: 52100 Bearing Steel Hardness: 60-Rc Stock: .048 Finish: 20-25 RMS Type Of Operation: Thru Feed Wheel Grade: 97A701 -16-VFME, or 29A801-I8-VAE .. MIL 000085 4-4 Typical Machine Manufacturers Bryant, Cincinnati Milacron, Landis, Norton, Gold Crown, Tschudin, Van Norman, White Sundstrand, Royal-Master CINCINNATI MILACRON 220-8 Cantilever Type Centerless Grinding Machine Cincinnati Milacron Inc. Cincinnati, OH Machine/Model CINCINNATI No. O Old Style Item Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels 4-5 CINCINNATI MILACRON 340-20 TWIN GRIP Type Centerless Grinding Machine Wheel Size 14" x r x 5" 14" x 1 7a" x 5" 14" x 2" x 5" 14" x 27s" x 5" 14" x 3" x 5" 7" x 1" x 2" 7" x 17/ x 2" 7" x 2" x 2" 14" x 377' x 5" 14" X 372" X 5" 14" X 37," X 5" 14" X 4" X 5" 7" x 27," x 2" 7" X 27{' X 2" 7" X 27," X 2" 7" X 3" X 2" 7" X 37," X 2" 7" X 37," X 2" 7" X 37," X 2" 7" X 4" X 2" Type T-1 T-1 R-2/S 8" X 7," R-2/S 8" X V/' R-2/S 8" X 7" R-2/S 8" X 'W R-2/S 37:' x 7," R-2/S 374" X 7, R-2/S 37/ X 7e" R-2/S 374" X %" R-2/S 37X 7S" R-2/S 37/' X 7/ R-2/S 37," X 'W R-2/S 37/ X 1" MIL 000086 ............... n . Cincinnati Milacron Inc. Cincinnati, OH Machine/Model CINCINNATI No. O New Style and 107-4 CINCINNATI No. 2 Item Grinding Wheel Regulating Wheel Grinding Wheels Regulating Wheel CINCINNATI No. 3 and No. 4 Grinding Wheels Regulating Wheels CINCINNATI CINCO 15 CINCINNATI 230-10 TWIN GRIP CINCINNATI 300 Series TWIN GRIP 325-12 330-15 340-20 Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels CINCINNATI 400 Series Cincinnati 430-12 twin grip 440-20 Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Wheel Size 16" x 4" x 10" 9" x 4" x4" 20" x 3" x 12" 20" x 4" x 12" 20" x 5" x 12" 20" x 6" x 12" 20" x 7" x 12" 20" x 8" x 12" 12" x 3" x 5" 12" x 4" x 5" 12" x 5" x 5" 12" x 6" x 5" 12" x 7" x 5" 12" x 8" X 5" 24" x 3" x 12" 24" x 4" x 12" 24" x 5" x 12" 24" x 6" x 12" 24" x 7" x 12" 24" x 8" x 12" 24" x 9" x 12" 24" x 10" x 12" 14" x 3" x 5" 14" x 4" x 5" 14" x 5" x 5" 14" x 6" x 5" 14" x 7" x 5" ' 14" x 8" x 5" 14" X 9" x 5" 14" x 10" x 5" 24" x 8" x 12" 12" x 8" x 5" 24" x 10" x 12" 12" x 10" x 5" 24" x 10" x 12" 24" x 12" x 12" 24" x 18" x 12" 24" x 20" x 12" 14" x 10" x 6" 14" x 12" x 6" 14" x 18" x 6" 14" x 20" x 6" 24" x 12" x 12" 14" x 12" x 6" 24" x 20" x 12" 14" x 20" x 6" Type R-2/S 5'/<" X5/," T-1 T-1 T-1 T-1 T-1 T-1 R-1/S 77," x 7," R-2/S 77," x 7," R-1/S 7'/a" x 7," R-0/S 77," x 17," R-1/S 77," x 7," R-0/S 77," x 17," R-2/S 77," x 17," R-1/S 77," x 7," R-0/S 77," x 27," T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 R-1/S 8" x 17," R-1/S 8"x 17," R-1/S 8" x 17," R-1/S8"x 17," R-1/S 8" x 1 7," R-0/S 8" x 1" R-1/S 8" x 17," R-0/S 8" x 2" R-1/S 8" x 17," R-O/S 8" x 7," R-1/S8"x 17," R-1/S 77," x 17," R-1/S 77," x 17," R-O/S 77," x 2" T-1 T-1 T-1 1 or 2 sections T-1 1 or 2 sections T-1 or recessed 1/S 2 sections recessed 1/S 2 sections recessed 1/S When Wheel cannot be made in one piece, it is best to order two equal sections. T-1 T-1 or recessed 2/S T-1 Recessed 2/S B MIL 000087 4-6 Cincinnati Milacron Inc. (cont.) Machine/Model CINCINNATI OMV-24 Item Grinding Wheel Regulating Wheels CINCINNATI 220-8 RK Grinding Wheels Regulating Wheels 230-12 RK Grinding Wheels Regulating Wheels 350-20-RK CINCINNATI 220-8 AE Grinding Wheel Regulating Wheel Grinding Wheels Regulating Wheels 230-12 AE 350-20 AE CINCINNATI Centerless Lapping Machine Grinding Wheel Regulating Wheel Grinding Wheel Regulating Wheel Grinding Wheels Regulating Wheels Bryant Grinder Corp., Springfield, VT (machines formerly built by Van Norman) Machine/Model 1C (new) 1M 45M 2CH 3CH Item Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Wheel Size 24" x 8" x 12" 24" x 10" x 12" 12" x 8" x 5" 12" x 10" x 5" 24" x 8" x 12" 24" x 10" x 12" 14" x 8" x 6" 14" x 10" x 6" 24" x 12" x 12" 24" x 14" x 12" 14" x 12" x 6" 14" x 14" x 6" 24" x 20" x 12" 14" x 20" x 6" 24" x 8" x 12" 24" x 10" x 12" 15" x 8" x 6" 15" x 10" x 6" 24" x 12" x 12" 15" x 12" x 6" 24" x 20" x 12" 15" x 20" x 6" 14" x 22" x 67/ 14" x 22" x 67a" Type T-1 T-1 R-1/S 7'/z" x 17/ R-1/S 7'/z" x 2" T-1 T-1 T-1 R-2/S 87/ x 1" T-1 T-1 T-1 R-2/S 87/ x 1" (17762Y) T-1 R-2/S 874" x 17/ (3800Y) T-1 R-1/S 147/x 7/ T-1 R-2/S 874" x 1" T-1 T-1 T-1 R-2/S87/X 17/(13168Y) T-1 i T-1 Wheel Size 16" x 4" x * 8" x 4" x ' 14" x .375" x 5" 2.500" x .311" x 1.000" 14" x .500" x " none 24" x 8" x 12" 12" x 8" x 5" 24" x 12" x 12" 12" x 12" x 5" 'Numerous sizes apply to this machine. Type May be recessed 1 recessed recessed recessed recessed MIL 000088 4-7 Landis Tool Co. Machine/Model Item Wheel Size LANDIS No. 12 LANDIS No. 121/2 LANDIS 12R LANDIS 14R LANDIS 24CR Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels 20" x 4" x 12" 20" x 5" x 12" 20" x 6" x 12" 20" x 8" x 12" 20" x 8" x 12" 12" x 4" x 5" 12" x 5" x 5" 12" x 6" x 5" 12" x 8" x 5" 12" x 4" x 5" 12" X 5" X 5" 12" X 6" X 5" 12" X 8" X 5" 24" x 4" x 12" 24" x 6" x 12" 24" x 8" x 12" 24" x 10" x 12" 14" x 4" x 5" 14" X 6" X 5" 14" X 8" X 5" 14" X 10"X 5" 20" x 8" x 12" 12" x 8" x 5" 24" x 14" x 12" 14" x 14" x 5" 24" x 14" x 12" 24" x 12" x 5" Most infeed jobs require a 1 -piece grinding wheel or 2-piece wheel cut on a bias. Van Norman Co., Springfield, MA Machine/Model No. 1C No. 2C Item Grinding Wheels Regulating Wheels' Grinding Wheels Regulating Wheels Wheel Size 14" x 4" x 8" 8" x 4" x 3" 24" x 4" x 12" 24" x 6" x 12" 24" x 8" x 12" 12" x 4" x 5" 12" x 6" x 5" 12" x 8" x 5" . Type T-1 T-1 T-1 T-2/S 14" x 1" T-1 T-1 T-1 T-1 R-2/S 77/ X 7/ R-1/S 77/ X 7/ R-O/S 77/ X 17/' R-1/S 77*" X 7*" R-O/S 77*" X 17*" R-1/S 77*" X 7*" R-O/S 77*" X 27*" T-1 R-1/S 8" X 1" R-1/S8"X 17*" R-1/S 8" X 17*" R-O/S 8" X 2" R-2/S 8" X 17*" May be recessed May be recessed May be recessed May be recessed May be recessed May be recessed Type R-2/S 107*" x 7*" R-1/S 47/ X 7*" R-O/S 47/' X 17/ T-1 R-1/S 14" X 7/ R-O/S 14" X 17/ R-1/S 14" X 17/ R-O/S 14" X 27/ R-2/S 77/ x 7/ R-1/S 77/ x 7/ R-O/S 77/ x 17/ R-1/S 77/ x 17*" R-O/S 77*" x 27*" White-Sundstrand, Syracuse, NY Machine/Model Model 20 Item Grinding Wheels Regulating Wheels Wheel Size 24" x 20" x 12" 16" x 20" x 10" Type (usually 2-10" sections) (usually 2-10" sections) MIL 000089 Royal Master, Inc. Riverdale, NJ Machine/Model Model PG-7 Model TG-12 Model TG 12x4 Model DRF 12 Model CG 12 Model TG 12GB Item Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Grinding Wheels Regulating Wheels Norton Co., Worcester, MA Wheel Size 7" x 87e" x 1.500" 3Ve"x8'A"x 1.000" 12" x 3" x 5" 6" x 3" x 1" 12" x 4" x 5" 6" x 4" x 1" 12" x 3" x 5" 6"x3"x 1" 12" x 3" x 5" 6" x 3" x 1" 12" x 3" x 5" 6" x 3" X 1" If wheel is mounted on a steel bushing, customer should supply Cincinnati with bushings. Type T-1 R-2/S 7'/2" X 'W various recesses various recesses various recesses Machine/Model Item Wheel Size Type No. 2 Grinding Wheels Regulating Wheels 20" x 3" x 12" 20" x 4" x 12" 20" x 5" x 12" 20" x 6" x 12" 20" x 7" x 12" 20" x 8" x 12" 12" x 3" x 5" 12" x 4" x 5" 12" x 5" x 5" 12" x 6" x 5" 12" x 7" x 5" 12" x 8" x 5" T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 Recessed wheels such as used on the Cincinnati No. 2 and Landis No. 12 may be used, with spacers. 'IS 'IS lUi IPI IK rit E s tol. lac T 1 MIL 000090 ! a.a ^nterless Grinding Material and Specifications material ALUMINUM OCLES, Automobile 3ALL BEARING RINGS Specification 7C461-J10-VSC 29A601-L4-VFM 29A801-J8-VA 3ARS Steel Stainless (300 Series) Brass and Bronze BRASS 3RONZE BARBON, Hard BAST IRON bemented CARBIDES 97A541-P6-B90 C2A541-Q6-B90 C2A541-P6-B90 6C46-N6-B90 6C46-N6-B90 6C80-K6-VSC 6C80-M6-VSC CMD120-N100-B BRILLS and REAMERS Hard 29A801-K4-VFM Soft 97A601-L6-VFM :ORGINGS 97A601-N6-VFM 3IPE BALLS, Manganese Steel Roughing 97A461-N6-VFM Finishing 29A601-K6-VFM 5ISTONS Aluminum Alloy Cast Iron 3ISTON PINS 3UBBER, Hard SPLINE SHAFTS 6C46-K6-VSC 6C46-M6-VSC 29A601-L4-VFM 7C541-J6-VSC 97A601-L4-VFM Material STEEL Hardened High Speed Soft Stainless Heat Treated Free Machining TUBING, Steel TUNGSTEN RODS VALVE STEMS, Automotive VALVE TAPPETS GENERAL PURPOSE Specification 29A801-K4-VFM 29A801-K4-VFM 97A601-L6-VFM 7C601-K4-VSC 29A541-L6-VFM 29A601-K8-VA 7C801-L4-VSC 97A1001-N4-VFM 97A1001-N4-VFM 29A601-K6-VFM REGULATING WHEEL General Purpose A80-R2-R A80-R2-RFW Bar Grind A80-R2-R A80-R2-RFW Small Parts A120-T2-R Very Small Parts A280-T2-R VITRIFIED REGULATING WHEEL For parts with interrupted surfaces such as holes, flats, grooves and keyways: General Purpose 2A100-P4-VFME1 Small Parts 2A120-R4-VFME1 Very Small Parts 2A150-T4-VFME1 3K Centerless Grinder Brief Specifications grinding Wheel Diameter maximum/minimum Hole size.................................... .24/17" (609/431 mm) ..............12" (304 mm) legulating Wheel Diameter maximum/minimum Hole size.................................. Jachine Capacities -- Standard Equipment .14/11" (355/279 mm) ................ 6" (152 mm) Machine Size 220-8 230-12 twin GRIP 350-20 twin grip Work Diameter 1/16 to 4-1/2" (1.6 to 114 mm) 1/2 to 6" (12.7 to 152 mm) 1/2 to 6" (12.7 to 152 mm) Grinding Wheel Width 10" max. (254 mm) 12" max. (304 mm) 20" max. (508 mm) Regulating Wheel Width 10" max. (254 mm) 14" max. (355 mm) 20" max. (508 mm) Main Drive Horsepower 20 hp (15 kW) 30 hp (22 kW) 50 hp (37 kW) RK Series 220-8 Centerless Grinder 8500 SFPM Typical Wheel Grades: - * Finishing -- 29A801-K4-VFME Roughing -- 97A601-L6-VFME MIL 000091 4-10 Gold Crown 200 Grinding Wheel 24" x 8" x 12" Regulating Wheel 14" x 8" x 6" No Recess Gold Crown 660 Grinding Wheel 24" x 26" x 12" Regulating Wheel 14" x 26" x 6" R (2 Sides) 87/'x VW For work up to 6" Dia. Additional Gold Crown Machines GC 500 GC 500 ER 15 Slant Bed GC300 GC250 Grinding Wheel 24" x 20" x 12" 24" x 20" x 12" 24" x 12" x 12" 24" x 10" x 12" Regulating Wheel 14" x 20" x 6" (3800Y) 14" x 20" x 6" (3800Y) 14" x 12" x 6" (S/S) 14" x 10" x 6" (R-1/S 87/' x 1>/2") Tschudin CNC 600 Series Typical Wheel Size: Grinding Wheel 24" x 14" x 12" Regulating Wheel 14" x 14"x 8" Typical Wheel Grades: 29A601-K6-VFME or 3MSB-601-J4-VSAE MIL 000092 4-11 CINC0-1 DE CINCO-t DR #1 DR #210-6 LR #220-3 LR #220-8 DE #230-1C DA #325-12 DE #330-15 DE #340-2G DE '430-12 0E '4J0-2C DE --2 O'-'V 24 . *220-8 AE i '230-12 [ AE *250-2' AE r `223-c - e220--'< r *350-2* ; PK Wheel Sizes And Machine Data For Centerless Grinders - Special ** = 2" Recess *** = Full Range **" = Machines after June, 1965 Have 6" Spindle 2** / ^ AR*l* // <? *</ $//*</ //*<$ //f& //*. Zf / # ? / ,*? //.$ # /j;&/ & /j>- f i * 1 L0 6-15/16 1 t\~ 1 LM 6-15/16 I TT~ 1 ea&om 8-7/16 r#f I L0 97. 16 16 20 20 1 /3 1 EA 97. 24 1 1 LL 1H 1 EA 97. 24 97, 24 1 /5 I EA #6 EA CINCO-15 DE 8-7/16 CINCO-15 OR 8-7/16 /I OR 6-15/16 #210-6 LR 97. #220-8 LR 97. #220-8 DE 97. #230-10 DA 97. #325-12 DE 97, #330-15 DE 97. #340-20 DE 97, #430-12 DE 97. ! #440-20 1 DE #2 : OMV-24 97, 97, #220-8 L AE f #230-12 _ AE #350-20 _ AE ! '220-8 ;_RK :#230-12 __ RK #250-20 __ RK 11 11 11 11 11 11 24 30 or 36 20 24 16 20 20 24 24 24 24 24 24 24 24 24 24 24 24 24 24 12 4 10 9 7 4 4 .5 0-7, 0-7: 12 4 147. 8 10 9 7 4 12 12 97, 8 4 77, 0-7, 0-7: 40 0-3 ! 7,-4 5 15 0-3 2-47, 15 8 12 12 or 13 10 10" 16 io- 12 14 10 12" 12,15. "12 16 20 12 14 10 15,20 16 io- 12 14 10 12" 16 36 12 16 10 36 5 5 5 5 8 20 1/16-3 1/16-3 1/16-4 2-47, 25 1/2-3 1/2-6 1/2-4 2-6 30 7,-3 7:-6 7,-4 2-7 25 7,-6 7,-6 1 50 1-7 1-7 2-77, 36 12 14 10 36 8 60 1-10 1-10 ; 15 8 12 12 97. 8 12 to 17 8 12 15 97, 8 5 15 1/16-3 1/16-3 7,-17, 5 15 1/16-3 1/16-3 7.-17, 12 4 10. 9 7 4 15 6 12 12 97, 6 15 8 12 13 97, 8 4 77, 0-17, 0-17: 1/165 10 0-3 0-3 27, 2-4 ! 1/165 20 0-3 0-3 1 27, 2-4 17 8 12 13 97. 8 5 20 0-47, 0-4 : [ 7,-4 2-47, i 17 10 12 13 107, 10 5 30 7.-4 /.-4 ! M 2-47, 17 12 12 14 107, 12 5 25 7,-6 /:-6 7,-4 2-47, 17 15 12 14 107, 15 5 30 7,-6 /.-6 7,-4 2-47, 17 20 12 14 107, 20 5 40-100 7,-6 7:-6 ; /:-4 1-8 17 12 12 14 107, 12 5 1 30 1-10 1-10 1 1-4 17 20 12 MAX 17 10 12 MAX 17 10 12 14 101/4 20 5"" 40 1-10 1-10 12 10 10 5 MAX 15 11 10 6 15 1/16-3 1/16-3 1/16- 1/1625 47, 4/ 1-4 17 12 12 15 11 12 6 25-30 7,-6 /.-6 17 20 12 15 11 20 6 50-100 7:-6 .-6 MAX MAX 1/16- 1.16- 17 10 12 14 10 10 6 25 4/: 4 MAX MAX 17 14 12 14 10 14 6 25-30 /.-6 /.-6 17 20 12 14 10 20 6 50-100 /.-6 6 40 65 65 65 65 65 150 150 65 65 40 75 75 75 150 ISO 150 150 150 150 65 75 150 150 75 150 150 MIL 000093 4-12 CINCINNATI Centerless Grinders Regulating Wheels Sizes Requirements For Regulating Wheel Recesses [Re Machine #0-EH #0-#1-NEW #2 (EA) (OM) Dimensions 7" x 7/ x 2" 7" x 3" x 2" 7" X 4" X 2" 9" x 7/ x 4" 9" x 3" x 4" 9" X 4" X 4" 12" X 3" X 5" 12" X 4" X 5" 12" X 5-6" X 5" 12" X 7" X 5" 12" X 8" X 5" #2-LO #2-LR 12" X 3-4" X 5" 12" X 5-8" X 5" 12" X 3" X 5" 12" X 4" X 5" 12" X 5" X 5" 12" X 6-8" X 5" 12" X 10" X 5" #3-LL #3-LR (Balancer) 14" X 4-11" X 5" 14" X 12" X 5" 14" x 4" x 5" 14" X 5" X 5" 14" X 6-10" X 5" 14" X 12" X 5" (After 1-61) #3-4 LR (Non-Balancer) 14" x 12" X 5" 14" X 4" X 5" 14" x 5" x 5" 14" X 6-10" X 5" 14" X 12" X 5" #5-6 Lapper 14" X 15" X 5" 14" X 20" X 5" 16" x 1 -6" x 8" 14" x 1 -6" x 8" 14" x 22" x 678" Recess R-2/S 37/ X V2" R-2/S 1"X 1" R-2/s 57s" X 7," R-2/S 57/ X 7/ R-1/S 77/ X 7/ R-2/S 77/ X 7/ R-1/S 77/X 17/ R-O/S 77" X 7/ R-2/S 77/ X 17/ R-1/S77/X 17/ R-O/S 77/ X 27/ R-1/S 77/ X 7/ R-1/S 77" X 17/ R-1/S 77/ X 7/ R-1/S 77/ X 1" R-1/S77/X 17/ R-1/S 77/ X 17/ R-O/S 77z X 2 R-1/S 8" X 17/ R-1/S 8" X 2" R-1/S 8" X 17/ R-1/S 8" X 1" R-1/S 8" X 17/ R-1/S 8" X 17/ R-O/S 8" X 2" R-2/S 8" X 17/ R-1/S 8" X 17/ R-1/S 8" X 7/ R-1/S 8" X 17/ R-1/S 8" X 2" R-O/S 8" X 17/ R-2/S 8" X 17/ R-2/S 8" X 17/ Machine #1-LM #325-12 Print #3988-Y Dimensions 9" x4" x 4" 14" x 15" x 6" Recess pRec R-2/S 57/ X R-2/S 87/ X if #330-15 Print #3988-Y #430-12 Print #5988-Y 14" x 15" x 6" 14" X 15" X 6" R-2/S 87/; R-2/S 87/ X l| #220-8 DE & LR #220-8 DE only 12" X 4" X 5" 12" x 5" x 5" 12" X 6" X 5" 12" X 7" X 5" 12" X 8" X 5" 12" X 10" X 5" #CINCO-15 12" X 3" X 5" All requirements 12" X 4" X 5" for 12" regulating 12" X 5" X 5" wheels will also 112" X 6" X 5" apply to 14" & 15' 112" X 7" X 5" diameter 12" X 8" X 5" regulating wheels Old TWIN GRIP #340-20 Print #1709-Y 14" X 20" X 5" #440-20 Print #1709-Y 14" x 20" x 5" New TWIN GRIP #340-20 14" X 20" X 6" Print #3800-Y #440-20 Print #3800-Y 14" X 20" X 6" AE 220-8. 15" X 8" X 6" AE 230-12 15" X 12" X 6" AE 350-20 15" X 20" X 6" RK 220-8 RK 230-12 RK 350-20 14" X 8" X 6" 14" X 12" X 6" 14" X 20" X 6" R-1/S R-1/S 77/ X 'll 77" X 1*1 [Dej R-2/S 77/ X 1 R-1/S 77/ X 1 R-1/S 77/ X llPop* R-1/S 77/ X 2*; R-O/S 77/ X 1 % !ness [grad ;^Rub! R-1/S 77/ X 7/ R-1/S 77/ X V/ R-1/S 77/ X vt |beer resili 'high* R-1/S R-1/S 77/ 77/ X X ivpf(Rec R-1/S 772 X 1 %IVitrif help [grinc R-2/S 8" X V/i Here pingw R-2/S 8" X 17/ Do L 1. Ft cr R-2/S 87/ X LA! 2. Ft cr R-2/S 87/ X VP3 Ft 9' R-1/S 87/ X Vp1Don' R-2/S 87/ X I7t 1. Fc ne R-2/S 87/' X BP12168Y Vl\ 2. Ui is R-1/S 8-//X17 [3. Oi R-1/S 87/ X Vi di: R-2/S 87/ X Yt [Grat BP3800Y [Then 2A80 other MIL 000094 [On si finer has a 4-13 {CINCINNATI Centerless Grinder [Regulating Wheel Bonds CINCINNATI Centerless Lapping Wheels [Regulating wheels are available in three bond systems: |BBi vitrified, and rubber. Grain IBond Type Type Grit Size Grades x rl BR tyitrified.'VFMEI A 2A 80, 100, or 120 R 80,100 or 120 N4, P4, Q4-VFME1 Rubber R A 80 & 120 R2, S2, or T2 /*' X 1' For additional grades consult your Cincinnati Milacron Marketing [company representative. iz" x va Description /" X ^ br Bond -- A resilient resin general purpose bond used x < argely in thrufeed grinding with waterbased grinding fluid. ^ J oopular in price and availability. Works well when round- ; less limit is above .0002 inches. (Recommended starting jrade is A80-R-BR.) 2 Rubber Bond -- The standard rubber bond which has A" X V, jeen the most popular regulating wheel due to the \ x esiliency and gripping action of the rubber bond. Slightly \ x ^ ligher in price and manufacturing time is slightly longer. X I'/ Recommended starting grade is A80-R2-R.) !{ x n / X Nitrified Bond --- (VFME1) Vitrified regulating wheels can 2 '"hteelp to ov\ ercome roundness problem jobs in centerless jrinding. x lere are some do's and don'ts for using vitrified regulat! ng wheels. x 17/ )c Use For parts with interrupted surfaces when roundness is critical, i.e., keyways, holes, notches. h" X I'/i - ^or both thrufeed and infeed jobs, when roundness is critical. h" X 1 Vj *:r Par*s that have an eccentric action during the grind. / X 1'./;/Pon't Use A" X 1'/| For bar grinding and thrufeeding rough parts (you still A" X I'/j need the resiliency of resin on these jobs). 3Y Under 1" thick except in special cases where the part is extremely small. 'li X 11 A" X I'/j On double diameter parts when there is an extreme A" X 1'/| difference in diameter ratios. Y rades piere does not appear to be a need for many grades. 2A80-P4-VFME1 has been very successful although pther standard vitrified grades can be used. small parts (less than V/') there may be a need to go ;ner anc1 harder. 2A120-Q4-VFME1 (especially if the part es an intricate form). Cincinnati Milacron formerly made a centerless lapper for producing fine finishes on cylindrical parts, the wheel sys tem consisted of a lap grinding wheel and a regulating wheel. Wheel Size 14 x 22 x 6V8 3-14 x 7.335 x 67s Sections Wheel Speeds Lap Grinding Wheel - 600 RPM Regulating Wheel - 300 RPM Product Availability Grain Type Grit Size Grade Structure VFM V10 V80 BY 2A 120, 150, 180, 220 A 120, 150, 180, 220 A 180, 220 C 320, 500 F-R F-S O-T T-V 4 4-7 5 No Stru;:.'6 Recommendations For Typical Operation Regulating Wheel Lap Grinding Wheel Finish Required C320-V-BY C320-V-BY C320-V-BY 2A220-R4-VFME1 C320-V-BY C500-T-BY Regular Lap Gnnd 6-8 RMS 4 RMS & Less Formula for Computing "G" Ratio On Centerless Grinder Do you have the occasion to compute a "G" ratio on cen terless grinding? If so, here are the formulas you need. n x D x Stock on Radius x L = Steel and it x D x W x Compensation = Wheel Divide Wheel into Steel Remember, although much higher "G" ratios are not as meaningful on semi finish or finish passes. Consider vitrified regulating wheels for work pieces which have interrupted surfaces, such as holes, flats, grooves, keyways and etc. Vitrified regulating wheels grades are: General Purpose Small Parts Very Small Parts 2A100-P4-VFME1 2A120-R4-VFME1 2A150-T4-VFME1 MIL 000095 4-14 The position of the center of the work in relation to the centerline of the wheels is the same for infeed as thrufeed. Raise the center of the work above the centerline of the wheel an amount equal to 'k the work diameter for work 1" diameter and smaller, to 'W maximum for work larger than 1". The regulating wheel truing slide is swiveled the same amount as the angle of inclination except when truing a special shape form the profile truing cam. When truing from the cam, the slide should be set at zero. The diamond holder should be set over for infeed work the same as for thrufeed work; however, if dressing a spe cial shape from the profile cam, the diamond holder should be set at zero. The workpiece may be set at any height above center to obtain required roundness. With a small angle of inclina tion, the line of contact of the workpiece will be full at any height above center. However, if the angle of inclination is increased beyond 1/4, the full line of contact will not result and further corrections will have to be made to set full line contact between the regulating wheel and workpiece. How To Use "Top" Mark When Mounting CINCINNATI MILACRON Grinding Wheels On-Machine Mounting The TOP mark indicates the point of contact between wheel and spindle when the wheel's OD was trued at Cincinnati. Wheel user should mount wheel in the same way (i.e. align TOP with point of contact) to minimize OD runout and truing. Typical mountings are shown schemat ically below. Contact Point Off-Machine Mounting Of TWIN GRIP Wheels Set wheel on cradle with TOP at 12 o'clock position. Place a blotter on fixed flange and insert spindle into wheel bore. Place a blotter on loose flange and mate flange with spindle; secure it with one screw, finger tight. Lift spindle-wheel assembly off cradle as shown. Insert remaining flange screws and tighten them, in approved manner, while wheel is suspended as shown. See photo opposite page. Contact Point Mounting Wheels On TWIN GRIP Centerless Grinders The Operators Hand Book has a comprehensive section on proper wheel mounting methods. Here are a few tips to make the job easier. 1. With wheels resting in cradle, install rear blotter, insert the spindle cartridge. 2. Install front blotter, flange, and bolts and snug up finger tight. 4-21 3. Raise assembly from the cradle, and tighten bolts with a torque wrench. NOTE: Wheel should be mounted with top up. 4. For wide wheel twingrips (18-20"), torque bolts to 45 foot pounds; for smaller twingrips (10-12") 35 foot pounds is sufficient. 5. Retorque the clamping flange bolts after the first 8 hours of operation. MIL 000096 tions when needed. The harder grades are used when the regulating wheels must be very thin and the general-pur pose grade deflects under the pressure of the grind. Harder grades also offer some advantage when work must be ground to very close tolerances, and when there is excessive regulating wheel wear due to the design of the work when grinding two or more diameters and one is much larger than the other. The difference in sfpm causes one of the diameters to slip or skid in contact with the wheel. The general-purpose grade gives a better drive or braking action and will resist spinning more than the finer, harder wheels on average work. The average starting speed of the regulating wheel is from 22 to 39 rpm, and for general work the angle of inclination of 3 is recom mended as a starting point. However, both the angle and wheel speed can be changed to suit specific conditions. The steeper the angle, the faster the traverse rate. The flatter the angle, the slower the traverse rate.The wheel speed also affects the traverse rate. The faster the wheel speed, the faster the traverse rate, and conversely, the slower the wheel speed, the slower the traverse rate. For work that is warped from hardening or machining, the best straightening effect can be obtained by using a high traverse rate or by increasing the angle of the regulating wheel. For work that is straight, but out-of-round, a faster rounding-up action can be obtained by using a higher reg ulating wheel speed and a flatter angle. This does not necessarily mean less production from the machine, because increasing the wheel rpm and reducing the angle of the regulating wheel could give approximately the same traverse rate. Truing The Regulating Wheel: Thrufeed Work The regulating wheel must be trued to a special shape so that the work, while passing between the wheels, makes a straight-line contact with the wheel face. Four factors must be considered to set the truing unit to form this shape: 1. Angle of inclination of the regulating wheel. 2. Location of the center of the work with respect to the centerline of the grinding and regulating wheels. 3. The angle to which the regulating wheel truing slide is swiveled. 4. The amount the diamond holder is set over. The first factor is fixed by the work. A general recommen dation for most thrufeed setups is a positive inclination of 3 as a starting point. The second factor is fixed by the diameter of the work. Generally, work is ground with its center above the cen terline of the grinding and regulating wheels. For small work up to 1" diameter, adjust the blade to position the work one half of its diameter above the centerline of the wheels. For larger work, the above center adjustment sel dom exceeds '/2 inch. The third and fourth factors are based on the ratio of the diameter of the regulating wheel and the diameter of the workpiece. Determine the ratio by dividing the diameter of the regulating wheel by the diameter of the workpiece. After establishing this ratio, refer to the following chart to determine the correct truing angle for the truing slide and the correct diamond holder setting for dressing the spe cial shape required on the regulating wheel. Table Of Truing Angles And Heights Above Center For Regulating Wheel Truing Truing Angle Setting WORK FEED ANGLE* 7 6 10` 6 !0 6 20' 6 25' 6 30* 6 35 6 45' 6 50 6 55 6 55 6' 5 15' 5 15 5 25' 5 30' 5`35 5 40' 5 45' S`55 5 55 5 55' 5 A 20' 4 25 4 30' 4-35' 4 40' 4 40` 4 `50* 4 55 5 4 3 30' 3 30 3 35' 3'40' 3' 45' 3 45' 3 50' 3 S5` 4 5 4 3 2 35' 2 40' 2 40' 2'45 2 50' 2 50' 2 55' 2 55' 3 2 1 45' 1 45' 1 50' 1 50' 1 50' 1 55 1 55' 2 2 l 50' 50' 55" 55' 55' 55' 55' 1 1 3 2 1 D RATIO -- d WORK HEIGHT ABOVE CENTER! 3 3.5 4 5 6 7 12 16 24 48 V8" 7/64" 7/64' 7/64" 7/64" 7/64' 1>8" 1/8' 1/9" 1.8 1'S' 1/4" 7/32" 7/32' 7/32" 15/64'15/64" 15-64' 15/64" 1/4' 1/4 1/4 3/8" 21/64" 21/64' 11/32' 11/32" 11/32" 23/64 23/64" 23/64" 3/8 3/3 1/2" 7/16" 7/16" 29/64" 29/64" 15/32" 15/32" 31/64" 31/64" i'2 1/2" 5/8" 35/64" 35/64" 9/16" 37/64" 37/64" 19/32" 19/3?'29/64" 5/8 5/8" 3/4" 21/32" 2U3?'43/64" 11/16" 45/64" 45/64" 23/32" 47/64" 47/64' 47/64 7/8" 3/4" 29/64" 25/32" 51/64" 13/16" 55/64'27/32" 55/64' 55* 64 55/64 1" 55/64" 7/8" 29/32" 59/64 ' 15/16" 15/16" 61/64" 63/64" 63/64 63/64 To use the chart, consider a setup with a 3 angle of incli nation, 2 work diameter, %" height above center, 12" diameter regulating wheel. To determine the ratio, divide the diameter of regulating wheel by the diameter of the work (12 divided by 2 = 6 ratio). Note chart -- ratio 6 -- read up on the chart to the line extending from 3 -- note angle to swivel truing slide is 250'.To determine the diamond holder setting, read down on the chart from ratio 6 to the line extending from 'W work height above center; note diamond holder 15/32 above center. See Sketch No. 15. Sketch No 15 Truing The Regulating Wheel: Infeed Work - Angle of inclination; Since the work does not traverse between the wheels, there is very little angle required. An angle between 0 and 7 is recommended to hold the work against the end-stop during grinding. MIL 000097 4-20 Table of Thrufeed Work Traverse Rates Inches Per Minute The rate at which the work feeds past the grinding wheel on thrufeed jobs depends upon the diameter, speed of rotation, and angle of inclination of the regulating wheel, the following table gives the approximate theoretical work feed rates in inches per minute for all combinations of these three variables. Reg. Wheel Angle r 2 3 Reg. Wheel Diam. 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 10 r.p.m. 4.4 4.7 4.9 5.2 5.5 5.8 6.0 6.3 6.6 6.9 7.1 7.4 7.6 8.8 9.3 9.9 10.4 11.0 11.5 12.1 12.6 13.2 13.7 14.3 14.8 15.4 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 15 r.p.m. 6.6 7.0 7.4 7.8 8.2 8.6 9.0 9.5 9.9 10.3 10.7 11.1 11.5 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 19.7 21.0 22.2 23.4 24.7 25.9 27.1 28,4 29.6 30.9 32.1 33.4 34.6 20 r.p.m. 8.8 9.3 9.9 10.4 11.0 11.5 12.1 12.6 ' 13.2 13.7 14.3 14.8 15.4 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 26.3 28.0 29.6 31.2 32.9 34.5 36.2 37.8 39.5 41.1 42.8 44.4 46.1 25 r.p.m. 11.0 11.6 12.3 13.0 13.7 14.4 15.1 15.8 16.4 17.1 17.8 18.5 19.2 21.9 23.3 24.7 26.0 27.4 28.8 30.2 31.5 32.9 33.2 33.6 33.9 34.3 32.9 34.9 37.0 39.1 41.1 43.2 45.2 47.3 49 3 51.4 53.4 55.5 57.5 Regulating Wheel Speeds, R.P.M. 30 r.p.m. 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 26.3 28.0 29.6 31.2 32.9 34.5 36.2 37.8 39.5 41.1 42.8 44.4 46.1 39.5 41.9 44.4 46.9 49.3 51.8 54.3 56.7 59.2 61.6 64.1 66.5 69.0 40 r.p.m. 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 35.1 37.3 39.5 41.7 43.9 46.0 48.2 50.4 52.6 54.8 57.0 59.2 61.4 52.6 55.9 59.2 62.5 65.8 69.1 72.3 75.6 78.9 82.2 85.5 88.8 92.1 50 r.p.m. 21.9 23.3 24.7 26.0 27.4 28.8 30.2 31.5 32.9 34.2 35.6 36.9 38.3 43.9 46.6 49.3 52.1 54.8 57.6 60.3 63.0 65.8 68.5 71 ;3 74.0 76.8 65.8 69.9 74.0 78.1 82.2 86.3 90.4 94.5 98.7 102.8 106.9 111.0 115.1 70 r.p.m. 30.7 32.6 34.5 36.5 38.4 40.3 42.2 44.1 46.0 47.9 49.8 51.7 53.6 61.4 65.2 69.1 72.9 76.7 80.6 84.4 88.3 92.1 96.0 99.8 103,7 107.5 92.1 97.8 103.6 109.3115.1 120.9 126.6 132.4 138.1 143.9 149.6 155.4 161.1 90 r.p.m. 39.5 41.9 44.4 46.9 49.3 51.8 54.3 56.7 59.2 61.6 64.1 66.5 69.0 78.9 83.9 88.8 93.7 98.7 103.6 108.5 113.5 118.4 123.4 128.3 133.3 138.2 118.4 125.8 133.2 140.6 148.0 155.4 162.8 170.2 177.6 185.0 192.4 199.8 207.2 125 r.p.m. 54.8 58.2 61.7 65.1 68.5 72.0 75,4 78.8 82.2 85.6 89.0 92.4 95.8 109.6 116.5 123.3 130.2 137.1 143.9 150.8 157.6 164.5 171.3 174.2 177.0 183.9 164.4 174.7 185.0 195.3 205.5 215.8 226.1 236.4 246.6 256.9 267.2 277.5 287.8 150 r.p.m. 70.2 74.6 78.9 83.3 87.7 92.1 96.5 100.9 105.3 109.7 114.1 118.5 122.9 140.3 149.1 157.9 166.7 175.4 184.2 193.0 201.7 210.5 219,2 228.5 236.7 245.5 210.5 223.6 236.8 249.9 263.1 276.2 289.4 302.6 315.7 328.8 341.9 355.0 368.1 MIL 000098 Table of Thrufeed Work Traverse Rates (cont.) Reg. Wheel Angle 4' 5' 6" 7 Reg. Wheel Diam. 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 120 12.5 13.0 135 140 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 90 9.5 100 105 11.0 11.5 12.0 12.5 130 13.5 14 0 8 0" 85 90 95 10.0 10.5 11.0 11 5 12 0 125 130 10 r.p.m. 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 21.9 23 3 24.6 26.0 27.4 28.8 30.1 31.5 32.9 34.3 35.7 37.1 38.5 26.3 27.9 29.6 31.2 32 8 34 5 361 37.8 39.4 41.0 42.6 44.2 45.8 30 6 32.5 34 5 36 4 38 3 40.2 421 44 0 459 47.8 49 7 15 r.p.m. 26.3 27.9 29.6 31.2 32.9 34.5 36.2 37.8 39.4 41.0 42,5 44 2 45.8 32.9 34.9 37.0 39.0 41.1 43.1 45.2 47.2 49.3 51.3 53.4 55.4 57.5 39,4 41.9 44.3 46.8 49.3 51.7 54.2 56.6 59.1 61.6 64.1 66.6 69.1 45 9 48.8 51 7 54 6 57.4 60 3 63.2 66 0 68 9 71 8 74.7 Regulating Wheel Speeds. R.P.M. 20 r.p m. 35.1 37.3 39.4 41.6 43.8 46.0 48.2 50.4 52.6 54.8 57 0 59 2 61.4 43.8 46.5 49.3 52.0 54.8 57.5 60.2 63.0 65.7 68.5 71.2 74.0 76.7 52.5 55.8 59.1 62 4 65 7 69 0 72.2 75.5 78 8 82.1 85 4 88.7 92.0 61 3 65.1 68 9 72,7 76 6 80 4 84.2 88 1 919 95 7 99 5 25 r.p.m. 43.8 46.6 49.3 52.1 54.8 57.5 60.3 63.0 67.7 68.5 71.3 74 1 76.9 54.8 58.2 61.6 65.0 68.5 71.9 75.3 78.7 82.1 85.5 88.9 92.3 95.7 65.7 69.8 73 9 78.0 82.1 86 2 90.3 94.4 98 5 102.6 106.7 110.8 114.9 76.6 81.4 86 1 90 9 95 7 100.5 105.3 110 1 114.9 119.7 124 5 30 r.p.m. 52.6 55.9 59.2 62.5 65.7 69.0 72.3 75.6 78.9 82.2 85.5 88.8 92.1 65.7 69.8 73.9 78.0 82.1 86.3 90.4 94.5 98.6 102.7 106.8 110.9 115.0 78.8 83.7 88 7 93.6 98.5 103.4 108.4 1133 1182 123.1 128.0 132.9 137.8 91.9 97.6 103 4 109 1 1149 120 6 126.3 132.1 137 8 143 5 149 2 40 50 r.p.m. r.p.m. 70.1 74.5 78.9 83,3 87.7 92.0 96.4 100.8 105.2 109.6 114.0 118.4 122.8 87.7 931 98.6 104.1 109.6 115.1 120.5 126,0 131,5 136.9 142.4 147.8 153.3 87.6 93.1 98.6 104.1 109.5 115.0 120.5 126.0 131.4 136.9 142.4 147.9 153.4 109.5 116.4 123.2 130.1 136.9 143.8 150.6 157.4 164.3 171.2 178,1 . 184.0 191.9 105.1 111.7 1182 124 8 131.4 137.9 144.5 151.1 157.6 164.3 170.9 177.5 184 1 131.4 139.6 147.8 156.0 164.2 172.4 180.6 188 8 197.0 205.2 213 4 221.6 229.8 122.5 130 2 137 8 145 5 1531 160.8 168 5 176 1 183 8 191.5 199.2 153 1 162.7 172.3 181.9 191.4 201.0 210 6 220.1 229 7 239.3 248 9 70 r.p.m. 122.7 130.4 138.1 145.7 153.4 161.1 168 8 176.4 184.1 191.7 199.4 2070 214 7 153.3 162.9 172.5 182.1 191.7 201.3 210.8 220.4 230.0 239.6 249.2 258.8 268.4 183.9 195.4 206.9 218.4 229.9 241.4 252.9 264.4 275.8 287.4 298.9 310.4 321 9 214 4 227.8 241 2 254 6 268 0 281.4 294.8 308 2 321 6 335 0 348 4 90 r.p.m. 125 r.p.m. 150 r.p.m. 157.8 167.7 177.5 187.4 197.2 207.1 217.0 226.8 236.7 246.5 256.4 266 2 276.1 197.2 209.5 221.8 234.1 246.4 258.8 271.1 283.4 295.7 308.0 320.3 332.6 344.9 236.4 251.2 266.0 280.8 295.6 3103 325.1 339.9 354.7 3695 384.3 399 1 413.9 275.7 292.9 310.1 327.4 344 6 361.8 379 0 396.3 4135 430 7 447 9 ' 219.2 232.9 246.6 260.3 273.9 287.6 301.3 315.0 328.7 342.4 356.1 369.8 383.5 273.8 290.9 308.0 325.2 342.3 359.4 376.5 393.6 410.7 427.8 444.9 462.0 471.9 328.4 348.9 369.4 390,0 410.5 431.0 451.5 472.1 492.6 513.1 533.6 554.1 574.6 382.9 406.8 430.7 454.7 478.6 502.5 526.4 550 4 574.3 598.2 622.1 280.5 298.1 315.6 333.1 350.7 368.2 385.7 403.3 420.8 438.4 456.0 473.6 491.2 350.5 372.4 394.3 416.2 438.1 460.0 481.9 503.8 525.7 547.6 560.5 591.4 613 3 420 3 446.6 472.9 499.2 525.4 551.7 578.0 604.2 630.5 656.8 683.1 709 4 735 7 490 1 520 7 551 3 582 0 612.6 643 2 673.8 704.5 735.1 765 7 796.3 MIL 000099 4-23 Typical Centerless Applications Selection of traverse rates for thrufeed work depends upon so many factors that it is not practical to compile exact tables for all the conditions which may be encoun tered. Perhaps the reason will be more apparent if we tabulate some of these factors: work material (including physical characteristics), stock removal, accuracy stan dards, blade material, type of grinding wheel, finish desired, diameter of part, weight of part, coolant avail able, and physical condition of machine. Practically every job must be considered on its own merits. A good prac- tice is to keep complete job records and use it as a guide in setting up duplicate or similar jobs. A few exam ples are given here to provide a starting point in select ing the correct traverse rate. All of them have been checked by time studies and represent actual job shop practice. Under high volume production conditions, the use of larger machines with higher horsepowers and wider wheels could be easily justified to reduce the num ber of operations. PISTON PIN Size -- 7a" diameter x 37i6" long. Material -- Hardened steel. Stock Removal -- .015" in four roughing and two finishing cuts. Finish -- High grade commercial. Wheel -- 97A-601-J6-VRW. Traverse Rate -- 12 feet per minute per cut. Machine -- 220-8 Centerless. CHAIN ROLLER PIN Size -- Vaz" diameter x 7.6" long. Material -- Hardened steel. Stock Removal -- .005" to .008", one cut. Finish -- High grade commercial. Wheel -- 97A-601-M4-VRW. Traverse Rate -- 7 feet per minute per cut. Machine -- 220-8 Centerless. STEEL ROD Size -- s/8" diameter x 12" long. Material -- Soft steel. Stock Removal -- .010" to .015", three cuts. Finish -- Commercial. Wheel -- 97A-601-J6-VRW. Traverse Rate -- 7 feet per minute per cut. Machine -- 220-8 Centerless. PISTON Size -- 37,6" diameter x 4" long. Material -- Cast iron. Stock Removal -- .005" three cuts. Finish -- Good commercial. Wheel -- 6C-46-K6-VSC. Traverse Rate -- 5 feet per minute per cut. Machine -- 325-12 Centerless. Add "E" to bond symbol of wheel speed is greater than 6500 SFPM vitrified and 9500 resin. FIN-TECH Finishing Technologies This fine grit product is available in grit sizes ranging from 220-1200. These wheels will produce finishes in the 2 - 4 micro inch Ra range. FIN-TECH Grinding Wheels for cylindrical and centerless grinding in thrufeed and plunge cut operations offer many technical and economical advantages. These FIN-TECH products are well suited and designed for the grinding of: Struts Rods, Piston Pins Needles, Rollers Roll Grinding Razor Blades Hypodermic Needles Thrufeed Grinding Increase of thrufeed speed in conjunction with maxi mum rate of metal removal. Reduction of dressing time. Superior surface quality. Very fine surface finishes produced 2-4 micro inch Ra. Very consistant surface finishes from ,3-.6 micrometer Rz. Plunge Cut Grinding Excellent profile stability. Good cutting characteristics which increase productivity. FIN-TECH Availability Resin Bond Bond Designator: BFG Diameter: 5.9 - 43.3 in. 150- 1100mm Thickness: .98 - 11 8 in. 25 - 300mm Grit Sizes: Structure: 220- 1200 7- 18 Vitrified Bond Bond Designator: VGF Max. 24 in. Max. 610mm Max. 4.7 in. Max. 120mm 220 - 600 7- 12 MIL 000100 4-24 MIL 000101 Trouble Shooting L Burn Marks On Workpiece I i. insufficient coolant ?2. Dull or flat diamond 3. Wheel too hard 4. Cutting on trailing edge of the wheel 5. Grinding wheel dressed with diamond traverse too slow. 6. Too heavy stock removal [b. Chatter 1. Work too high above center 2. Wheel out of balance 3. Blade angle too steep (30 standard) 4. Blade too thin or warped 5. Machine leveling screws not adjusted for even torque when machine is finally leveled 6. Glazed wheel caused by dull diamond, wheel too hard, grit size too fine or dressing rate too slow 7. Outside "Floor Harmonics" 8. Motors out of balance 9. Grinding wheel mount fits loosely on spindle 10. Stock removal too heavy 11. Blade not properly clamped |j-12. Blade being used too long for width of wheel Dull Diamond -- Grinding Wheel Truing Attachment * 1. Diamond nib not turned periodically 2. Excessive infeed of diamond (should not take more than 0.001" depth of cut under normal conditions) L Erratic Sizing 1. Gibs not properly adjusted on upper and lower slides 2. Wear in infeed screw and nut 3. Infeed lever not held tight (for thrufeed work) 4. Soft wheel ' 5. Insufficient lubrication on lower slides causing slides to hang or jump (infeed) 6. Improper tension on backlash spring 7. Loose work support blade 8. Parts overheating during cut, due to improper wheel or insufficient coolant 9. Regulating wheel camming fO. Work improperly rough ground Feed Lines T Grinding wheel not relieved on exit side 2. Work guides not properly set 3- On long bar fixtures -- excessive pressure on workpiece by roller hold-down F. Finish 1. Improper wheel grade 2. Dirty or insufficient coolant 3. Setup not correct 4. Diamond dressing traverse rate too fast 5. Erratic movement of truing attachments 6. Pick-up on blade 7. Blade not tight in work rest 8. Blade angle too steep 9. Unbalanced wheel 10. Loose, cracked or dull diamond 11. Oil on face of wheel 12. Regulating wheel not tight on its mount 13. Work too high above center 14. Regulating wheel SFM excessive G. Fish Tails (Scratches) 1. Dirty coolant 2. Loose grit in wheel H. Grinding Wheel 1. Too hard a. May cause burn marks b. Can cause squeal because it is not free cutting c. Glazing may occur on wheel face d. Soft materials may "load" wheel e. Often produce chatter on workpiece f. Sizing trouble, due to no spark out g. May cause heat checks or cracks 2. Too soft a. Sizing trouble, because wheel breaks down rapidly. b. Chatter may develop c. Rough finish I. Height Above Center of Workpiece 1. If too high, chatter can develop 2. Optimum rounding action will not occur if center height is too low 3. Three-point out-of-roundness is a good sign of low center J. Intermittent Cut 1. Grinding wheel not correctly trued 2. Regulating wheel "camming" 3. Warped workpiece K. Jumpy Truing Device 1. Air in hydraulic lines . . 2. Slides not lubricated properly 3. Gib adjusted improperly MIL 000102 4-26 inder in ilons when needed. The harder grades are used when the !!*niiating wheels must be very thin and the general-pur- on very | [Jose grade deflects under the pressure of the grind, pass, the jjnrder grades also offer some advantage when work m betwe must be ground to very close tolerances, and when there e parts.1 js excessive regulating wheel wear due to the design of )re the'iJlitis work when grinding two or more diameters and one is his probe more )ld-downJ d the pa until it is much larger than the other. The difference in sfpm causes one of the diameters to slip or skid in contact with the 'wheel. The general-purpose grade gives a better drive or braking action and will resist spinning more than the finer, harder wheels on average work. The average starting speed of the regulating wheel is from 22 to 39 rpm, and or general work the angle of inclination of 3 is recom- nended as a starting point. However, both the angle and ration on wheel speed can be changed to suit specific conditions. d which The steeper the angle, the faster the traverse rate. The n falls into flatter the angle, the slower the traverse rate.The wheel iables mi speed also affects the traverse rate. The faster the wheel dened of Sp6ecj) the faster the traverse rate, and conversely, the jth of the s|0Wer the wheel speed, the slower the traverse rate. For i size of 8 work that is warped from hardening or machining, the stock best straightening effect can be obtained by using a high . and pro- traverse rate or by increasing the angle of the regulating informal* wheel. For work that is straight, but out-of-round, a faster ar center- r0unding-up action can be obtained by using a higher reg- elected t( j|atjng wheel speed and a flatter angle. This does not I or rule necessarily mean less production from the machine, selected necause increasing the wheel rpm and reducing the because angle of the regulating wheel could give approximately ffect grind he same traverse rate. ts o e t-rujng RegU|atjng vvheel: ; action' 1, finish, hrufeed Work The regulating wheel must be trued to a special shape so hat the work, while passing between the wheels, makes straight-line contact with the wheel face. Four factors =ral rea- nust be considered to set the truing unit to form this grinding, ihape: to restore . . ,. ent chatte ' An9'e f inclination of the regulating wheel, ne wheel - Location of the center of the work with respect to the etc.). The :er|terline of the grinding and regulating wheels. el face is 3. The angle to which the regulating wheel truing slide is juired onl Swiveled. amunt the diamond holder is set over. travel for [he *'rst factor is *'xed by the work. A general recommen- 40" to > n *or most hrufeed setups is a positive inclination of te. While *as a starting point. er, a good [he second factor is fixed by the diameter of the work, neel to ?eneraliy, work is ground with its center above the cenby the tru erline of the grinding and regulating wheels. For small more that !^orL up to r diameter, adjust the blade to position the leel. one half of its diameter above the centerline of the j ee,s- For larger work, the above center adjustment selexceeds '/2 inch. )-R-BR ftfrh rarder ' h 6 '^Ircl 3nc* ^0urth factors are based on the ratio of the rial applirflameter tfle re9ulating wheel and the diameter of the workpiece. Determine the ratio by dividing the diameter of the regulating wheel by the diameter of the workpiece. After establishing this ratio, refer to the following chart to determine the correct truing angle for the truing slide and the correct diamond holder setting for dressing the spe cial shape required on the regulating wheel. Table Of Truing Angles And Heights Above Center For Regulating Wheel Truing Truing Angle Setting WORK FEED ANGLE* 7 6 10` 6"10` 6 20 6 2S` 6 301 6 35' 6 4S' 6 50' " 6 55" 6 55 6' 5 15' 5" 15' 5 25- 5'30` S"35` 5'40` 5 45' 5-55' 5 SS- 5 55 s- 4"20* 4 `25' 4 30 4V3S` 4 "40' 4 40' 4-50' 4 55 S 4 3 30' 3"30` 3 35 3"40' 3M51 3`45* 3 50' 3 55' 4 5 4 3 2 35' 2 '40' 2 40 2'45' 2 50' 2 '50' 2 SS' 2 55' 3 3 2 145' 1 '45' 1 SO 1 '50` 1VS0` 1 55' 1 55' 2 2 2 1 50` 50' 55 55' 55' 55' 55' 1 1 i D RATIO -- d WORK HEIGHT ABOVE CENTER! 3 3.S 4 S 6 7 12 18 24 48 1/8"1 7/64" 7/64" 7/64 7/64" 7/64" 1/8" 1/8' 1/8 1/8 U8 1/4 1 7/32" 7/32" 7/32 15/64" 15/64" 15/64" 15/64' 1/4 1/4 1-4 3/8 21/64" 21/64` 11/32 11/32" 11/32" 23/64" 23/64" 23/64" 3/8 3/8 1/2" 7/16" 7/16" 29-64 29/64" 15/32" 15/32" 31/64 ' 31/64 1/2" 1/2 S/8" 35/64" 35/64" 9'16 37/64" 37/64" 19/32" 19/32" 29/64' 5/0' S'8 3/4" 21/32" 21/32" 43-'64 11/16" 45/64" 45/64" 23/32' 47/64" 47/64 47*64 7/8" 3/4 29/64 25/32 51/64" 13/16" SS/64" 27/32 55/64 55*64 55- 64 1" 55/64" 7/8" 29.32 59/64" 15/16" 15/16" 61/64 * 63/64" 63'64 63 64 To use the chart, consider a setup with a 3 angle of incli nation, 2 work diameter, 72" height above center, 12" diameter regulating wheel. To determine the ratio, divide the diameter of regulating wheel by the diameter of the work (12 divided by 2 = 6 ratio). Note chart -- ratio 6 -- read up on the chart to the line extending from 3 -- note angle to swivel truing slide is 250'.To determine the diamond holder setting, read down on the chart from ratio 6 to the line extending from 'A" work height above center; note diamond holder 15/32 above center. See Sketch No. 15. Sketch No 15 Truing The Regulating Wheel: Infeed Work Angle of inclination: Since the work does not traverse between the wheels, there is very little angle required. An angle between 0 and 'IS is recommended to hold the work against the end-stop during grinding. MIL 000103 4-20 The position of the center of the work in relation to the centerline of the wheels is the same for infeed as thrufeed. Raise the center of the work above the centerline of the wheel an amount equal to % the work diameter for work 1" diameter and smaller, to %" maximum for work larger than 1". The regulating wheel truing slide is swiveled the same amount as the angle of inclination except when truing a special shape form the profile truing cam. When truing from the cam, the slide should be set at zero. The diamond holder should be set over for infeed work the same as for thrufeed work; however, if dressing a spe cial shape from the profile cam, the diamond holder] should be set at zero. The workpiece may be set at any height above centS obtain required roundness. With a small angle of incja tion, the line of contact of the workpiece will be full al height above center. However, if the angle of inclinatfl increased beyond 1/4, the full line of contact will notj result and further corrections will have to be made tol full line contact between the regulating wheel and woj piece. How To Use "Top" Mark When Mounting CINCINNATI MILACRON Grinding Wheels On-Machine Mounting The TOP mark indicates the point of contact between wheel and spindle when the wheel's OD was trued at Cincinnati. Wheel user should mount wheel in the same way (i.e. align TOP with point of contact) to minimize OD runout and truing. Typical mountings are shown schemat ically below. Contact Point Off-Machine Mounting Of TWIN GRIP Wheels Set wheel on cradle with TOP at 12 o'clock position. Place a blotter on fixed flange and insert spindle into wheel bore. Place a blotter on loose flange and mate flange with spindle; secure it with one screw, finger tight; Lift spindle-wheel assembly off cradle as shown. Insert remaining flange screws and tighten them, in approved manner, while wheel is suspended as shown, See photo opposite page. Mounting Wheels On TWIN GRIP Centerless Grinders The Operators Hand Book has a comprehensive section on proper wheel mounting methods. Here are a few tips to make the job easier. 1. With wheels resting in cradle, install rear blotter, insert the spindle cartridge. 2. Install front blotter, flange, and bolts and snug up finger tight. 4-21 3. Raise assembly from the cradle, and tighten bolts with a torque wrench. NOTE: Wheel should be mounted with top up. 4. For wide wheel twingrips (18-20"), torque bolts to 45 foot pounds; for smaller twingrips (10-12") 35 foot pounds is sufficient. 5. Retorque the clamping flange bolts after the first 8 hours of operation. MIL 000104 ier gjggPof Thrufeed Work Traverse Rates finches Per Minute enter? inclin -ill at`i inatiofi . not' rate at which the work feeds past the grinding wheel on thrufeed jobs depends upon the diameter, speed of le to < Station and angle of inclination of the regulating wheel, the following table gives the approximate theoretical d wor| (work feed rates 'n 'nc^es Per minute for all combinations of these three variables. Wheel Angle on. into nate er tight] r t Point 2 3 bolts ae Reg. Wheel Diam. 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 10 r.p.m. 4.4 4.7 4.9 5.2 5.5 5.8 6.0 6.3 6.6 6.9 7.1 7.4 7.6 8.8 9.3 9.9 10.4 11.0 11.5 12.1 12.6 13.2 13.7 14.3 14.8 15.4 13.2 14.0 .14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 15 r.p.m. 6.6 7.0 7.4 7.8 8.2 8.6 9.0 9.5 9.9 10.3 10.7 11.1 11.5 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 19.7 21.0 22.2 23.4 24.7 25.9 27.1 28.4 29.6 30.9 32.1 33.4 34.6 20 r.p.m. 8.8 9.3 9.9 10.4 11.0 11.5 12.1 12.6 13.2 13.7 14.3 14.8 15.4 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 26.3 28.0 29.6 31.2 32.9 34.5 36.2 37.8 39.5 41.1 42.8 44.4 46.1 25 r.p.m. 11.0 11.6 12.3 13.0 13.7 14.4 15.1 15.8 16.4 17.1 17.8 18.5 19.2 21.9 23.3 24.7 26.0 27.4 28.8 30.2 31.5 32.9 33.2 33.6 33.9 34.3 32.9 34.9 37.0 39.1 41.1 43.2 45.2 47.3 49.3 51.4 53.4 55.5 57.5 Regulating Wheel Speeds, R.P.M. 30 r.p.m. 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 26.3 28.0 29.6 31.2 32.9 34.5 36.2 37.8 39.5 41.1 42.8 44.4 46.1 39.5 41.9 44.4 46.9 49.3 51.8 54.3 56.7 59.2 61.6 64.1 66.5 69.0 40 r.p.m. 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 35.1 37.3 39.5 41.7 43.9 46.0 48.2 50.4 52.6 54.8 57.0 59.2 61.4 52.6 55.9 59.2 62.5 65.8 69.1 72.3 75.6 78.9 82.2 85.5 88.8 92.1 50 r.p.m. 21.9 23.3 24.7 26.0 27.4 28.8 30.2 31.5 32.9 34.2 35.6 36.9 38.3 43.9 46.6 49.3 52.1 54.8 57.6. 60.3 63.0 65.8 68.5 71 ;3 74.0 76.8 65.8 69.9 74.0 78.1 82.2 86.3 90.4 94.5 98.7 102.8 106.9 111.0 115.1 70 r.p.m. 30.7 32.6 34.5 36.5 38.4 40.3 42.2 44.1 46.0 47.9 49.8 51.7 53.6 61.4 65.2 69.1 72.9 76.7 80.6 84.4 88.3 92.1 96.0 99.8 103.7 107.5 92.1 97.8 103.6 1M3 115.1 120.9 126.6 132.4 138.1 143.9 149.6 155.4 161.1 90 r.p.m. 39.5 41.9 44.4 46.9 49.3 51.8 54.3 56.7 59.2 61.6 64.1 66.5 69.0 78.9 83.9 88.8 93.7 98.7 103.6 108.5 113.5 118.4 123.4 128.3 133.3 138.2 118.4 125.8 133.2 140.6 148.0 155.4 162.8 170.2 177.6 185.0 192.4 199.8 207.2 125 r.p.m. 54.8 58.2 61.7 65.1 68.5 72.0 75.4 78.8 82.2 85.6 89.0 92.4 95.8 109.6 116.5 123.3 130.2 137.1 143.9 150.8 157.6 164.5 171.3 174.2 177.0 183.9 164.4 174.7 185.0 195.3 205.5 215.8 226.1 236.4 246.6 256.9 267.2 277.5 287.8 150 r.p.m. 70.2 74.6 78.9 83.3 87.7 92.1 96.5 100.9 105.3 109.7 114.1 118.5 122.9 140.3 149.1 157.9 166.7 175.4 184.2 193.0 201.7 210.5 219.2 228.5 236.7 245.5 210.5 223.6 236.8 249.9 263.1 276.2 289.4 302.6 315.7 328.8 341.9 355.0 368.1 Its to 45 5 foot first 8 MIL 000105 4-22 Table of Thrufeed Work Traverse Rates (cont.) Reg. Wheel Angle 4 5 6J 7 Reg. Wheel Diam. 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14,0 8.0" 8.5 90 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 130 13.5 14.0 8 0" 85 9.0 9.5 10.0 105 11 0 11 5 12.0 12.5 130 10 r.p.m. 17.5 18.6 19.7 20.8 21.9 23 0 24.1 25.2 26.3 27 4 28.5 29.6 30.7 21.9 23.3 24.6 26.0 27.4 28.8 30.1 31.5 32.9 34.3 35.7 37.1 38.5 26.3 27.9 29.6 31.2 32.8 34 5 36 1 37.8 39.4 41 0 42.6 44.2 45.8 30 6 32 5. 34 5 36.4 38.3 40 2 42 1 44 0 45 9 47 8 49.7 15 r.p.m. 26.3 27.9 29.6 31.2 32.9 34.5 36.2 37.8 39.4 41 0 42.5 44.2 45.8 32.9 34.9 37.0 39.0 41.1 43.1 45.2 47.2 49.3 51.3 53.4 55.4 57.5 39.4 41.9 44.3 46.8 49.3 51.7 54.2 56.6 59.1 61.6 64 1 66.6 69 1 45 9 43 8 51 7 54.6 57 4 60 3 63 2 66.0 68 9 71.8 74.7 Regulating Wheel Speeds. R.P.M. 20 r.p.m. 35.1 37.3 39.4 41.6 43.8 46.0 48.2 50.4 52.6 54.8 57.0 59.2 61.4 43 8 46.5 49.3 52.0 54.8 57.5 60.2 63.0 65.7 68.5 71.2 74.0 76.7 52.5 55.8 59.1 62.4 65,7 69.0 72.2 75.5 78.8 82.1 85.4 88.7 92.0 61.3 65 1 68 9 72.7 76.6 80.4 84 2 88.1 91 9 95 7 99.5 25 r.p.m. 43.8 46.6 49.3 52.1 54.8 57.5 60.3 63.0 67.7 68.5 71.3 74.1 76.9 54.8 58.2 61.6 65.0 68.5 71.9 75.3 78.7 82.1 85.5 88,9 92.3 95.7 65.7 69.8 73.9 78.0 82.1 86.2 90.3 94.4 98.5 102.6 106.7 110.8 114.9 76.6 81 4 86.1 90.9 95.7 1005 105.3 110.1 1149 119.7 124.5 30 r.p.m. 52.6 55.9 59.2 62.5 65.7 69.0 72.3 75.6 78.9 82.2 85.5 88.8 92.1 65.7 69.8 73.9 78.0 82.1 86.3 90.4 94.5 98.6 102.7 106.8 110.9 115.0 78.8 83.7 88.7 93.6 98.5 103.4 108 4 113.3 118.2 123.1 128 0 132.9 137.8 91.9 97 6 103.4 109.1 114.9 120 6 126.3 132 1 137.8 143.5 149.2 40 r.p.m. 70.1 74.5 78.9 83.3 87.7 92.0 96.4 100.8 105.2 109.6 114.0 118.4 122.8 87.6 93.1 98.6 104.1 109.5 115.0 120.5 126.0 131.4 136.9 142.4 147.9 153.4 105.1 111.7 1182 124.8 131.4 137.9 144.5 151.1 157.6 164.3 170.9 177.5 184.1 122.5 130.2 137.8 145.5 153.1 160.8 168.5 176 1 183.8 191.5 199.2 50 r.p.m. 87.7 93.1 98.6 104.1 109.6 115.1 120.5 126.0 131.5 136.9 142.4 147.8 153.3 109,5 116.4 123.2 130.1 136.9 143.8 150.6 157.4 164.3 171.2 178 1 184.0 191.9 131.4 139.6 147.8 156.0 164.2 172.4 180.6 188.8 197.0 205.2 213.4 221 6 229.8 153 1 162 7 172.3 181.9 191 4 201 0 2106 220 1 229 7 239 3 248 9 70 r.p.m. 122.7 130.4 138.1 145.7 153.4 161.1 168.8 176.4 184.1 191.7 199.4 207.0 214.7 153.3 162.9 172.5 182.1 191.7 201.3 210.8 220.4 230.0 239.6 249.2 258.8 268.4 183.9 195.4 206.9 218.4 229,9 241,4 252.9 264 4 275 8 287.4 298.9 310.4 321.9 214.4 227.8 241 2 254 6 268.0 281 4 294 8 308.2 321 6 335.0 348.4 90 r.p.m. 157.8 167.7 177.5 187.4 197.2 207.1 217.0 226.8 236.7 246.5 256.4 266.2 276.1 197.2 209.5 221.8 234.1 246.4 258.8 271.1 283.4 295.7 308.0 320.3 332.6 344.9 236.4 251.2 266.0 280.8 295.6 3103 325.1 339.9 354.7 369.5 384.3 399.1 413.9 275.7 292.9 310.1 327.4 344.6 361.8 379 0 3963 413.5 430.7 447 9 125 r.p.m. 219.2 232.9 246.6 260.3 273.9 287.6 301.3 315.0 328.7 342.4 356.1 369.8 383.5 273.8 290.9 308.0 325.2 342.3 359.4 376.5 393.6 410.7 427.8 444.9 462.0 471.9 328.4 348.9 369.4 390.0 410.5 431.0 451.5 472.1 492.6 513.1 533.6 554.1 574.6 382.9 406.8 430.7 454.7 478.6 502.5 526 4 550.4 574.3 598.2622.1 150 r.p.m. 280.5 298.1 315.6 333.1 350.7 368.2 385.7 403.3 420.8 438.4 456.0 473.6 491.2 350.5 372.4 394.3 416.2 438.1 460.0 481.9 503.8 525.7 547.6 560.5 591.4 613.3 420.3 446.6 472.9 499.2 525.4 551.7 578.0 604.2 630.5 656.8 683.1 709.4 735.7 490.1 520.7 551.3 582.0 612.6 643.2 673.8 704.5 735 1 765.7 796.3 MIL 000106 4-23 Wd "E" l :IN-TE "his fine 20-120( Hicro inc _in-tec rinding echnica1 Tiese Fi pr the gi , Struts [ Rods, ; Needk i Roll G ; Razor :Hypod 'hrufe Increa mum r lyptcaTCenterless Applications ealfldion of traverse rates for thrufeed work depends 581 so ^any factors that it is not practical to compile ct tables for all the conditions which may be encounrad Perhaps the reason will be more apparent if we fate some of these factors: work material (including leal characteristics), stock removal, accuracy stan ds blade material, type of grinding wheel, finish sired, diameter of part, weight of part, coolant avail`0 and physical condition of machine. Practically every must be considered on its own merits. A good prac- tice is to keep complete job records and use it as a guide in setting up duplicate or similar jobs. A few exam ples are given here to provide a starting point in select ing the correct traverse rate. All of them have been checked by time studies and represent actual job shop practice. Under high volume production conditions, the use of larger machines with higher horsepowers and wider wheels could be easily justified to reduce the num ber of operations. PISTON PIN fee -- 7/j" diameter x 37.6" long, aterlal -- Hardened steel, tock Removal -- .015" in four roughing and two ishing cuts. nish -- High grade commercial, eel -- 97A-601-J6-VRW. verse Rate -- 12 feet per minute per cut. achine -- 220-8 Centerless. CHAIN ROLLER PIN tze -- Vk" diameter x V,6" long, aterlal -- Hardened steel, tock Removal -- .005" to .008", one cut. nlsh -- High grade commercial, heel -- 97A-601-M4-VRW. reverse Rate -- 7 feet per minute per cut. achine -- 220-8 Centerless. STEEL ROD Size -- 7a" diameter x 12" long. Material -- Soft steel. Stock Removal -- .010" to .015", three cuts. Finish -- Commercial. Wheel -- 97A-601-J6-VRW. Traverse Rate -- 7 feet per minute per cut. Machine -- 220-8 Centerless. PISTON Size -- 37is" diameter x 4" long. Material -- Cast iron. Stock Removal -- .005" three cuts. Finish -- Good commercial. Wheel 6C-46-K6-VSC. Traverse Rate -- 5 feet per minute per cut. Machine -- 325-12 Centerless. dd "E" to bond symbol of wheel speed is greater than 6500 SFPM vitrified and 9500 resin. IN-TECH Finishing Technologies bis fine grit product'is available in grit sizes ranging from 20-1200. These wheels will produce finishes in the 2 - 4 ticro inch Ra range. IN-TECH Grinding Wheels for cylindrical and centerless rinding in thrufeed and plunge cut operations offer many >chnical and economical advantages. bese FIN-TECH products are well suited and designed )r the grinding of: Struts Rods, Piston Pins Needles, Rollers Roll Grinding Razor Blades i hypodermic Needles hrufeed Grinding locrease of thrufeed speed in conjunction with maxi- mum ra*e of metal removal. Reduction of dressing time. Superior surface quality. Very fine surface finishes produced 2-4 micro inch Ra. Very consistant surface finishes from ,3-.6 micrometer Rz. Plunge Cut Grinding Excellent profile stability. Good cutting characteristics which increase productivity. FIN-TECH Availability Resin Bond Bond Designator: BFG Diameter: 5.9 - 43.3 in. 150 - 1100mm Thickness; .98 -11.8 m. 25 - 300mm Grit Sizes- 220 - 1200 Structure 7-18 Vitrified Bond Bond Designator VCF Max. 24 in. Max. 610mm Max. 4.7 in. Max. 120mm 220 - 600 7-12 MIL 000107 4-24 Basic Principles Of Centerless Grinding Type of Parts A. Parts that don't have centers, such as valve lifters, piston pins, bars, bearing rollers, bearing cups, sock ets, irregular shape parts, etc. Selection Of Wheels For Centerless Grinder Guidelines A. Things to consider: 1. Roughing or finishing 2. Thrufeed or infeed 3. Stock removal 4. Requirements of finished part Grading The Wheel A. For roughing, use coarse grain and medium grade. B. For finishing, use finer grain and harder grade. C. For thrufeed in general, use medium grades according to stock removal. D. For infeed, use finer grades and usually tighter structure. E. For heavy stock removal on soft parts, use coarse resin wheel or coarse medium grade vitrified wheel. F. For lighter stock removal of hard parts, use medium to fine grain and medium to hard wheel K-L, vitrified. G. For medium finish, use medium grit size and grade 60K. H. For high finish, use finer grit and medium to harder grade. Setting Up The Machine A. For roughing soft parts at fast rate, use 4-5 angle, 4050 RPM, center height -- variable. B. For finishing hard parts, use slower rate, 2-3 angle, 25 - 35 RPM, same center height. Trouble Shooting A. Parts Spinning -- usually losing regulating wheel con tact, regulating wheel too fine or too hard, usually hap pens with small hard part during a light cut using a coolant with a lot of lubricant. 8. Out of Roundness -- usually center height too low or chatter is being read as out of roundness. C. Chatter -- usually occurs when wheel is too hard, too high above center, lack of rigidity in setup. Theory And Principles Of Centerless Grinding The three elements of the centerless grinder are the grinding wheel, regulating wheel, and workrest (Sketch No. 1). The work lies between the two wheels: a grinding wheel of the correct size to fit the machine and of specifications appropriate to the material and nature of the work: and the regulating wheel. The regulating wheel serves as both a driving wheel and a brake, rotating the work at a con stant surface speed equal to that of the regulating wheel. This wheel is usually rubber bond, aluminum oxide grain, 80 grit, "R" grade. Harder grades and finer grain sizes are available for special application on very small diameter parts or for use with thin grinding wheels. A workrest blade supports the work between the two wheels. It is adjustable for height to raise or lower the center of the work in relation to the centerline of the grinding wheel and the regulating wheel. To grind the work cylindrically, the work blade height is usually adjust ed to raise the center of the work above the centerline of the wheels an amount equal to 'k the work diameter on small diameter parts, and to 'W maximum for work over 1" diameter. The distance between the grinding wheel and Effect of out of-round work on flat top blade, and with work on center the regulating wheel controls the diameter of the work; the height of the center of the work in relation to the cen terline of the wheels controls the roundness of the work. Sketch No. 2 further illustrates this phenomenon. This setup shows the center of the work in line with the center- 4-15 MIL 000108 line of the wheels and the flat top blade. The surface of the wheels contacting the work and the flat top blade form three sides of a square. As the work is rotated, any high spot coming in contact with the regulating wheel will push the work into the grinding wheel, causing a diametrically opposite low spot. With this setup, the work will not be ground round, although it will mic or gauge perfectly. This setup creates a shape like a rounded 120 triangle (note Sketch No. 3). To check for this out-of-round shape, the work must be put in a 120 "V" block and rotated with an indicator in contact with the work. When checked in a 90 "V" block, with micrometers or by snap gauges, this defect in geom etry will not be detected. Exaggerated shape generated by above setup When the center of the work is raised above the centerline of the wheels' raising the workrest blade, any high spot on the work coming in contact with the regulating wheel will push the work into the grinding wheel, creating a low spot, but not diametrically opposite. As the work is rotated, the high and low spots do not occur opposite each other as they do when the center of the work is on the centerline of the wheels and a gradual rounding up takes place. Maximum rounding action occurs when an angle top blade is used, as shown in Sketch No. 4. The higher the work is positioned above the centerline of the wheels, the quicker the rounding action. However, if the work is too high, chatter develops from the work being squeezed up from between the wheels or raised off the blade and dropped back on the blade rapidly, causing chatter. Since the height of the center of the work above the centerline of the wheels controls roundness, it may be necessary to set the blade extra high to grind a particular part within a specified tolerance. When this condition exists, an extra soft grade of wheel will help to prevent chatter that results when the work is too high above cen terline of wheels. The soft wheel reduces the contact pressure, which reduces the tendency to lift the work from the blade. When grinding long work such as steel bars, or tubing that is not straight, the workpiece will whip and chatter. Better results can be obtained by lowering the blade to position the center of the work below the centerline of the wheels for the first pass. Then raise the blade to put the center of work above the centerline of the wheels for additional passes to round up the work and grind to size. When grinding below the centerline of the wheels, the wheels hold the work down firmly against the blade, thus reducing the tendency of the bar to whip and chatter. If straight bars are required, they must be straightened before grinding since bent or crooked bars cannot be cor rected by the centerless grinder. There are three general methods of centerless grinding: thrufeed, infeed, and endfeed. Thrufeed is the method whereby work is passed between the grinding wheel and the regulating wheel, and grinding takes place as the work passes from one side of the wheels to the other. Since the work passes between the wheels from side to side, only straight cylindrical work, without shojlders, can be ground thrufeed (note Sketch No. 5). The lateral move ment of the work past the grinding wheel is a result of the angle of the regulating wheel (note Sketch No. 6). Thrufeed centerless grinding {top view) Sketch showing derivation of feed rate formula B Maximum corrective rounding action obtained with this basic setup WHEEL Sketch No 5 Sketch No. 6 MIL 000109 4-16 This angle can be varied from 2 below to approximately 8 above a line relative to the axis of the grinding wheel spindle. It is often necessary to pass work between the wheels more than once to remove the stock and set the straightness, roundness, and finish required. The thrufeed workrest (note Sketch No. 7) holds the work blade and has adjustable guides at both the front and rear of the wheels to direct the work in a straight line into and from the wheels. guioe ADJUSTING SCREW WORK BLADE WORK GUIOE EJECTOR LEVER ADJUSTING SCREW #A" LOCKNUT WORK BLADE WORK EJECTOR 6 The infeed method is used when the work has a shoulder or head, when more than one diameter is ground at the same time, or when some other irregular shape is being ground. The part length that can be ground by this method is limited by the width of the grinding wheel. The wheel is dressed to match the form of the part, either by using a cluster or single-point diamond and a cam in the profile dressing attachment, or a diamond impregnated roll, or the wheel is crush dressed to shape. As the work does not traverse across the wheel face, the regulating wheel is set with only a slight angle to keep the work against the end stop. The part is laid on the work blade and regulating wheel and against the end stop, either manually or mechanically, and advanced into the grinding wheel (note Sketch No. 8 and Sketch No. 9). Infeed centerless grinding (top view) When the work is ground to size, the regulating wheel is moved back away from the grinding wheel; either a manual or automatic ejector kicks the work out from between the wheel; and the operator places another piece in position. The endfeed method is used on taper work only. The grinding wheel, the regulating wheel, and the work blade are set in a fixed relation to each other and the work is fed in from the front to a fixed end-stop. The taper is dressed on either the grinding wheel, the regulating wheel, or both (note Sketch No. 10). . Endfeed centerless grinding (top view) GRINDING WHEEL WORK i END STOP REGULATING WHEEL 4-17 Sketch No. 8 Sketch No. 10 Work Blades Blade material is an important consideration in obtaining good blade life between regrinds and a satisfactory finish on the workpiece. The blade can be soft bronze, cast iron, or harder alloys like stellite or sintered carbide. In general.! it is advisable to start with the hardest material. Bronze, cast iron, and soft materials are used when blade pickup MIL 000110 occurs and cannot be controlled by other methods. Increasing the lubricity in the grinding fluid or changing to one with more lubricity reduces friction between the work and blade, and helps prevent blade pickup. Fluid applica tion is as important as type of fluid. The work can be flooded on top but may remain dry between the work and the blade. The position of the work relative to the centerline of the wheels is another factor that affects blade pick up. The closer the center of the work is to the centerline of the wheels, the lower the pressure between the work and the blade. The higher the center of the work in rela tion to the centerline of the wheels, the lower the pres sure between the work and the blade. A softer grade of grinding wheel will also reduce pressure on blade and help eliminate blade pickup and reduce blade wear. Blade Angle Most centerless grinding is done with an " angle top" blade. The angle of the blade should be varied to match the diameter of the work. The larger the work diameter or the longer the blade, the flatter the blade angle. The smaller diameter work requires a steeper angle. By using the steeper blade angle, more pressure is put on the reg ulating wheel, giving it more control of the rotating speed of the grinding wheel. However, this also increases the side pressure on the workrest blade and on narrow blades. Too steep an angle can cause the blade to deflect under the pressure, thus developing chatter. For work 'W diameter or larger, a blade angle of 20 to 30 is generally satisfactory. Centerless Grinding Corrective Adjustments Barrel-Shaped Parts, Thrufeed Grinding Taper on the ends of short work (barrel shape) or taper toward the center of short bars is usually caused by improper alignment of the work guides and blade, or the regulating wheel has not been trued correctly (note Sketch No. 11). Taper on the front end of the work as it leaves the machine is caused by deflection of the work guides on the entrance side towards the regulating wheel. Taper on the rear end of the work is generally caused by the guides on the exit side of the machine. Barrel shape is usually caused by deflection of the work guides, both front and rear, toward the regulating wheel. Work guides, when deflected towards the grinding wheel, on either or both sides, have a tendency to produce work with a hol low shape (note Sketch No. 12). Effect of deflecting guides towardgrinding wheel Sketch No. 12 Barrel-shaped and hollow parts can also be caused by an improperly trued regulating wheel. A concave face on the regulating wheel will produce work that is small in the center, and a convex face will produce barrel-shaped work (note Sketch No. 13). A warped blade will also pro duce barrel-shaped work. To produce work with a true cylindrical shape, the guides and blade must be properly aligned and wheels trued correctly. Effect of deflecting guides toward regulating wheel Effect of convex and concave , face regulating wheel GRINDING WHEEL C 3 WORK GUIDE Sketch No, 11 Sketch No. 13 MIL 000111 4-18 Work Guide Adjustments ForThrufeed Work For all thrufeed work, set the bearing surface of the workrest guides on the regulating wheel side parallel and in line with the face of the regulating wheel. To accurately set the regulating wheel guides (front and rear), use an aligning bar or other shaft that is straight within 0.0001", approximately of the same diameter as the workpiece, and as long as the width of the regulating wheel plus the length of the front and rear guides. Set up the machine to grind the workpiece. Set the blade for height above the centerline of the wheels, set the reg ulating wheel housing to feed angle to be used, and true the regulating wheel. Back off the regulating wheel guides and place the aligning bar on the blade, adjust the regu lating wheel to support the aligning bar, but do not allow the aligning bar to contact the grinding wheel. Place two small wooden wedges between the grinding wheel and the bar to hold the aligning bar against the face of the regulating wheel. Bring the regulating wheel guides forward until they lightly contact the aligning bar. Use a feeler gage to determine if a full line contact is obtained between the workrest guides and the alignment bar. The workrest guides on the grinding wheel side are adjusted to 1/64" to 1/32" clearance since the work does not contact these guides. Refer to Sketch No. 14. FRONT GRINOING REAR Sketch No. 14 Spiral Feed Lines On Work Spiral feed lines are usually caused by the trailing edge of the grinding wheel. To prevent these marks, dress a short taper on the back edge of the wheel so the part will quit grinding approximately 1/2" from the edge of the wheel. By using a crowned cam in the dressing attachment this can be done more uniformly, and each dress will repro duce the taper without special attention from the operator. Spiral feedlines can also be generated when the grinding wheel is dressed out of parallelism to the plane of feed. To correct, reset the taper control adjustment build into the machine. Tolerance Work is ground in regular production to a tolerance of +0.0002 on long bars and to a total tolerance of 0.0002 on short bars. However, under ideal conditions (machines and parts in air conditioned rooms, temperature controlled coolant, etc.), tolerances as small as 25 to 50 millionths of 4-19 an inch have been ground on the centerless grinder in regular production. When grinding to extremely close tolerances, on very fine finishes which require a light cut on the finish pass, the parts may stop rotating before they are out from between the wheels, and flat spots will be ground on the parts. This usually occurs when the cut runs out before the part is clear of the grinding wheel. To help correct this prob lem, adjust the stock removal per pass to leave more stock on the part for the finish pass. Also, a hold-down roller or some other device can be used to hold the part against the regulating wheel to keep it turning until it is clear of the grinding wheel. Grade of Grinding Wheel To select a grade of grinding wheel for an operation on a centerless grinder after it has been determined which of the three general classes of work the operation falls into (thrufeed, infeed or endfeed), the following variables must be considered: material (type and whether hardened or green grind), the diameter of the part, the length of the part (if infeed, the contour or form to hold), the size of the grinding wheel, both diameter and thickness, stock removal (per pass, if thrufeed), finish required, and pro duction per hours or parts per dress. With this information and a grinding wheel recommendation chart for center less grinders, a trial or starting grade can be selected to grind the part. There is no established method or rule whereby the optimum grade of wheel can be selected from a chart or a known set of circumstances, because there are many uncontrollable variables that affect grind ing. A grade must be tried and, from the results of the trial, the grade can be adjusted to improve the action of the grinding wheel until the desired production, finish, etc, are achieved. Truing The Grinding Wheel The grinding wheel may require truing for several rea sons: to correct wheel imbalance, to do rough grinding, to do finish grinding, for accuracy requirements, to restore the wheel to shape, to remove glaze and prevent chatter and burning of work, or to remove load from the wheel when grinding soft material (brass, aluminum, etc.). The rate of travel of the truing tool across the wheel face is governed by the type of tool and the finish required on the work. General recommendations for truing with a diamond are: rough grinding, 10" to 20" per minute; finish grinding, 4" to 7" per minute. The recommended rate of travel for truing with a metallic dresser is: rough grinding, 40" to 60" per minute: finish grinding 10" to 20" per minute. While truing with a diamond or metallic rotary dresser, a good volume of coolant should be flowing on the wheel to reduce heat and wash away the grit removed by the tru ing operation. The depth of cut should-not be more than 0.001 inch per pass across the face of the wheel. Regulating Wheel The general-purpose regulating wheels, 2A80-R-BR, have proved satisfactory for most work. There are harder grades and finer grain sizes available for special applica MIL 000112 tions when needed. The harder grades are used when the regulating wheels must be very thin and the general-pur pose grade deflects under the pressure of the grind. Harder grades also offer some advantage when work must be ground to very close tolerances, and when there is excessive regulating wheel wear due to the design of the work when grinding two or more diameters and one is much larger than the other. The difference in sfpm causes one of the diameters to slip or skid in contact with the wheel. The general-purpose grade gives a better drive or braking action and will resist spinning more than the finer, harder wheels on average work. The average starting speed of the regulating wheel is from 22 to 39 rpm, and for general work the angle of inclination of 3 is recom mended as a starting point. However, both the angle and wheel speed can be changed to suit specific conditions. The steeper the angle, the faster the traverse rate. The flatter the angle, the slower the traverse rate.The wheel speed also affects the traverse rate. The faster the wheel speed, the faster the traverse rate, and conversely, the slower the wheel speed, the slower the traverse rate. For work that is warped from hardening or machining, the best straightening effect can be obtained by using a high traverse rate or by increasing the angle of the regulating wheel. For work that is straight, but out-of-round, a faster rounding-up action can be obtained by using a higher reg ulating wheel speed and a flatter angle. This does not necessarily mean less production from the machine, because increasing the wheel rpm and reducing the angle of the regulating wheel could give approximately the same traverse rate. Truing The Regulating Wheel: Thrufeed Work The regulating wheel must be trued to a special shape so that the work, while passing between the wheels, makes a straight-line contact with the wheel face. Four factors must be considered to set the truing unit to form this shape: 1. Angle of inclination of the regulating wheel. 2. Location of the center of the work with respect to the centerline of the grinding and regulating wheels. 3. The angle to which the regulating wheel truing slide is swiveled. 4. The amount the diamond holder is set over. The first factor is fixed by the work. A general recommen dation for most thrufeed setups is a positive inclination of 3 as a starting point. The second factor is fixed by the diameter of the work. Generally, work is ground with its center above the cen terline of the grinding and regulating wheels. For small work up to 1" diameter, adjust the blade to position the work one half of its diameter above the centerline of the wheels. For larger work, the above center adjustment sel dom exceeds '/2 inch. The third and fourth factors are based on the ratio of the diameter of the regulating wheel and the diameter of the workpiece. Determine the ratio by dividing the diameter of the regulating wheel by the diameter of the workpiece. After establishing this ratio, refer to the following chart to determine the correct truing angle for the truing slide and the correct diamond holder setting for dressing the spe cial shape required on the regulating wheel. Table Of Truing Angles And Heights Above Center For Regulating Wheel Truing Truing Angle Setting WORK FEED ANGLE* 7 6 10' 6 10' 6 20* 6 25* 6"30' 6 *35` 6 45' 6 50' 6 55' 6 55 6" SMS' 5"l5* 5"2S* 5'30* 5-35' S'MO* S"45* 5'55' 5'SS' 5'55 5' 4'20' 4'25' 4 30' 4''35' 4-40' 4"40* 4 "50 4 55* S1' 5 4 3'30* 3 *30' 3 35' 3 '40* 345` TAS' 3*50* 3 55' 4 4 3 2 35' 2 40* 2*,40* 2` 45' 2'*50' 2*50' 2 55` 2 55* 3 3 2 1 45' 1*45* 1 '50* t 'SO' r5Q' 1 '55' 1-55' 2 2` 2 r 50* 50* 55* 55' 55* 55- 55* 1 1 1 0 RATIO - d WORK HEIGHT ABOVE CENTER! 1/8' 1/43/8` 1/2" 5/8" 3/4" 7/8" 1" 3 3.5 4 S 6 7 12 18 24 48 7/64 ' 7/64" 7/64" 7/64' 7/64" 1/8" 1/8 1/8' 1/8 1/8' 7/32" 7/32' 7/32" 15/64" IS/64" 15/64" 15/64 ' 1/4" 1/4" 1/421/64 21/64" 11/32" 11/32" 11/32" 23/64" 23/64" 23/64" 3/8" 3/8` 7/16' 7/16" 29/64- 29/64" 15/32** 15/32" 31/64" 31/64" 1/2" 1/235/64" 35/64" 9/16" 37/64" 37/64" 19/32** 19/32" 29/64" 5/8" 5/9 21/32 21/32" 43/64" 11/16" 45/64" 45/64" 23/32" 47/64" 47/64" 47/64 ' 3/4" 29/64'25/32" 51/64" 13/16" 55/64" 27/32'55/64' 55/64" 55/64 55/64" 7/8" 29/32 59/64" 15/16" l5/l6"6l/64"63/64" 63/64" 63/64* To use the chart, consider a setup with a 3 angle of incli nation, 2 work diameter, V2" height above center, 12" diameter regulating wheel. To determine the ratio, divide the diameter of regulating wheel by the diameter of the work (12 divided by 2 = 6 ratio). Note chart -- ratio 6 -- read up on the chart to the line extending from 3 -- note angle to swivel truing slide is 250'. To determine the diamond holder setting, read down on the chart from ratio 6 to the line extending from V2" work height above center; note diamond holder 15/32 above center. See Sketch No. 15. Sketch No 15 Truing The Regulating Wheek Infeed Work Angle of inclination: Since the work does not traverse between the wheels, there is very little angle required. An angle between 0 and 'A is recommended to hold the work against the end-stop during grinding. MIL 000113 d-oci The position of the center of the work in relation to the centerline of the wheels is the same for infeed as thrufeed. Raise the center of the work above the centerline of the wheel an amount equal to 'U the work diameter for work 1" diameter and smaller, to %" maximum for work larger than T'. The regulating wheel truing slide is swiveled the same amount as the angle of inclination except when truing a special shape form the profile truing cam. When truing from the cam, the slide should be set at zero. The diamond holder should be set over for infeed work the same as for thrufeed work; however, if dressing a spe cial shape from the profile cam, the diamond holder should be set at zero. The workpiece may be set at any height above center to obtain required roundness. With a small angle of inclina tion, the line of contact of the workpiece will be full at any height above center. However, if the angle of inclination is increased beyond 1/4, the full line of contact will not result and further corrections will have to be made to set full line contact between the regulating wheel and workpiece. HowTo Use "Top" Mark When Mounting CINCINNATI MILACRON Grinding Wheels On-Machine Mounting The TOP mark indicates the point of contact between wheel and spindle when the wheel's OD was trued at Cincinnati. Wheel user should mount wheel in the same way (i.e. align TOP with point of contact) to minimize OD runout and truing. Typical mountings are shown schemat ically below. Contact Point Off-Machine Mounting Of TWIN GRIP Wheels Set wheel on cradle with TOP at 12 o'clock position. Place a blotter on fixed flange and insert spindle into wheel bore. Place a blotter on loose flange and mate flange with spindle; secure it with one screw, finger tight. Lift spindle-wheel assembly off cradle as shown. Insert remaining flange screws and tighten them, in approved manner, while wheel is suspended as shown. See photo opposite page. Contact Point Mounting Wheels On TWIN GRIP Centerless Grinders The Operators Hand Book has a comprehensive section on proper wheel mounting methods. Here are a few tips to make the job easier. 1. With wheels resting in cradle, install rear blotter, insert the spindle cartridge. 2. Install front blotter, flange, and bolts and snug up finger tight. 4-21 3. Raise assembly from the cradle, and tighten bolts with a torque wrench. NOTE: Wheel should be mounted with top up. 4. For wide wheel twingrips"(18-20"), torque bolts to 45 foot pounds; for smaller twingrips (10-12") 35 foot pounds is sufficient. 5. Retorque the clamping flange bolts after the first 8 hours of operation. MIL 000114 Table of Thrufeed Work Traverse Rates Inches Per Minute The rate at which the work feeds past the grinding wheel on thrufeed jobs depends upon the diameter, speed of rotation, and angle of inclination of the regulating wheel, the following table gives the approximate theoretical work feed rates in inches per minute for all combinations of these three variables. Reg. Wheel Angle 1 2 3 Reg. Wheel Diam. 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 10 r.p.m. 4.4 4.7 4.9 5.2 5.5 5.8 6.0 6.3 6.6 6.9 7.1 7.4 7.6 8.8 9.3 9.9 10.4 11.0 11.5 12.1 12.6 13.2 13.7 14.3 14.8 15.4 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 15 r.p.m. 6.6 7.0 7.4 7.8 8.2 8.6 9.0 9.5 9.9 10.3 10.7 11.1 11.5 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 19.7 21.0 22.2 23.4 24.7 25.9 27.1 28.4 29.6 30.9 32.1 33.4 34.6 20 r.p.m. 8.8 9.3 9.9 10.4 11.0 11.5 12.1 12.6 13.2 13.7 14.3 14.8 15.4 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 26.3 28.0 29.6 31.2 32.9 34.5 36.2 37.8 39.5 41.1 42.8 44.4 46.1 25 r.p.m. 11.0 11.6 12.3 13.0 13.7 14.4 15.1 15.8 16.4 17.1 17.8 18.5 19.2 21.9 23.3 24.7 26.0 27.4 28.8 30.2 31.5 32.9 33.2 33.6 33.9 34.3 32.9 34.9 37.0 39.1 41.1 43.2 45.2 47.3 49.3 51.4 53.4 55.5 57.5 Regulating Wheel Speeds, R.P.M. 30 r.p.m. 13.2 14.0 14.8 15.6 16.4 17.3 18.1 18.9 19.7 20.5 21.3 22.1 22.9 26.3 28.0 29.6 31.2 32.9 34.5 36.2 37.8 39.5 41.1 42.8 44.4 46.1 39.5 41.9 44.4 46.9 49.3 51.8 54.3 56.7 59.2 61.6 64.1 66.5 69.0 40 r.p.m. 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 35.1 37.3 39.5 41.7 43.9 46.0 48.2 50.4 52.6 54.8 57.0 59.2 61.4 52.6 55.9 59.2 62.5 65.8 69.1 72.3 75.6 78.9 82.2 85.5 88.8 92.1 50 r.p.m. 21.9 23.3 24.7 26.0 27.4 28.8 30.2 31.5 32.9 34.2 35.6 36.9 38.3 43.9 46.6 49.3 52.1 54.8 57.6. 60.3 63.0 65.8 68.5 71 ;3 74.0 76.8 65.8 69.9 74.0 78.1 82.2 86.3 90.4 94.5 98.7 102.8 106.9 111.0 115.1 70 r.p.m. 30.7 32.6 34.5 36.5 38.4 40.3 42.2 44.1 46.0 47.9 49.8 51.7 53.6 61.4 65.2 69.1 72.9 76.7 80.6 84.4 88.3 92.1 96.0 99.8 103.7 107.5 92.1 97.8 103.6 109.3 115.1 120.9 126.6 132.4 138.1 143.9 149.6 155.4 161.1 90 r.p.m. 39.5 41.9 44.4 46.9 49.3 51.8 54.3 56.7 59.2 61.6 64.1 66.5 69.0 78.9 83.9 88.8 93.7 98.7 103.6 108.5 113.5 118.4 123.4 128.3 133.3 138.2 118.4 125.8 133.2 140.6 148.0 155.4 162.8 170.2 177.6 185.0 192.4 199.8 207.2 125 r.p.m. 54.8 58.2 61.7 65.1 68.5 72.0 75.4 78.8 82.2 85.6 89.0 92.4 95.8 109.6 116.5 123.3 130.2 137.1 143.9 150.8 157.6 164.5 171.3 174.2 177.0 183.9 164.4 174.7 185.0 195.3 205.5 215.8 226.1 236.4 246.6 256.9 267.2 277.5 287.8 150 r.p.m. 70.2 74.6 78.9 83.3 87.7 92.1 96.5 100.9 105.3 109.7 114.1 118.5 122.9 140.3 149.1 157.9 166.7 175.4 184.2 193.0 201.7 210.5 219.2 228.5 236.7 245.5 210.5 223.6 236.8 249.9 263.1 276.2 289.4 302.6 315.7 328.8 341.9 355.0 36.1 MIL 000115 4-22 Table of Thrufeed Work Traverse Rates (cont.) Reg. Wheel Angle 4 5 6' T Reg. Wheel Diam. 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 135 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 8.0" 8.5 9.0 9.5 10.0 10.5 11.0 11 5 .12.0 12.5 13.0 13.5 14.0 8 0" 85 90 9.5 10.0 10.5 11 0 11 5 120 12.5 130 10 r.p.m. 17.5 18.6 19.7 20.8 21.9 23.0 24.1 25.2 26.3 27.4 28.5 29.6 30.7 21.9 23.3 24.6 26.0 27.4 28.8 30.1 31.5 32.9 34.3 35.7 37.1 38.5 26.3 27.9 29.6 31.2 32.8 34.5 36.1 37.8 39.4 41.0 42.6 44.2 45.8 30 6 32,5 34.5 36,4 38.3 40.2 42.1 44.0 45 9 47 8 49.7 15 r.p.m. 26.3 27.9 29.6 31.2 32.9 34.5 36.2 37.8 39.4 41.0 42.5 44.2 45.8 32.9 34.9 37.0 39.0 41.1 43.1 45.2 47.2 49.3 51.3 53.4 55.4 57.5 39.4 41.9 44.3 46.8 49.3 51.7 54.2 56.6 59.1 61.6 64.1 66.6 69.1 45.9 48.8 51.7 54.6 57 4 60 3 63.2 66.0 68.9 71 8 74.7 Regulating Wheel Speeds, R.P.M. 20 r.p.m. 35.1 37.3 39.4 41.6 43.8 46.0 48.2 50.4 52.6 54.8 57.0 59.2 61.4 43.8 46.5 49.3 52.0 54.8 57.5 60.2 63.0 65.7 68.5 71.2 74.0 76.7 52.5 55.8 59.1 62.4 65.7 69.0 72.2 75.5 78.8 82.1 85.4 88.7 92.0 61 3 65.1 68 9 72.7 76.6 80.4 84.2 88.1 91 9 95.7 99.5 25 r.p.m. 43.8 46.6 49.3 52.1 54.8 57.5 60.3 63.0 67.7 68.5 71.3 74.1 76.9 54.8 58.2 61.6 65.0 68.5 71.9 75.3 78.7 82.1 85.5 88.9 92.3 95.7 65.7 69.8 73.9 78.0 82.1 86.2 90,3 94.4 98.5 102.6 106.7 110.8 114.9 76.6 81.4 86.1 90.9 95.7 100.5 105.3 110.1 114.9 119.7 124.5 30 r.p.m. 52.6 55.9 59.2 62.5 65.7 69.0 72.3 75.6 78.9 82.2 85.5 88.8 92.1 65.7 69.8 73.9 78.0 82.1 86.3 90.4 94.5 98.6 102.7 106.8 110.9 115.0 78.8 83.7 88.7 93.6 98.5 103.4 108.4 113.3 118.2 123.1 128.0 132.9 137.8 91.9 97.6 103.4 109.1 114.9 120.6 126,3 132.1 137 8 143.5 149.2 40 r.p.m. 50 r.p.m. 70.1 74.5 78.9 83.3 87.7 92.0 96.4 100.8 105.2 109.6 114.0 118.4 122.8 87.7 93.1 98.6 104.1 109.6 115.1 120.5 126.0 131.5 136.9 142.4 147.8 153.3 87.6 109.5 93.1 116.4 98.6 123.2 104.1 130.1 109.5 136.9 115.0 143.8 120.5 150.6 126.0 157.4 131.4' 164.3 136.9 171.2 142.4 178.1 147.9 184.0 153.4 191.9 105.1 111.7 118.2 124.8 131.4 137.9 144.5 151.1 157.6 164.3 170.9 177.5 184.1 131.4 139.6 147.8 156.0 164.2 172.4 180.6 188.8 197.0 205.2 213.4 221.6 229.8 122.5 130.2 137.8 145.5 153.1 160.8 168.5 176.1 183 8 191.5 199.2 153.1 162.7 172.3 181 9 191.4 201.0 210 6 220,1 229.7 239.3 248 9 70 r.p.m. 122.7 130.4 138.1 145.7 153.4 161.1 168.8 176.4 184.1 191.7 199.4 207.0 214.7 153.3 162.9 172.5 182.1 191.7 201.3 210.8 220.4 230.0 239.6 249.2 258.8 268.4 183.9 195.4 206.9 218.4 229.9 241.4 252.9 264.4 275.8 287.4 298.9 310.4 321.9 214.4 227.8 241.2 254.6 268.0 281.4 294.8 308.2 321.6 335.0 348.4 90 r.p.m. 157.8 167.7 177.5 187.4 197.2 207.1 217.0 226.8 236.7 246.5 256.4 266.2 276.1 197.2 209.5 221.8 234.1 246.4 258.8 271.1 283.4 295.7 308.0 320.3 332.6 344.9 236.4 251.2 266.0 280.8 295.6 310.3 325.1 339.9 354.7 369.5 384.3 399.1 413.9 275.7 292.9 310.1 327.4 344.6 361.8 379.0 396.3 413.5 430.7 447.9' 125 r.p.m. 219.2 232.9 246.6 260.3 273.9 287.6 301.3 315.0 328.7 342.4 356.1 369.8 383.5 273.8 290.9 308.0 325.2 342.3 359.4 376.5 393.6 410.7 427.8 444.9 462.0 471.9 328.4 348.9 369.4 390.0 410.5 431.0 451.5 472.1 492.6 513.1 533.6 554.1 574.6 382.9 406.8 430.7 454.7 478.6 502.5 526.4 550.4 574.3 598.2 622.1 150 r.p.m. 280.5 298.1 315.6 333.1 350.7 368.2 385.7 403.3 420.8 438.4 456.0 473.6 491.2 350.5 372.4 394.3 416.2 438.1 460.0 481.9 503.8 525.7 547.6 560.5 591.4 613.3 420.3 446.6 472.9 499.2 525.4 551.7 578.0 604.2 630.5 656.8 683.1 709.4 735.7 490.1 520.7 551.3 582.0 612.6 643.2 673.8 704.5 735.1 765.7 796.3 MIL 000116 4-23 if Typical Centerless Applications Selection of traverse rates for thrufeed work depends upon so many factors that it is not practical to compile exact tables for all the conditions which may be encoun tered. Perhaps the reason will be more apparent if we tabulate some of these factors: work material (including physical characteristics), stock removal, accuracy stan dards, blade material, type of grinding wheel, finish desired, diameter of part, weight of part, coolant avail able, and physical condition of machine. Practically every job must be considered on its own merits. A good prac- tice is to keep complete job records and use it as a guide in setting up duplicate or similar jobs. A few exam ples are given here to provide a starting point in select ing the correct traverse rate. All of them have been checked by time studies and represent actual job shop practice. Under high volume production conditions, the use of larger machines with higher horsepowers and wider wheels could be easily justified to reduce the num ber of operations. PISTON PIN Size -- 78" diameter x 37,6" long. Material -- Hardened steel. Stock Removal -- .015" in four roughing and two finishing cuts. Finish -- High grade commercial. Wheel -- 97A-601-J6-VRW. Traverse Rate -- 12 feet per minute per cut. Machine -- 220-8 Centerless. CHAIN ROLLER PIN Size -- S/K" diameter x Vie" long. Material -- Hardened steel. Stock Removal -- .005" to .008", one cut. Finish -- High grade commercial. Wheel -- 97A-601-M4-VRW. Traverse Rate -- 7 feet per minute per cut. Machine -- 220-8 Centerless. STEEL ROD Size -- 78" diameter x 12" long. Material -- Soft steel. Stock Removal -- .010" to .015", three cuts. Finish -- Commercial. Wheel -- 97A-601-J6-VRW. Traverse Rate -- 7 feet per minute per cut. Machine -- 220-8 Centerless. PISTON Size -- 37,6" diameter x 4" long. Material -- Cast iron. Stock Removal -- .005" three cuts. Finish -- Good commercial. Wheel -- 6C-46-K6-VSC. Traverse Rate -- 5 feet per minute per cut. Machine -- 325-12 Centerless. Add "E" to bond symbol of wheel speed is greater than 6500 SFPM vitrified and 9500 resin. FIN-TECH Finishing Technologies This fine grit product is available in grit sizes ranging from 220-1200. These wheels will produce finishes in the 2 - 4 micro inch Ra range. FIN-TECH Grinding Wheels for cylindrical and centerless grinding in thrufeed and plunge cut operations offer many technical and economical advantages. These FIN-TECH products are well suited and designed for the grindinq of: Struts Rods, Piston Pins Needles, Rollers Roll Grinding Razor Blades Hypodermic Needles Thrufeed Grinding Increase of thrufeed speed in conjunction with maxi mum rate of metal removal. Reduction of dressing time. Superior surface quality. Very fine surface finishes produced 2-4 micro inch Ra. Very consistant surface finishes from .3-.6 micrometer Rz. Plunge Cut Grinding Excellent profile stability. Good cutting characteristics which increase productivity. FIN-TECH Availability Resin Bond Bond Designator: BFG Diameter: 5.9 - 43 3 in. 150 - 1100mm Thickness: .98 - 11.8 in. 25 - 300mm Grit Sizes: 220- 1200 Structure' 7 - 18 Vitrified Bond Bond Designator: VGF Max. 24 in. Max. 610mm Max. 4.7 in. Max. 120mm 220 - 600 7-12 MIL 000117 4-24 fi'l MIL 000118 4-25 Trouble Shooting A. Burn Marks On Workpiece 1. Insufficient coolant 2. Dull or flat diamond 3. Wheel too hard 4. Cutting on trailing edge of the wheel 5. Grinding wheel dressed with diamond traverse too slow. 6. Too heavy stock removal B. Chatter 1. Work too high above center 2. Wheel out of balance 3. Blade angle too steep (30 standard) 4. Blade too thin or warped 5. Machine leveling screws not adjusted for even torque when machine is finally leveled 6. Glazed wheel caused by dull diamond, wheel too hard, grit size too fine or dressing rate too slow 7. Outside "Floor Harmonics" 8. Motors out of balance 9. Grinding wheel mount fits loosely on spindle 10. Stock removal too heavy 11. Blade not properly clamped 12. Blade being used too long for width of wheel C. Dull Diamond -- Grinding Wheel Truing Attachment 1. Diamond nib not turned periodically 2. Excessive infeed of diamond (should not take more than 0.001" depth of cut under normal conditions) D. Erratic Sizing 1. Gibs not properly adjusted on upper and lower slides 2. Wear in infeed screw and nut 3. Infeed lever not held tight (for thrufeed work) 4. Soft wheel 5. Insufficient lubrication on lower slides causing slides to hang or jump (infeed) 6. Improper tension on backlash spring 7. Loose work support blade 8. Parts overheating during cut, due to improper wheel or insufficient coolant 9. Regulating wheel camming 10. Work improperly rough ground E. Feed Lines 1. Grinding wheel not relieved on exit side 2. Work guides not properly set 3. On long bar fixtures -- excessive pressure on workpiece by roller hold-down F. Finish 1. Improper wheel grade 2. Dirty or insufficient coolant 3. Setup not correct 4. Diamond dressing traverse rate too fast 5. Erratic movement of truing attachments 6. Pick-up on blade 7. Blade not tight in work rest 8. Blade angle too steep 9. Unbalanced wheel 10. Loose, cracked or dull diamond 11. Oil on face of wheel 12. Regulating wheel not tight on its mount 13. Work too high above center 14. Regulating wheel SFM excessive G. Fish Tails (Scratches) 1. Dirty coolant 2. Loose grit in wheel H. Grinding Wheel 1. Too hard a. May cause burn marks b. Can cause squeal because it is not free cutting c. Glazing may occur on wheel face d. Soft materials may "load" wheel e. Often produce chatter on workpiece f. Sizing trouble, due to no spark out g. May cause heat checks or cracks 2. Too soft a. Sizing trouble, because wheel breaks down rapidly. b. Chatter may develop c. Rough finish I. Height Above Center of Workpiece 1. If too high, chatter can develop 2. Optimum rounding action will not occur if center height is too low 3. Three-point out-of-roundness is a good sign of low center J. Intermittent Cut 1. Grinding wheel not correctly trued 2. Regulating wheel "camming" 3. Warped workpiece K. Jumpy Truing Device 1. Air in hydraulic lines 2. Slides not lubricated properly 3. Gib adjusted improperly ' MIL 000119 4-26 L. Loading Of Wheels 1. See grinding wheels (H.) 2. Wheel too fine. Larger grain size allows more chip clearance. 3. Ineffective grinding fluid -- due to the lack of lubricity of grinding fluid, chips adhere to grit of wheel. Change to coolant with greater lubricity or increase amount of concentration in mix. M. Low Ends On Work -- Chamfered 1. Work guides deflected toward regulating wheel 2. Face of regulating wheel not straight at work con tact point (truing device worn or not on correct angle) N. Low Center -- High Ends 1. Work guides deflected toward grinding wheel 2. Face of regulating wheel not straight at work con tact point (truing device work or not on correct angle) O. Nicks In Workpiece I. Do not drop parts into tote pans. Provide bumpers to cushion workpiece. P. Out Of Round Work 1. Out of balance workpiece 2. Work not high enough above center 3. Workpiece bowed 4. Regulating wheel not dressed round 5. Regulating wheel loose on mount 6. Blade angle not steep enough 7. Not enough stock to round up 8. Regulating wheel speed too slow 9. Interrupted cut due to keyways, holes, flats, etc. 10. On infeed only end stop or ejector may be worn on locating surface II. Grinding wheel not properly graded for job 12. Flat diamond Q. Pick-Up On Blade 1. Grinding fluid not lubricating work-to-blade contact point. Use grinding fluid with greater lubricity or increase concentration. 2. Blade too hard for material being ground (use cast iron or bronze blade) R. Regulating Wheel "Camming" 1. Collet screws loose 2. Bearings worn 3. Regulating wheel spindle eccentric or out of round S. "Spiral Chatter" 1. Improper wheel grade 2. Chipped edge of wheel 3. Loose machine elements 4-27 T. Straightness 1. Work not straightened sufficiently before grinding 2. Insufficient grinding stock left on workpiece 3. Too much stock removal on first pass 4. Wheel not cutting freely (part heats up, relieving internal stresses to cause part to bow) 5. Insufficient coolant (same thing happens) U. Taper 1. Work guides not set properly 2. Dirt under workrest or blade 3. Loose gibs 4. Failure to keep parts butted end to end on thrufeed 5. Too much feeding pressure (race grinding fixture) 6. Non-uniform spark out time from one piece to the next (infeed setup) 7. Wheel not cutting freely (part expands due to sur face temperature immediately behind leading end. This results in tapered part with leading end high.) V. Vibration 1. Check outside sources 2. Leveling screws not snug against floor 3. Motors not balanced or drive belts too loose 4. Faulty hydraulic pump causing erratic pressure vibrations to be transmitted to machine W. Warped Work (Usually Long Bar Or Tubing) 1. Insufficient flow of coolant 2. Wheel not cutting efficiently. Either dressed too fine or too small grit size. 3. Workpiece not straightened before grinding X. See Back Cover For Helpful Hints to Problem Solving MIL 000120 5 Centertype Grinding Wheels Step up your production rates with our 480 Series Step Grinder, a complete CNC centertype grinding package, especially designed to provide maximum performance with flexibility for the precision grinding of your multi diameter, cylindrical parts. Automatically grind multiple OD's, shoulders, tapers and radii all in one continuous operation. Our ACRAMATIC 760G Grinding Control makes it easy. Choose either the 0 degree "straight" or the 30 degree "angular" wheelhead version to suit your part mix. A vari ety of machine configurations offers a range of capaci ties with 14 or 24" (355 or 610 mm) of swing, up to 12" (305 mm) of wheel width, and 20, 40, 60, 80 or 100" (510, 1015, 1525, 2030 or 2540 mm) between centers. Speed Programming and Setup Times, Spend More Time Grinding The ACRAMATIC 760G CNC gets you into production fast. Programs are entered through a single page dis play. Color touch screen, pop-up windows, and the use of normal grinding terminology speed entry. Simple parts can be ground manually with an electronic handwheel, giving you the precision of servo-controlled digital feed and the benefit of automatic dressing without program ming. Setup and alignment data can be re-used from job to job. Advanced CNC technology plus these innovative, stan dard features make setups fast and simple. Dead Spindle Headstock -- This variable speed unit has a broad range of part rotational speeds, program mable in rpm, surface speed or constant surface speed. A. live spindle option allows work to be mounted in chucks, or ground between centers. Eccentric Quill Footstock -- Fast, fingertip taper cor rections are possible -- without swiveling the table -- by using the eccentric quill adjustment knob located on the top of the footstock. Automatic Flagging -- This programmable, automatic flagging gage provides accurate closed-loop lateral (Zaxis) positioning. It allows for flip over, groove or man drel-mounted part flagging, and is bi-directional with setup change. CNC Table-Type Dresser -- This unit, which can be mounted on either the headstock or footstock, is used in combination with the ACRAMATIC 760G CNC's table dressing software. True CNC flexibility to dress both basic and complex wheel forms is possible, a necessity in multiple contour OD grinding. In-Process Gaging Alternatives -- Several electronic gaging options are available for grinding continuous as well as interrupted surfaces to extremely close tolerances. MIL 000121 5-1 Cimform Grinding Wheels Cylindrical Grinding Material ALNICO ALUMINUM ARMATURES, Laminated AXLES Automobile Railway BOLTS, Case-Hardened Steel BRONZE, Hard CAM SHAFT BEARINGS CAR WHEELS, Regrinding Chilled Iron High Speed Low Speed Steel High Speed Low Speed CAST IRON CEMENTED CARBIDE Roughing Finishing CHROMIUM PLATING Commercial Finish COPPER CRANKSHAFTS Roughing Finishing Rough and Finish Regrinding GAGES, Plug GLASS TUBING MEEHANITE MONEL METAL NITRALLOY Before Nitriding After Nitriding PISTONS Aluminum Alloy Cast Iron PISTON RODS, Locomotive PORCELAIN RIFLE BARRELS Specification 29A601-K6-VFM C54-K5-V8 6C60-K6-VSC 97A601-J4-VFM 97A541-K6-VFM 97A601-K6-VFM C54-K5-V8 29A701-J6-VFM 97A541-L4-VFM 6C60-J6-VSC 6C46-L6-VSC 29A601-J6-VFM 97A461-L6-VFM 6C46-K6-VSC CMD220-N100-B CMD220-P100-B 12A60-K6-VFM 7C801-K6-VSC 97A541-N4-VFM 29A701-L4-VFM 97A701-M4-VFM 29A801-K6-VFM 9A80-J6-VFM 5C100-J6-VSC 7C461-L6-VSC 7C601-J6-VSC FA46-H5-V9 29A601-J6-VFM 7C461-K6-VSC 7C461-L6-VSC 29A461-N4-VFM 7C461-K6-VSC 97A601-K4-VFM Material ROLLS Brass and Copper Roughing Finishing Cast Iron Roughing Finishing Granite Roughing Finishing PAPER MILL ROLLS** CAST IRON RUBBER Soft Hard STEEL MILL ROLLS** Large Diameter 30" through 36" HOT MILL ROLLS Chilled Iron Roughing Finishing COLD MILL ROLLS Steel and Chilled Iron Finishing Hardened Steel Roughfng Finishing SPLINE SHAFTS STEEL Hardened High Speed Soft Stainless Heat Treated (400 Series) Free Machining (300 Series) STELLITE VALVE STEMS, Automotive VALVE TAPPETS GENERAL PURPOSE UP TO 12" OVER 12" Specification 97A461-N9-B90 29A1001-J6-B90 6C36-J6-VFM 7C801-I6-VFM 6C36-M6-VSC 7C541-K4-VSC 7C461-M9-B90 5C36-J10- VSC 7C541-J6-VSC 6C36-N6-B90 7C541-M9-B90 97A801-L6-B90 97A361-N9-B90 29A801-K7-B90 97A601-N4-VFM 29A801-K4-VFM 29A801-K4-VFM 97A601-M4-VFM 7C601-K4-VSC 29A541-L6-VFM 7C601-N4-VSC 97A1001-N4-VFME 97A1001-N4-VFME 29A601-L4-VFM 29A541-J6-VFM "SEE PRECISION RESINOID RECOMMENDATIONS. For large diameter, thin wall, or burn sensitive parts, use VA bond. For High Precision and Form Grinding, use VRW bond. Always establish the operating RPM before ordering. MIL 000123 Starting Grade Recommendations For Hi Production With Optimum Setup Use VRW 1 Grade Softer. For Improved Part Quality With Normal Production And Setup Use VQC 1 Grade Softer. MATERIAL--OPERATION Alnico - Cylindrical Aluminum - (Hard) Aluminum - (Soft) Armature Axles (Auto) Axles (Railway) Brass & Bronze (Soft) Brass & Bronze (Hard) Bushings (Hardened Steel) Bushings (Cast Iron) Camshaft (Bearings) (Steel Forging) (Cast Iron) Camshaft (Lobes) Steel Forging Rough Steel Forging Finish Cast Iron Rough Cast Iron Finish Cast Iron - General Purpose Chromium Plating Colmonoy Commutators (Copper) Copper Crankshaft (Auto) Pin Bearings (Steel Forging) (Nodular Iron) Regrind (Forged Steel) Regrind (Nodular Iron) Crankshaft (Regrind) Sprayed Metal Drills Forgings (Steel) Gages (Plug) Glass (Rough) (Finish) General Purpose Monel Metal Nitralloy - Before Nitriding After Nitriding Pistons (Aluminum) (Cast Iron) Proferall (Iron Alloy) Rough Finish Rubber Rolls (Soft) (Hard) Steel General Purpose Soft General Purpose Hardened Stainless Steel 300 Series 400 Series LESS THAN 1" DIAMETER 97A601-K4-VFM 97A601-J6-VFM 6C46-K6-VSC 97A601-L4-VFM -- -- 6C60-L6-VSC 97A601-J6-VFM 12A80-K4-VFM 97A601-K4-VFM 97A701-L4-VFM 97A541-M4-VFM 97A701-S7-B90 97A701-M4-VFM 97A701-S7-B90 6C70-L6-VSC 12A801-K4-VFM 6C60-L6-VSC 6C60-L6-VSC 6C46-L6-VSC 97A541-N4-VFM 97A701-M4-VFM -- -- 6C60-L6-VSC 97A601-L4-VFM 97A461-L6-VFM 97A601-J4-VFM 5C80-I6-VSC 97A1801-M4-VFM 12A60-K4-VFM 97A601-J6-VFM 6C46-J6-VSC 97A601-J4-VFM 971801-J4-VFM 6C46-K6-VSC 97A461-J6-VFM 97A541-M4-VFM 97A801-R9-B90 6C361-K10-VSC 6C301-J9-B90 97A601-L4-VFM 12A80-K4-VFM 6C60-K6-VSC 97A601-J6-VFM 1" TO 2" 0IAMETER 97A601-J4-VFM 97A601-I6-VFM 6C46-J6-VSC 97A601-K4-VFM 97A601-J4-VFM -- 6C46-K6-VSC 97A601-I6-VFM 12A80-J4-VFM 97A701-J4-VFM 97A601-K4-VFM 97A701-K4-VFM 97A541-M4-VFM 97A701-R9-B90 97A701-M4-VFM 97A701-R9-B90 6C70-K6-VSC 12A801-J4-VFM 6C60-K6-VSC 6C60-K6-VSC 6C46-K6-VSC 97A541-M4-VFM 97A701-L4-VFM 97A601-L4-VFM 97A601-K4-VFM 6C60-L6-VSC 97A601-K4-VFM 97A461-K6-VFM 97A801-I4-VFM 5C80-H6-VSC 97A1801-L4-VFM 12A60-J4-VFM 97A6Q1-I6-VFM ' 6C36-I6-VSC 97A601-I6-VFM 97A801-I6-VFM 6C46-J6-VSC 97A461-I6-VFM 97A601-M4-VFM 97A801-Q9-890 6C361-J10-VSC 6C301-J9-B90 97A601-K4-VFM 12A80-J4-VFM 6C60-J6-VSC 97A601-I6-VFM 2" TO 4" DIAMETER 97A601-14-VFM 12A60-H6-VFM 6C46-I6-VSC 97A601-J4-VFM 97A601-I4-VFM 97A601-I4-VFM 6C46-K6-VSC 97A601-H6-VFM 12A80-14-VFM 97A701-I4-VFM 29A601-J4-VFM 97A701-J4-VFM 97A541-L4-VFM 97A701-Q9-B90 97A701-L4-VFM 97A701-Q9-B90 6C70-J6-VSC 12A801-I6-VFM 6C60-J6-VSC 6C60-J6-VSC 6C46-J6-VSC 97A541-M4-VFM 97A701-L4-VFM 97A601-K4-VFM 97A601-K4-VFM 6C60-K6-VSC 97A601-J4-VFM 97A461-J6-VFM 29A801-G6-VFM 5C80-G6-VSC 97A1801-K4-VFM 12A60-I4-VFM 97A601-H6-VFM 6C36-H6-VSC 97A601-H6-VFM 97A801-H6-VFM 6C36-J6-VSC 12A36-16-VFM 97A601-L4-VFM 97A801-P9-B90 6C361-H10-VSC 6C301-J9-B90 97A601-J6-VFM 12A80-I4-VFM 6C60-I6-VSC 97A601-H6-VFM 4" TO 6" DIAMETER 97A601-G6-VFM 12A60-G6-VFM 6C46-H6-VSC 97A601-I4-VFM -- 97A6011-H4-VFM 6C46-J6-VSC 97A601-G6-VFM 12A80-H4-VFM 97A701-H4-VFM ___ -- _ -- -- -- 6C60-H6-VSC 12A801-H6-VFM 6C60-I6-VSC 6C60-I6-VSC 6C60-16-VSC ____ -- -- -- 6C60-J6-VSC -- -- -- _ -- 12A60-H4-VFM 97A601-H6-VFM -- -- -- 6C36-I6-VSC 12A36-H6-VFM _ -- -- 6C301-J9-B90 97A601-I6-VFM 12A80-H4-VFM ____ -- "For large diameter parts, consider 29A-VA. MIL 000124 5-4 Starting Grade Recommendations (cont.) Diameter Of Work Piece USE CLASSIFICATION Alloy Steel (hard) Alloy Steel (free machining) Carbon Steel (plain) Carbon Steel (free machining) Cast Iron Cast Steel Copper Alloys High Temperature Alloys Stainless Steel (400 Series) (300 Series) Steel (high strength) Tool Steel LESS THAN 1" 97A801-K6-VRW 97A801-L6-VFM 97A461-K6-VRW 97A461-L6-VFM 12A80-M4-VRW 12A80-N4-VFM 2A60-L4-VRW 2A60-M4-VFM 97A601-K4-VRW 97A601-L4-VFM 2A46-M6-VRW 2A46-N6-VFM 6C46-N6-VSC 97A601-K6-VRW 97A601-L6-VFM 97A601-L6-VRW 97A601-M6-VFM 6C60-M6-VSC 97A801-K6-VRW 97A801-L6-VFM 9A8Q-K6-VRW 9A80-L6-VFM 1" TO 2" 97A801-J6-VRW 97A801-K6-VFM 971461-J6-VRW 97A461-K6-VFM 12A80-L4-VRW 12A80-M4-VFM 2A60-K4-VRW 2A60-L4-VFM 97A601-J4-VRW 971601-K4-VFM 2A46-L6-VRW 2A46-M6-VFM 6C46-M6-VSC 97A601-J6-VRW 97A601-K6-VFM 97A601-K6-VRW 97A601-L6-VFM 6C60-L6-VSC 97A801-J6-VRW 97A801-K6-VFM 9A80-J6-VRW 9A80-K6-VFM 2" TO 4" 29A801-I6-VRW 97A801-J6-VFM 97A461-I6-VRW 97A461-J6-VFM 12A80-K4-VRW 12A80-L4-VFM 2A60-J4-VRW 2A60-K4-VFM 29A601-I4-VRW 97A601-J4-VFM 2A46-K6-VRW 2A46-L6-VFM 6C46-L6-VSC 97A601-I6-VRW 97A601-J6-VFM 29A601-J6-VRW 97A601-K6-VFM 6C60-K6-VSC 97A801-I6-VRW 97A801-J6-VFM 9A80-I6-VRW 9A80-J6-VFM "VQC will apply to most jobs where VRW is recommended. "For large diameter parts, consider 29A-VA. 4" TO 6" 29A801-H6-VRW 97A801-I6-VFM 97A461-H6-VRW 971461-16-VFM 12A80-J4-VRW 12A80-K4-VFM 2A60-I4-VRW 2A60-J4-VFM 29A601-H4-VRW 97A601-I4-VFM 2A46-J6-VRW 2A46-K6-VFM 6C46-K6-VSC 97A601-H6-VRW 97A601-I6-VFM 29A601-I6-VRW 97A601-J6-VFM 6C60-J6-VSC 97A801-H6-VRW 97A801-I6-VFM 9A80-H6-VRW 9A80-I6-VFM Centertype Wheels Commonly In Stock In Various Grades OD xTHK x ID GRADE 30 X 2 X 12 97A601-J-VQC 30 X 2 X 12 97A601-K-VQC 30X2X 12 W5A14-Q4-BF-4 Reinforced Snagging 30 x 2 x 12 W514-R4-R4-B254-4 Reinforced Snagging 30 x 27* x 12 W5A14-P4-BF-8 Standard Centertype Wheels 30 x 3 x 12 97A601-I-VQC 30 X3X 12 97A601-J-VQC 30 X3X 12 97A801-J-VQC 30 X 3 X 20 97A601-J-VQC 30 X4 X 12 97A601-I-VQC 30 X4X 12 97A601-J-VQC 36 X3 X 12 97A601-K-VQC Okamoto OGM Series Cylindrical Grinders Typical Wheel Grade: 29A601-J6-VFME or 3MSB601-I6-VSAE OGM-8*10U & 8*20U Models (diameter x width x bore) 12" x (1" ~ 1-1/2") x 5" OGM-8*10P & 8*20P Models (diameter x width x bore 14" x (1" ~ 1-1/2") x 5" OGM-12*24U, 12*401) & 12*601) Models (diameter x width x bore) 14" x (1" -- 1-1/2") x 5" OGM-12*24P, 12*40P & 12*60P Models (diameter x width x bore) 16" x (1-1/2" ~ 2") x 5" U denotes Universal P denotes Plain MIL 000125 5-5 Specification Selection Guide Machine And Wheel Size Application Pistons aluminum cast iron Piston Rods (locomotive) Plastics Thermoplastics wet dry Thermosetting Porcelain Pulley (cast iron) Reamers Rubber soft hard Silver Spline Shafts Sprayed Metal Stainless Steel 300 Series 400 Series Steel (high speed) 14" and less 16" and larger Steel (soft) less than 1" diameter over 1" diameter Steel (hardened) less than 1" diameter over 1" diameter Stellite Tantalum Tap Shanks Titanium Tool Steels Tungsten Valve Stems (automotive) Valve Tappets Vitallium Wheel Specifications 6C46-I6-VSC 6C60-J6-VSC 97A461-L4-VFM 6C46-J6-VSC 2A46-J10-VL 6C36-J9-B90 6C36-J9-B90 6C60-J6-VSC 6C54-J6-VSC 97A601-K6-VFM 6C36-I10-VSC 6C36-J10-VSC 9A100-J6-VFM 97A601-K4-VFM 7C601-K6-VSC 6C60-I6-VSC 97A601-J6-VFM 9A80-I6-VFM 9A80-H6-VFM 97A601-M4-VFM 97A601-K4-VFM 29A601-J4-VFM 29A601-I4-VFM 6C54-L6-VSC 97A601-J6-VFM 97A701-J6-VFM 7C601-J6-VSC See Tool Room Section 5C60-I6-VSC 2A60-M4-VFM 97A601-L4-VFM 9A60-I6-VFM To substitute VQC or VRW for VFM go 1 grade softer. Cylindrical grinding may be considered to include all out side grinding of round work even though the finished product is not always a true cylinder. The work may be, for instance, conical in shape or it may consist of special form grinding with the face of the wheel dressed to an irregular shape. Wheels in this class include those for grinding work held between centers and in chucks. Requirements in cylindrical grinding vary from fast stock removal (with rough finishes permissible) to ultra smooth finishes (called "mirror finishes"). In general, finishes required on the final product range from 1 RMS to 100 RMS. The average "commercial finish" will run between 16 RMS and 32 RMS. It is necessary to use coarse grit wheels with rough dressing for rapid stock removal, and fine grit wheels with fine dressing for fine finishes. Hard materials require softer grade wheels than soft work in the same diameters. Small work diameters require finer and harder wheels than large diameters. Sharp corners require finer and harder wheels with emphasis on finer grits rather than harder grades, but wide shoulders call for softer and coarser wheels, particularly if the stock is hardened. Most wheels are Type 1, 5, or 7 and in addition may be relieved on one or both sides conforming to Types 20 to 26 inclusive. Wheels range from 10 to 42 inches in diam eter and 3/4 to 6 inches thick. The larger and thicker wheel's are usually recessed. They are predominantly vit rified bonded in aluminum oxide (2A-9A-97A-29A-4A-12A and silicon carbide 5C-6C and 7C). Cylindrical wheels are used extensively throughout the automotive, aircraft, shipbuilding, engine, turbine, bear ing, and metalworking machine industries as well as in general shops and toolrooms. General maximum operat ing speed is 6500 SFPM, although 8500 SFPM and high er speeds are used in some applications. For all speeds above 6500 SFPM for Vitrified bonds and above 9500 SFPM for Organic bonds, verify the specification recom mendations with a Cincinnati Milacron Marketing Company Sales Representative. (Refer to Safety Section.) MIL 000126 5-6 Machine And Wheel Size (cont.) Brown & Sharpe Manufacturing Company, Providence, Rl Machine/Model No. 1 Universal (10 x 20) No. 2 Universal (14x30) No. 3 Universal (14x40) No. 4 Universal (14x60) No. 5 Plain (3x12.3x18) No. 10 Plain (6x18,6x30) No. 10 Plain (old style) No. 11 Plain (old style) No. 14-J (old style) No. 20(10x18) No. 22 (10 x 36) No. 23 (10 x 48) Wheel Size 6 x /, x 2 10 x 7? x 3 14 x 'A x 5 14 x IV* x 5 14x1x5 14 x 17? x 5 14 x (V,.7. 1.17? x 2) x 5 24 x (1 `A, 2 3.4) x 12 12 X (1.1 Vi. 2) x5 14 x (1,2.3) x 5 20 x 2 x 5 20 x 3 x 5 20 x 4 x 5 30 x 2 x 12 30 x (3,4) x 12 24 x (4,5,6,7) x 12 Type 1 1 1 recess diameter should be 7`A" recess diameter should be 1477 1 1 1 1 Rec. 1/S8 x 1" 1 1 (if necessary to recess, the recess diameter should be 1477) Cincinnati Milacron, Cincinnati, OH Machine/Model 12". 14", 16", 18" Universal Model ER 12", 14" 16"and 18" Universal Model ER 4" Plain Model OH 6" Plain Model EA and ER 10" Umv OL 10" Light Type Model OE Wheel Size 14x1x5 14 X 17; X 5 14x2x5 14 x 27? x 5 14x3x5 14 x 4 x 5 16x1x8 16x2x8 16x2x8 20 x (1.2,3,4) x 12 24 x (1.2.3.4) x 12 12x1x5 20 x (1,2.3,4) x 12 10" Plain Model EA 10" Plain Model ER 14" Light Type Model OE 14"and 16" 440 Plunge STEPTRONIC 24 x (2.3,4, 5.6) x 12 24 x (2,3,4, 5.6) x 12 30x(17?.2.3. 4,5,6) x 12 30 x (17.2.3,4, (5,6,7) x 20 30x6x12 36x6x12 Type 1 Rec. 1/S8 x 7? 1 Rec. 1/S8 x 7? Rec. 1/S8 x 1 Rec. 1/S8 x 2 1 Rec. 1/S 107? x 7? Rec. 2/S 107? x 7? 1 (if necessary to recess, except lor the 12 x 1 x 5", the recess diameter should be 147?") Recess diameter should be 1477) (if necessary to recess, the recess diameter should be 1477) 1 Landis Tool Company, Waynesboro, PA Machine/Model Old Style Universal No. 1 & No. 11/2 Old Style Universal No. 2. No. 3 & No. 4 10 x 20 Type H Universal 10 x 24 Type C & CH 12" Type LC & LCH Hydraulic Universal 12", 14", 16" & 18" Type C 4" Type H Plain Hydraulic 6" Type CH Plain Hydraulic 10". 14", 16" Type BD, C, CH,D & DC Plain Hydraulic Old Style 10" and 20" Plain Old Style 12" Plain Wheel Size 10 x 7? x 5 12x1x5 14x1x5 10 x 7? x 3 12x1 x 5 14 x (1, 17? 17?) x 5 14 x 17? x 5 16 x (1,17?,2 3) x 8 20x (1,17?, 2) 3) x 8 24 x (2,27?, 3,4) x 8 30 x (2,27?, 3.4) x 12 12x1x5 14x1 x 5 14 x 17?,2) x 5 10x2x8 18 27? x 8 16", 20", 24" & 28" Type B Plain Hydraulic 2R Plunge Grinder 4R Angle Side Plunge Grinder 18x3x8 30x3 x 12 30 x (1,2,3) x 12 36 x (1.2.3,4) x 12 Van Norman Machine Co., Springfield, MA (Including Fitchburg Grinding Mach. Corp.) Machine/Model "Bowgage Head" (mounted on various bases or other makes of grinding machines) 6x32" Adjustable Head Types B and C 6" Plain Type B and C 10" Plain Model A 6" Old Style 8" 12" Model 418 Plain Wheel Size 24x2x12 24x3x12 20x4x12 (Also found with 5, 8 or 16" hole) 20x2x12 20x7., 1,17?, 2,3) x 12 24 x (Y.,1,17?, 2.3) x 12 18x2x5 18x3x5 18x3x5 14x2x5 - Type 1 1 1 1 1 1 (if necessary to recess, the recess diameter should be 11") 1 (if necessary to recess, the recess diameter should be 1577) 1 Rec. 1/S 77, x 3/16" other side 77? x 7/16" Rec. 1/S 11 x 77 Rec. 0/S 11 x V7 Rec. 1/S 11 x V Rec. 0/S 11 x */' Rec. 1/S 11 x 7?" Rec. (0/S 11x7." (if recessed, recess diameter is 1577) (if recessed, recess diameter is 1577) (face bevel 1/side or N face) recess diameter should be 1577 Type 1 1 1 1 1 1 MIL 000127 5-7 Machine And Wheel Size (cont.) Warner and Swasey, Worcester, MA (including Norton Company) Machine/Model 4" Type C Plain & SemiAutomatic 4'Type CTU Plain & SemiAutomatic 6" Type C & CTU 10" Type LC & LCTU Plain & Semi-Automatic 6" Angular Wheel Slide Semi-Automatic' 10" Type C & CTU 14" Type LC & LCTU Plain & Semi-Automatic Old Style 6" Type A Old Style 10" to 20" Type A (with Spanner nut) 10" Type CD (Type D Wheel Slide) 10" Type C 45 (angular wheel side) Wheel Size 16 x (1,17., 1'/j,2)x5 16 x (1,2) x 8 20x2x12 20x2x 12 20x3x12 20x3x12 20x4x12 24x2x12 24x2x12 24x3x12 24x3x12 24 x (2,3) x 12 24 x (2,3) x 12 20 x (2,3,4,5) x 12 20x2x 12 20 x (3,4,5,6,7) x 12 24 x (2, 3, 4. 5) x 12 24x2x12 24 x (3,4,5) x 12 30 x (2.3) x 12 30x2x 12 30x3x12 14 x (1.17,. 2) x5 18x2x5 18x3x5 18x4x5 20 x 2 x 5 20 x 3 x 5 20 x 4 x 5 24x2x5 24 x 3 x 5 30 x (2,3,4) x 12 30 x (3,4,5,6) x 12 36 x (2,3,4) x 20 36 x (3.4) x 20 42 x (2.3.37:) x 20 42 x (3,37:) x 20 20 x (2,3,4) x 12 20 x (3,4,5,67) x 12 10" Angular Wheel Slide Semi-Automatic 10" Type CV-4 14" Type LCV-4 Semi-Automatic Angular Wheel Slide 14". 16", 18" Type C Plain 14", 16" & 18" 30 x (3. 37:) x 12 30 x (3.4) x 12 24 x (2.3.4.S.6) x 12 24x7x12 24 x (8,9,10) x 12 30 x (2,3,4) x 12 30 x (3,4,5.6) x 12 Type 1 1 Rec. 2/S 147, x a 1 Rec. 2/S 147: x Rec. 2/S 147: x 13/16 1 Rec. 2/S 147: x 1 Rec. 2/S 147: x a 1 1 Rec. 2/S x 147: x Rec. 2/S 147: x 1 Rec. 2/S 147, x Rec. 2/S 147, xD 1 Rec. 2/S 147- x Rec. 2/S 147, xQ 1 1 Rec 1/S 87: x 1" Rec. 1/S 87: x 2" 1 Rec. 1/S 87, x 1" Rec. 1/S 87, x 2" 1 Rec. 1/S 107, x 1" 1 Rec. 2/S 147, x 1 Rec. 2/S 227, x 1 Rec. 2/S 227: x with "E" lace Rec. 2/S 14 Ax a with "E" face 45'5 1 1 Rec. 2/S 147, x 13/16 Rec 2/S 147: xG 5-8 Warner and Swasey, Worchesler, MA (including Norton Company) (cont'd.) Machine/Model Type C Plain 14" Type C-2 18" Type LC-2 Plain and Semi-Automatic 18" & 24" Type C-2 Plain and Semi-Automatic Type "L" Multipurpose 10" Universal 12",14",18" Type U-4 Universal STEPMASTER PLUNGEMASTERS C-5, LC-5 CU-5, LCU-5 C-6, LC-6 CU-6, LCU-6 Wheel Size 36 x (2,3,4) x 12 36 x (3, 4) x 12 30 x (3,4, 5. 6) x 12 30 x (3, 4, 5, 6. 7, 8) x 12 10 X (7:, 7., 7., 1) x 3 12x7:, x 5 14 x (7:, 7:,) x 5 14 x (1,17., 17:) x 5 12x2x5 12 x 27, x 5 12x3x5 10x1x3 14 x 17, x 5 30 x (3, 4,5) x 12 36 X (3. 4, 5) X 12 24 x (2, 3,4) x 12 30 x (3, 4,5) x 12 30 x (3, 4.5) x 12 Type Rec. 2/S 147, x 1 1 Rec. 1/S 8 x 7," Rec. 1/S 10 x D Rec. 1/S 10x0 Rec. 1/S 10x0 1 1 1 1 1 MIL 000128 Basic Principles Of Centertype Grinding 1. Type of Parts A. Parts with centers such as motor shafts, output shafts, axles, crankshafts, etc. 2. Selection of Wheel Guidelines A. Things to consider: 1. Roughing or finishing 2. Traverse or plunge 3. Stock Removal 4. Requirements of finished part 3. Grading the Wheel A. For roughing use coarse grain and soft grade. Grade differences often depend on part size. B. For finishing, use fine grain and medium grades and light passes. RMS will be controlled by varying the traverse rate or increasing the amount of dwell time. C. For traverse grinding, establish a setup of work RPM with a good even infeed rate (don't crowd the grind) and a spark out period to produce the RMS required. D. Stock removal, for heavy stock removal, use coarse grain size and medium wheel grade. When stock removal is heavy, part will usually be soft. E. For light stock removal, use a finer grain size and a soft to medium grade J - K and slow traverse rate to obtain higher RMS. For light stock removal and good RMS, part will usually be hard. F. Requirements of finished part for good RMS, use a finer grit size 60 - 80 and medium grade J - K. If RMS is not that critical, use a 46-60 grit J or K and change your RMS by changing the traverse rate. On plunge grinding the RMS will be controlled by the grit size and amount of spark out. G. In centertype grinding especially, it is better to have a wheel too soft than too hard. A wheel too soft can still be used, but a wheel too hard may start to chatter just as you near final size and chop under size in places. Centertype Cylindrical Grinding In centertype cylindrical grinding the work usually is held rigidly between centers and ground on the O.D. there are two general types of cylindrical grinding machines: plain and universal. Plain centertype cylindrical machines are designed for plain cylindrical work, are good production machines, and are not readily adaptable to other types of work. The wheel slide is at 90 degrees to the table travel, and nei ther the wheel slide nor the head stock can be swivelled. The universal machine wheel slide and head stock can be swivelled in relation to the table travel and can be readily adapted to do a variety of grinding jobs. The uni versal usually adapts to internal grinding, also. The center holes in the work and the work centers of the machine must be round and ground or lapped to the cor rect angle to produce accurate work. The center holes in the work should always have a relief at the bottom to clear the point of the work center. If the point of the work center touches the bottom of the center hole, the work will revolve on the point instead of bearing on the angle, and the shaft will wobble around causing out-of-round work. The cylindrical grinding of any work between cen ters cannot be more accurate than the center holes or the work centers. Steadyrests Steadyrests are necessary when grinding long, small diameter parts that will be sprung or deflected from revolving on their true axis by the pressure of the cut. They help prevent chatter and make it possible to take deeper cuts. The number of steadyrests required depends on the length and diameter of the part. If more than one is -used, they are generally spaced from 6 to 10 times the diameter of the work between them. When setting the steadyrests, one should be located in the approximate center of the work, and if more are needed, they should be equally spaced on both sides of the center. Both work and wheel balance are necessary for accurate work on the centertype grinder, particularly when they cannot be held rigidly in the machine. The speed of the work is generally from 50 to 100 sfpm; however, on some work that is badly out of balance, lower sfpm is necessary to get a round part. Soft metals and nonferrous alloys grind better at higher work speeds, up to 200 sfpm, where shape and design of work permits. Traverse speed is limited by the width of the wheel and the finish required. Traverse should never be greater than approximately 3/4 of wheel thickness per revolution of the work for rough grinding, and should be reduced to the speed necessary to produce the finish desired when finish grinding. The length of traverse should never extend beyond the work. In general, the work rpm and the traverse rate can be used to make a wheel act softer or harder as needed. If the work rpm is increased, the wheel will act softer and conversely, if the work rpm is decreased, the wheel will act harder.lf the traverse rate is increased, the wheel will act softer, and conversely, if the traverse rate is reduced, the wheel will act harder. In general, as the traverse rate or work rpm is increased, more work is presented to the wheel in the same space MIL 000129 5-9 Basic Principles of Centertype Grinding (cont.) of time. This creates more mechanical stress on the grains of the wheel, causing the wheel to break down faster or act softer. If the traverse rate or rpm is reduced, less work is presented to the wheel in the same space of time. This puts less stress on the grain of the wheel, causing the wheel to break down more slowly and act harder. To prevent damage to the work and reduce the heat of the grinding operation, most work on centertype machines is ground wet. To get the full benefit from a grinding fluid, it is necessary to keep a good volume of fluid on the work during grinding, with the nozzle adjust ed to force the fluid between the wheel and the work. In centertype cylindrical grinding there are many jobs grinding a diameter and shoulder, holding a radius or fil let to close tolerances, or grinding a flange face with the side of the wheel. Recessing and dishing the side of the wheel will reduce the contact area between the wheel and the work, giving a cooler and freer cut than when using a straight-side wheel. On a machine where the wheelhead can be swivelled or on a plain machine with a 30 degree or 45 degree angle, this type of operation can be done with an "E" face or an "N" face wheel. Grinding both the diameter and face (shoulder) with the periphery of the wheel, gives a freer cut and better finish with less heat damage to hardened parts than when grinding with the side of the wheel. Selection of the wheel grade depends on the kind of material (hard or soft), stock removal, finish required, form to hold,fillet or radii, and tolerance. Generally, small diameter work permits use of harder wheels; hardened material requires finer grain and softer wheels. Soft, ductile metals or heavy stock removal or unhardened metals (green grind) require coarse grain sizes. The same wheel can be used to rough and finish by chang ing the dressing technique. For free cutting or roughing, a fast pass with a diamond dressing tool across the wheel face approximately 0.001 inch deep will open up the wheel face or cut grooves in it, making the wheel act coarse giving good stock removal but poor finish. If several slow passes are made across the wheel face with the diamond dressing tool with very little infeed, the wheel face will be closed up or seized and the wheel will finish like a wheel several grain sizes finer. However, a wheel in this condition will not remove much stock and could develop chatter if glazed too much. In production quantities of work requiring better than commercial finish and heavy stock removal, it is better to rough with a coarse grit wheel and finish with a fine grit wheel than it is to control finish by dressing. 5-10 Center Holes Centertype grinding relies on the center holes in the part, mating with the precision work centers in the headstock and footstock, to establish an axis of part rotation. The inter-relationship of the center holes and the centers is important for three reasons: 1. It establishes part location and aligns part features, shoulders, etc., with the grinding wheel. This positioning has a direct effect on finished part tolerance. 2. It establishes a true axis of rotation which controls roundness and concentricity. 3. It provides work support, and, therefore, is the first consideration in system rigidity. Geometry Center holes should be held as close to 60 degrees as possible, (Figure 1). The depth of the center hole is equally important, for it is these two factors which con tribute to proper work center bearing within the center hole. Center hole geometry should always include suffi cient relief at the bottom of the hole as well as at its largest diameter. The latter is especially important where the end squareness of the workpiece may vary, or where mass production situations create fluctuations in the center hole depth. Figure 1 MIL 000130 Squareness The examples in Figure 2 a, b, c illustrate some proper and improper conditions for center holes. A condition as indicated in Figure 2c would result in an elliptical contact with the work center, thereby seriously affecting part roundness and concentricity. 5 INCORRECT Cleanliness Cleanliness of center holes is just as critical as the pre viously mentioned geometry. Any dirt in the contact area can be disastrous, in addition to its affect on part round ness and concentricity, dirt can create serious scoring in the center holes which could jeopardize future opera tions requiring those holes. There also exists the possi bility of work center scoring which could lead to a setup change. Lapping and Straightening Heat treating workpieces creates additional problems in part processing. The heat treat operation can easily destroy a center hole, and/or warp a long workpiece. Lapping of center holes following heat treat is always a wise consideration. This operation helps to remove unwanted scale and insures a full circular contact with the work center. Longer parts should be considered for a straightening operation to eliminate warpage. It is tempting for a process engineer to eliminate center hole lapping or straightening as a cost savings. This will usually turn out to be false economy, since the part roundness can be no better than center hole roundness. Work Centers Work center points are usually ground to a slightly larger included angle (60 degrees 15 min.) to insure proper contact with the largest available center hole diameter (Figure 3). In addition to the accuracy of the points, the accuracy of the work center taper should be carefully monitored. Both points and tapers should be free of nicks, burrs or other imperfections. Centers should be frequently inspected and reground at the slightest indication of a problem. Let common sense prevail in the selection of centers. Never try to hedge on a setup, trying to "get by" with a half-center or other special configuration when the job doesn't call for it. Rigidity of setup, even part holding capability can be seriously undermined by these prac tices. And, as always, be sure that good engineering practices are followed with regard to specifications for center hole dimensions, as compared to part weight and diameter. MIL 000131 5-11 Basic Principles of Centertype Grinding (cont.) Centertype Grinding The two methods of centertype grinding are traverse and plunge. As the majority of applications involve plunge grinding, this is where we will focus our attention. Plunge grinding involves the straight line feed of the wheel into the workpiece. The application will determine the approach angle, 0 degrees or 30 degrees, which is most practical. The part geometry will also determine the wheel profile, straight or formed. When simultaneous shoulder/diameter grinding is required, the only efficient processing method to be con sidered is angular feed. The normal 30 degrees approach angle creates a diameter to shoulder stock removal ratio of 3.5 to 1, therefore, grinding stock on the face and diameter becomes an important consideration for production efficiency. When a condition exists where the length of the shoul der to be ground exceeds the length of the adjacent ground diameter, the wheel angle should be increased to 45 degrees (available only on chucking grinders) to achieve grinding efficiency. Now, however, troublesome differences in wheel surface speed and part rpm becomes a problem. In addition, because of the dressed angle on the wheel and the size of its shoulder, the smallest operating diameter of the wheel is reached after minimal wheel wear. With most plunge grinding applications, a flagging (later al positioning) attachment is necessary to help maintain the required wheel to part alignment. Any variations in the center hole depth, or fluctuations in shoulder dimen sions as the parts come to the grinder necessitates this type of option. Summary This issue has only scratched the surface of the subject. The important things to remember are the five criteria, mentioned at the beginning, which help to classify a job as "centertype", and the care required in the production and maintenance of center holes and work centers. Plunge Grinding 30 available on EC Cenlertypes - only available on Chucking Grinders. MIL 000132 5-12 Trouble Shooting Problem 1. Chatter marks 2. Short wave marks. 3. Long wave marks 4. Shadows 5. Burlap finish 6. Diamond Truing Lines 7. Feed lines 8. Barber pole finish ' 9. Burnt Work and cracked surfaces Possible Causes Grinding cut too heavy. Wheel too hard. Wheel out of balance. Slender work unsupported. Machine vibration. Vibration from belts. Vibration transmitted from other machines. Vibrations in hydraulic system. Vibration from motors. Vibration from chains and sprockets. Seal in headstock too tight. Imperfect gear action. Out of balance wheel. Stopping wheel without turning coolant off, causing unbalanced wheel. Wheel oil soaked on one side. Allowing wheel to absorb moisture from floor. Grease or oil spots on wheel face. Hard spots in wheel surface. Wheel loading. See long wave marks. Loose diamond tool. Vibration of diamond tool support Uneven table traverse when truing. Diamond too sharp. Table traverse too fast. Wheel too hard. Wheel not suitable. Improper control of traverse or work speed when finishing. Improper coolant distribution when truing. Improper use of steadyrests. Head or footstock out of alignment. Improper lubrication of tableways. Work loose on centers. Centers do not fit spindles. Loose fitting footstock spindle. Wheel too hard. Wheel structure too dense. Wrong wheel bond. Grinding wheel over speed. Work revolving too slowly. Grinding cut too heavy. Insufficient coolant. Nozzle not directing coolant properly. Wrong coolant. Grinding wheel improperly trued. Suggested Correction Lighter cuts. Softer wheel, increase work speed, dress coarser, reduce wheel speed, enrich grinding fluid mixture. Check for vibration within the machine and for vibration transmitted to the machine. Balance the wheel. All these possible causes are corrected by repair and/or replacement of machine components. Rebalance wheel. Rebalance wheel and make it a rule to stop coolant and run wheel until moisture is thrown off. Replace wheel. Store in racks off of floor. Redress wheel. Heavily redress wheel or replace wheel. Redress wheel. Keep tool securely fastened. Dampen vibration. Check hydraulic system. Try a duller diamond. Slow table speed. Try softer wheel or make act softer. (See #i above.) Change wheel. Change work speed or wheel speed when finishing. Readjust coolant flow and direction. Ensure steadyrests are even. Check head and footstock, tableways and center holes. -Adjust oil flow or change oil. Be sure head and footstock are properly clamped. Check centers for fit. Obtain new footstock spindle. Try softer wheel or make act softer. Try more open structure wheel. Consult Cincinnati Mllacron Marketing Company Sales Representative. Reduce speed. Increase work speed. Rough and finish grind with two wheels. Check coolant level, pipes and pumps. Redirect flow or obtain new nozzle. Consult Cincinnati Mlladron Marketing Company Sales Representative. Redress wheel. MIL 000133 5-13 Trouble Shooting (cont.) Problem 10. Rough finish 11. Uneven wheel surface. 12. Out-of-round work when plunge grinding Possible Causes Wheel too coarse or too hard. Diamond too sharp. Dressing too coarse. Cut too heavy. Traverse loo fast. Work speed too fast. Lack of proper steadyrest. Dirty coolant. Solution of coolant too weak. Rapid diamond wear. Improper distribution of coolant. Diamond tool holder not securely clamped. Table floating. Workpiece centerholes out of round or not in line. Burrs in workpiece center holes. Work loose on centers. Centers loose. Centers do not fit spindles. Center holes out-of-round. Workpiece center holes not deep enough. Work centers scored. Center points worn down. Work too tight on centers. Insufficient coolant. Worn footstock spindle. Misalignment of workheads. Swivel table gibs loose. 13. Intermittent cutting action while traverse grinding 14. Adjacent diameters of work not concentric. 15. Unable to keep work straight Heavy work too tight on centers. Work out of balance. Base high in middle or at one or both ends. Work loose on centers. Centers not in alignment on workpiece. Headstock or footstock moving away from work. Centers do not fit spindles. Base out of alignment. Headstock or footstock out of alignment and center holes of varying depth. Common Dimensional Standards It is not possible to list the exact sizes of wheels for all of the various models of cylindrical grinding machines, because the size depends upon what wheel and what size wheel guard are on the machine. The only way to be certain of the size is to measure the wheel, the guard, the wheel collet or all three, if you need to. For further information write Cincinnati Milacron Marketing Company Abrasive Applications Dept., or con tact your local Cincinnati Milacron Marketing Company Sales Representative. Suggested Correction See above suggested correction. Change to larger diamond. Readjust coolant flow and direction. Securely fasten holder. Reduce lubricant flow to table or change to a lighter oil. Relap center holes. Clean holes. Be sure footstock & headstock are clamped. Tighten and clean centers. Replace spindles or change center holes. Regrind center holes. Deepen holes or blunt center points slightly. Regrind centers and lubricate. Regrind centers. Loosen footstock spring tension. Readjust coolant flow. Replace spindle or use steadyrest close to footstock. Realign workheads. Be sure gibs fit and clamp swivel table securely. Back off footstock .002 to .004. Add weights to balance workpiece. Realign or possibly rescrape base. See above for suggested corrections. Correct alignment and/or regrind centers. MIL 000134 5-14 Cam Grinding (Centertype) Starting Grade Recommendations Specification Selection Guide Application production Grinding: Automotive (cast alloys and forgings) roughing finishing roughing and finishing (hand machine) finished bearings dual cycle (rough and finish with same wheel on same machine) Automotive (hardened steel) roughing finishing Cast Iron roughing finishing dual cycle Chilled Iron roughing finishing Diesel and truck hardened forged shatts roughing roughing (100%) burn free) finishing rough bearings finishing bearings Wheel Specifications 97A601-N4-VFME 97A801-J4-VFME or 9A80-J4-VFME, or 97801-09-B2 97A801-P9-B2 97A701-M4-VFME, or 6C60-L4-VSCE 97A701-N4-VFME 97A601-L4-VFME C12A801-N9-B2 97A701-N4-VFME 97A801-L4-VFME 97A701-M4-VFME 97A541-L4-VFME 97A701-K4-VFME 97A601-K4-VFME 9A70-I6-VRWE 9A80-H6-VFME C2A801-P9-B90 2A54-L6-VFME 97A801-L4-VFME Application Wheel Specifications Regrinding Cast Iron Chilled Iron Spheroidal graphite iron Steel roughing finishing Steel (hardened) Wide Lobes roughing finishing Narrow Lobes roughing finishing Ceramic (MSB) Most Lobes roughing finishing 97A801-N4-VRWE 9A70-L4-VFME 9A60-L4-VFME 97A601-M4-VFME 97A541-N4-VFME 97A801-L4-VFME 9A60-K4-VFME 29A601-K6-VAE 29A801-J4-VAE 97A601-M4-VFME 29A801-K4-VAE 3MSB601-K4-VSAE 3MSB801-J4-VSAE For wheel speeds over 8500 SFPM, on vitrified applications, contact your Cincinnati Milacron Marketing Company Sales Representative. To use VQC or VRW, go one grade softer. Starting Grades Narrow Lobe - 97A701-M4-VFME Wide Lobe - 97A601-I6-VFME A high volume of a good quality coolant is a necessity in cam grinding, i.e., CIMCOOL 400 or CIMPERIAL 20. As most cam grinding machines are custom fitted to the part being ground, it is impossible to properly specify a wheel without certain information. Before ordering any cam wheel, be sure to accurately obtain: The machine model and serial number. The actual spindle speed, roughing and finishing. The wheel size. (A blueprint would be helpful.) The current specification in use. PLEASE ADJUST COOLANT NOZZLES A MINIMUM OF FOUR TIMES PER SHIFT One of the most common causes of burn on cam grinding operations is failure to keep the coolant nozzle close to the wheel, the intermittent dressing over a 2 hour period causes the grinding face to move away from the coolant nozzle thus we get burn. MIL 000135 5-15 Machine And Wheel Size Cam Grinding Cam grinding is another special class of cylindrical grinding and is unusual in that, because of the eccentric shape of the cam, the ratio of the workpiece surface speed is always varying in relation to the wheel surface speed. Depending upon the shape of the cam, the workpiece surface speed can vary greatly. To compensate for this variance the wheel must be as free cutting as possible. This is especially true at the time when the nose of the cam has passed the wheel and is turning away. A wheel that is not free cutting will enlarge on the turning-away motion by adding some push of its own which can produce an out-of-shape cam. On the other hand, the wheel must be chosen for dura bility, because the irregularity in work surface speed tends to abuse the wheel face; this can be amplified by poor machine condition. Production cam grinding is found in the automotive, air craft, truck, ship-building, locomotive and farm equip- ment engine industry. Two types of installations are found: 1 Dual cycle machines which rough and finish with one wheel specification, and 2 Two separate machines - one for roughing and one for finishing. In the first case, special high speed vitrified wheels are nor mally used: in the second, standard vitrified wheels are used for roughing and resinoid or rubber wheels are used for finishing. Cam regrinding is found in engine rebuilding shops throughout the country. The amount of material which must be removed is less than in original manufacture, but the same critical shape tolerances apply. Type 1 wheels, 24 inches in diameter with thickness ranging from 1/2 to 2 inches are most common. Aluminum oxide abrasives, in grit sizes 46 to 120, are used in vitrified, resinoid and rubber bonds. Grades 16 thru N4 vitrified and K9 thru S7 resinoid are also used. Typical Machine Manufacturers Landis Norton Warner and Swasey Landis Tool Co., Waynesboro, PA Machme/Modei 5R-IW Mufti-Wheel Grinder Capacity 14 x 36' 16 x 48' 10 x 36' Wheel Size 42x0x12 42xOx 12 36.42x0x12 Type S (Dial Cycle) Cam Control Grinder Type R Cam Grinder 5x30- 5x26* 5 x 30* 5x40- 18 24 x O x 12050 24x0x12 24 xOx 18 M0S/SFPM 8500 8500 8500 Rough Finish 12.000 6.000 Norton Company, Worcester, MA Machine/Model CAM-0-MATIC #1. #2. #3 Warner and Swasey. Worcester. MA Machine/Model #3 CAM-0-MAT1C CAM-MASTER /4 CAM-0-MATIC Wheel Size 24 x V, x 18 24 x 1 x 18 24 x 17, x 18 Wheel Size 24x0x18 various 24x0x 16050 tAny combination up to 30" including spacers. M0S/SFPM 6500 6500 6500 M0S/SFPM 8500 or 10.000 10.000 Basic Principles *lt is obvious that the complexity of generating cam shapes by grinding demands that the machine be in very good condition. When conditions such as these exist, some vari ation in grain and grade can improve the results, but wheel produced chatter will normally show all the way around the cam periphery. Also, if the wheel is affecting one ramp con tour, it should affect both. It is a good idea to check the machine before changing the wheel specifications. When testing specifications, do not attempt to judge the wheel on lobe shape generated, as this is strictly a function of the master cam. The master cam itself may have to be altered, particularly if changing from vitrified to resin wheels or vice-versa. The wheel itself should be judged on the stock removal rate, G-ratio, lobe-to-lobe size control, freeness of cut, etc. Trouble Shooting Problem Possible Causes Suggested Correction 1. Chatter on cam nose.' Interference of rocker bar motion. Scored bearings Sludge lamming motion, clean or replace. Check for irregularities in Insufficient lubrication. rocker bearings. Tight bearings in rocker bar -- lubricate. 2. Irregular ramp contour Interference of rocker motion. Loose bearings Sludge jamming motion or scored bearing; clean and/or replace: lubricate. Check bearings for Insufficient contact between master cam and follower. excessive wear Ensure positive contact between masters 3. Poor quality of grind Wheel too coarse Wheel too hard Poor quality of dressing Use finer gril wheel Use softer grade of grinding wheel. Ensure quality diamond and dress technique Dirty coolant Ensure clean coolant and filter regularly (also, see Cylindrical Grinding) MIL 000136 5-16 Crankshaft Grinding (Centertype) Starting Grade Recommendations Specification Selection Guide Application Wheel Specifications Airplane Crankshafts pins bearings Automotive crankshaft (pins & bearings) roughing: heavy side removal light side removal finishing roughing and finishing regrinding Automotive pins forged steel nodular iron Cast Iron pins bearings center thrust bearings Diesel crankshafts before nitriding after nitriding Multi-wheel arrangements (bearings) Steel (nitrided) pins bearings center thrust bearings Steel (induction hardened) pins bearings center thrust bearings Thrust Walls Transfer pin grinders - dress each pin 97A461-K4-VFME 97A701-L4-VFME 97A461-04-VFME 97A541-N4-VFME 97A701-K4-VFME 97A701-K4-VFME 97A701-K4-VFME 2A54-N4-VFME 97A701-04-VFME 97A701-04-VFME 97A601-M4-VFME 97A701-M4-VFME 97A701-M4-VFME 97A601-K4-VFME 97A701-K4-VFME 97A601-N4-VFME 97A701-N4-VFME 97A701-K4-VFME 97A541-M4-VFME 97A601-N4-VFME 97A601-04-VFME 97A541-N4-VFME 97A601-M4-VFME 29A461-L4-VFME 29A701-M4-VFME 97A6Q1-N4-VFME 29A601-L4-VFME 29A701-L4-VFME 29A701-L4-VFME 29A701-14-VFME 97A541-M4-VFME 97A601-N4-VFME 971601-N4-VFME 29A701-L4-VFME 29A701-L4-VFME 29A701-L4-VFME 29A601-L4-VFME 29A601-L4-VFME 29A701-N4-VFME 29A701-N4-VFME 29A701-K4-VFME 29A601-M4-VFME 29A601-N4-VFME 29A601-N4-VFME 29A541-M4-VFME 29A541-M4-VFME 3MSB541-K4-VSAE 3MSB601-K4-VSAE 3MSB541-M4-VSAE 3MSB5601-K4-VSAE 3MSB801-J6-VSAE 3MSB541-L4-VSAE 3MSB801-J4-VSAE 3MSB601-K4-VSAE 3MSB601-K4-VSAE 3MSB601-L4-VSAE 3MSB601-K4-VSAE 3MSB601-K4-VSAE 3MSB601-K4-VSAE 3MSB601-K4-VSAE 3MSB601-K4-VSAE 3MSB601-L4-VSAE 3MSB801-K4-VSAE 3MSB801-J6-VSAE 3MSB601-M4-VSAE 3MSB801-K4-VSAE 3MSB801-J6-VSAE 3MSB601-K4-VSAE 3MS8601-L4-VSAE For wheel speeds over 8500 SFPM, contact your Cincinnati Mllacron Marketing Company Sales Representative for recommendations. To use VQC or VRW, go one grade softer. MIL 000137 5-17 Basic Principles of Crankshaft Grinding Wheels for crankshaft grinding are purposely oversize in thickness, and the additional stock is dressed away by the customer to the required size, usually given with a decimal tolerance. These wheels are speed tested and marked for operation at speeds higher than 6500 SFPM. Your Engineering data sheets and order entry forms must specify "Crankshaft" or "Camshaft" wheels if you want delivery of the wheels marked with the higher operating speeds. There are many diameters of wheels used on crankshaft grinders but the 42" diameter has been found to be the mos popular size. Crankshaft grinding is a special class of cylindrical grind ing which is one of the most severe precision jobs that will be encountered. Not only must large amounts of stock be removed from the pins and bearings as well as from the sidewalls by plunge grinding, but dimensional accuracy, corner radii and surface finish must be main tained.' Most crankshaft wheels are Type 1, ranging from 24 to 60 inches in diameter and 1/2 to 6 inches thick. Cincinnati's diameter limitation is 42". Very often customers will speci fy special thickness dimensions that conform to the mean width of the pin or bearing. Always specify tolerances on thickness to be sure that the wheel, as ordered, is at least .031 thicker than the pin or bearing width, to allow for truing allowance and assure true running sides. Some of the thicker wheels may be relieved or recessed to wheel Types 5, 7 or 21. Aluminum oxide abrasives in vitrified bond are predominantly used. Grit sizes 36 to 80 in grades J thru Q cover most of the range. Crankshaft grinding is found throughout the automotive, truck, diesel, aircraft, small engine manufacturing industry and also in many engine rebuilding firms for regrinding of the pins and bearings. Wheel speeds of up to 8500 SFPM are most common, however, some newer produc tion machines will run at higher speeds. If in doubt of which specifications can be used for the speed required, contact your Cincinnati Milacron Marketing Company Sales Representative. Trouble Shooting Problem 1. Poor Finish 2. Flats generated on diameter 3. Chatter in radii 4. Thrust face poor geometry (stepped/taper) 5 Thrust face burning Possible Causes Suggested Correction Wheel too coarse or too soft. Improper wheel dressing. Use harder grade and/or finer grit. Use sharp, rigidly held diamond dressing attachment with point con tact below center. Wheel too hard. Wheel out of balance. Steady rest deflection. Use softer cutting wheel. Balance wheel. Ensure rigid steady rest. Dull diamond in radii attachment. Work head speed too high. Too high stock removal. Poor quality coolant. Check and replace. Slow work head speed. Reduce stock removal rate. Increase lubricity of coolant. Wheel too soft. Wheel speed too low. Tapered wall wheel too hard. Use harder acting, better corner holding wheel. Increase wheel speed, check correct pully. Use softer acting wheel. One side burning poor diamond dress. Both sides burning poor diamond dressing. Redress and/or redress at increased infeed. Use corner diamond dress & check for worn diamond. (also, see Cylindrical Grinding) NOTES: MIL 000138 5-18 6 Precision Roll Grinding MIL 000139 6-1 Roll Grinding Basics Introduction Roll grinding is a specialized form of cylindrical grinding requiring considerable skill since it is precision grinding of a high caliber. Roll grinding wheels are used to grind rolls which are tools used for shaping many types of materials such as steel, copper, aluminum, tin, paper, paint, ink, etc. Unless the rolls are ground accurately, it is impossible to produce rolled steel strip or aluminum sheet of the required quality. The finish on the rolled material can never be better than the surface of the roll itself, and unless the roll is ground accurately with respect to straightness, (or crown) the gauge of the metal being rolled will not be uniform. The present day trend in roll grinding is toward closer tolerances and high finishes. The trends challenge not only the wheel manufacturer but the machine builder and the machine operation as well. Without the skill of the operator, no grinding wheel will produce the desired results, while on the other hand, without the right wheel, an operator, no matter how skilled will have trouble. What must be realized is that the best grinding wheel made is of little value when used on the wrong job or application even though diverse cut ting characteristics can be given a wheel by skillful manipulation, with relative speed of the work, traverse and wheel. A skillful operator can, by manipulation of controllable factors, compensate for deficiencies in wheel size and grade. The Roll Grinding Machine Roll grinding machines are basically large powerful cylin drical grinding machines of very sturdy construction to assure minimum vibration when grinding. Conventional roll grinding machines range in size from 10" to 80", this dimension designating the maximum outside diameter of the roll it will accommodate. The 28", 36", 48", 60" and 80" machines are commonly used in steel and aluminum plants. Most machines use 36 x 4 x 20 or 36 x 4 x 12 inch wheels although thickness of these wheels can range from 2 to 6 inches and diameters from 20 to 42. Rolls are generally ground by supporting them on their necks, and journal rests may be either brass, iron or babbit. The roll drive is generally of the universal type to insure uninterrupted and smooth rotation. Most machines allow the wheel traverse, wheel speed and roll speed to be varied allowing the operator to vary each to obtain the best grinding results. By referring to the ammeter, the operator can obtain the highest rate of pro duction possible and learn at what point the wheel is working at its maximum efficiency. Because it is neces sary to crown many of the rolls, these machines have attachments that make it possible to grind either a crown 6-2 or concave on the roll. The initial cost of roll grinding machines and high quality work they must produce makes it very important that they be kept in excellent condition mechanically at all times. The Roll Grinding Wheel What is the definition of the perfect roll grinding wheel? The perfect roll wheel: 1. Will never wear out. 2. Will produce a finish which meets the RMS specified by the rolling mills. 3. Will remove the necessary stock in one or two passes and always get beneath any chatter and eliminate it in one pass. 4. Will require no dressing. 5. Will perform all the above functions day after day in summer and winter with exact consistency. The cutting action of a wheel depends upon (1) the kind of abrasive used, (2) the size of the abrasive grain, (3) the bond that holds the abrasive grains together, and (4) the spacing of the abrasive grains in the bond. We, at Carlisle, Pennsylvania, as in most other grinding wheel companies, specify and design grinding wheels by volume structure. For example, a wheel might have 52% abrasive by volume, and 16% of a bonding agent by vol ume which adds up to 68% leaving 32% of the wheel as voids or simply air. Such a wheel would be a K grade and in a 6 structure. So the grade is simply an indication of the amount of bond holding the abrasive grain. The more bond in the wheel, the harder the wheel will act. As we increase the grade, the voids in the wheel become less. So, if we keep the abrasive at 52% by volume, but go to 18 bond by volume, we. reduce the voids to 30% and the wheel will act harder. Here the wheel will be an L grade, 6 structure. If we are grinding soft material and want more chip clearance, we may want wider grain spacing or less vol ume % of abrasive per wheel. So we might change to 48% abrasive by volume. To keep the grade the same as the L grade we just mentioned, we will have to keep the voids at 30%, so our bond content would increase from 18 to 22% by volume. The wheel here would be an L grade', 8 structure. The grinding wheel, in theory, and to some degree in practice, is self-sharpening. Grains fracture and present new cutting edges so when dulled or worn down badly, they are torn out of their setting and so allow other grains to come into play. When an abrasive grain starts to enter and penetrate the work as the wheel and work revolve, the depth of the cut gradually increases to a MIL 000140 maximum somewhere along the arc of contact, and since the wheel usually rotates much faster than the roll, the greatest depth of cut is very near the spot where the wheel leaves the work. The two key components in any grinding wheel are the grain and the bond. The two most commonly used types of grain in roll wheels are aluminum oxide and silicon carbide. Most iron rolls use silicon carbide and steel rolls use aluminum oxide. Depending on the type of roll being ground and the finish required, aluminum oxide can be supplied in a variety of friabilities or toughnesses. The abrasive grains can each be furnished in at least 32 dif ferent sizes and in most cases, two or three sizes of abrasives are used in each specification. Structures and grades have a wide variety of combinations and are usu ally tailored to the particular application. Turning to the other major component, bonds, there are mainly four different types of bond used in roll grinding: (1) Resinoid; (2) Shellac; (3) Epoxy; and (4) Vitrified. Although there are only two key components in a roll wheel, there are literally thousands of different combina tions that can be produced. Therefore, careful considera tion must go into specifying the wheels. Some of the fac tors that must be considered to choose the right wheel are: 1. The kind of material being ground: iron, steel, rubber, etc. 2. The amount of stock to be removed; accuracy and finish required and rate of production desired. 3. Type and condition of the machine. 4. Size of the wheel and arc of contact between the wheel and the roll. 5. The skill of the operator. Harder grade wheels may be employed to an advantage for heavy stock removal on sturdy machines which are equipped with generous size wheel spindle bearings and motors. Small diameter wheels work better on large diameter rolls due to a narrower arc of contact, allowing the abrasive grains of the wheel face to properly pene trate the hard roll surface and readily remove stock. Besides the variables of the wheel itself, there are a great many other variables that can affect the wheel. Many of these variables can be controlled by the opera tor and can make the difference between a wheel that works and one that doesn't. Some of these variables are: Work Speed -- By changing the speed that the work is rotating, a skilled operator can change the way the wheel will act when cutting. If the wheel is acting too hard, an increase in the speed the roll is turning can make this wheel act softer. If the wheel is acting too soft, decreasing the roll speed will cause the wheel to act harder. Wheel Speed -- It must be emphasized here that the wheel should never be run over the maximum operating speed specified by the wheel manufacturer. But by chang ing the wheel speed, the cutting action of the wheel can be changed. For a wheel acting too hard, reducing the speed of the wheel will make the wheel act softer and increasing the speed of a soft wheel will make it act harder. Traverse Speed -- If the rate of traverse is increased, a hard wheel will act softer but the fin ish of the wheel will be rougher. If the traverse rate is decreased on a soft wheel, the wheel will tend to act harder and give a better finish. Wheel Dressing -- Varying the type of dress, the same wheel can be used for roughing and finishing. When dressing the wheel for roughing, a quick pass across the face of the wheel will leave a rough surface sufficient for most roughing operations. Redressing the wheel very slowly across its face will pro duce a wheel that is suitable for fin ishing operations on the rolls. The grinding of rolls is done with a constant stream of fluid ideally directed at the point of contact between the sheet and the roll. Wet grinding is done because the material used to bond the abrasive grain in roll wheels breaks down under the heat of grinding. So the grinding fluid helps slow this breaking down by acting as a coolant. Water is the best coolant and some mills use it right out of the lake onto the work. But the problem with water is that it tends to rust the rolls. Soluble oils used with soft water has the advantage of not rusting the rolls and also reducing friction between the wheel and work thus improving the grinding action. But soluble oil must be neutral - neither alkali or acidic to prevent damage to the wheel. Soluble oil mixed too rich can cause a wheel to gum up. Detergent solutions keep the face of the wheel clean but sometimes keeps the wheel cutting so well that good finishes cannot be produced. Each mill selects one or a combination of grinding solutions depending on its own requirements and developed grind ing practices. MIL 000141 6-3 6 Roll Grinding Basics cont'd. As with most wheel manufacturers, Cincinnati Milacron Resin Abrasives has very strict quality and manufactur ing standards that follow throughout the entire manufac turing process. These standards run from the testing of raw materials to the final shipping of the product. Now that we have briefly covered some of the basic prin ciples of roll grinding, let's look at some of the various types of rolls that are ground with these wheels. Hot-Strip Mill Rolls The sheet rolling process starts in the hot strip mills where slabs of metal are rolled into sheets. Rolls of this sheet metal are then stored to be rerolled to a finished thickness in a cold mill. These work rolls are usually 20" to 30" in diameter and up to 130" long. They are com monly called "chilled iron rolls" which are usually nickel grain or nickel chill castings, alloyed with chrome nickel an molybdenum. Here the typical abrasive would be sili con carbide. Because the finish of these rolls is not too critical, a 36 or 46 grit wheel would be recommended. The rolls often come into the roll shop in bad condition and stock removal of .030 to .040 is often required. Here the preferred wheel would be a fairly free cutting wheel in a J or K grade with fairly wide grain spacing to remove the stock rather quickly. The bond by choice in this wheel would be a resinoid bond. Cold-Strip Mill Rolls There are various mills that cold roll the steel to its fin ished size. Some of these are temper mills, tandem mills, skin mills, tin mills and other but most of these use forged steel rolls usually 25" to 30" in diameter. Because the finish on these rolls is transmitted to the finished product, it is important that these rolls be chatter free, with no scratches, traverse lines or other surface imper- fetions. The typical specification here would be an alu minum oxide 80 grit wheel with a resin bond in a J or K grade. If the finish and dimensional accuracy is extreme ly important, then we might specify an 80 grit shellac wheel. Where even finer finishes are needed, 150 grit might be used. Back-Up Rolls Back-up rolls in both the Hot Strip Mills and Cold Strip Mills are larger in diameter than the work rolls. These rolls are usually about 60" in diameter and as long as 154". Back-up rolls are usually steel with a few being cast iron. These rolls are usually ground with a 24 grit aluminum oxide wheel. The bond in this type of wheel is normally a resinoid bond but in some cases the use of shellac and epoxy has proven successful. Paper Mill Rolls Paper mill rolls require frequent regrinding. These rolls ae relatively small in diameter in comparison to their length, a typical size being 11-30" in diameter and 120 to 250" long. These rolls are usually chilled iron with a few steel and some rubber. These machines usually use 2 wheels 20" in diameter, one in the front of the roll and the omer in the back of the roll. The usual specification here is a very open silicon carbide shellac wheel in the 36 to 60 grit range for the chilled iron. A good choice for a rubber roll would be silicon carbide 24 grit I or J grade in a resin bond. MIL 000142 precision Roll Grinding The Roll Wheel Cutting action depends on: 1. Kind of abrasive 2. Size of abrasive 3. The bond that holds the grains together 4. The spacing of the abrasive grain General rules: 1. Always start with silane coated 2. Brown A/O for most steel 3. White and brown for chrome and exotics 4. S/C for iron rolls 5. The coarser the wheel, the harder it will act Hot Strip Mill Work Rolls Rolling hot steel into sheets Called chilled iron rolls -- Ni grain or Ni chill castings -- Alloyed with chrome nickel and Molybdenum Shore 60 - 85 20 to 30" diameter, 24 to 132" length Crowned rolls Commercial finish .015-.040 removal Material usually rerolled Open S/C wheel Free cutting J or K grade Resinoid - B320 or B90 Bond Hot Strip Mill Back-Up Rolls Used for added pressure while rolling Cast alloy or forged steel 60 to 80 Shore Larger - up to 60" diameter, 30" length Must be straight and accurately ground 24 to 46 grit A/O wheel, Resin J or K grade, B320, B90 Bond Cold Strip Work Rolls Steel rolled to finish size Tempermills, Tandem mills, Skin mills, Tin mills Mostly forged steel - some iron 25 to 30" diameter Harder - 70 to 100 Shor Finish critical Typical 80 grit shellac or epoxy A/O or combination H5A Also use of some resin B6959 Shellac preferred on work rolls - stay sharp - free cutting Bond Type B320 Straight resin product Used for most applications Good on old machines J thru L grades most common 24 thru 80 grit A/O or S/C Bond Type B90 Straight resin Used for coarser grit 24, 36, 46, 60 Modified resin Good for roughing wheels H thru N grade 24 to 60 grit, A/O or S/C Bond Type BM-6959 Straight resin S/C filler Usually used in softer grades Coarser grits H thru L grades most common 24 thru 46 grit B320 acts approximately 2 grades harder than B90 Bond Type Shellac Straight shellac Used where finish is critical Extremely hard material I thru L grades most common 24 thru 180 grit, A/O or S/C Bond Type Epoxy Straight epoxy Substitute for shellac Used where resin is too hard, shellac is too soft Good for older machines where resin bounces Usually H thru K grades 24 thru 100 grit, A/O or S/C 6 MIL 000143 6-5 How To Make A Wheel Act Harder 1. Decreasing the work speed 2. Decreasing the traverse speed 3. Decreasing infeed/downfeed 4. Increasing the wheel speed while observing proper safety procedures 5. Dressing at a slower traverse rate 6. Using a lighter dressing feed How To Make A Wheel Act Softer 1. Increasing the work speed 2. Increasing traverse speed 3. Increasing infeed/downfeed 4. Decreasing the wheel speed 5. Dressing at a faster traverse rate 6. Dressing the wheel face thinner 7. Increasing the depth of dress per traverse 8. Dressing more often Functions of Grinding Fluids Cooling, protects the workpiece. Lubrication allows for "`Cool" cutting. A reduced loading wheel cuts cooler. Swarf may harm the finished surface. Corrosion is bad for workpiece, figuring, machine tool, etc. Transparent fluid for visual control of grinding pattern in roll grinding. Advantages of Using Grinding Fluids The proper selection and application of the RIGHT grinding fluid can substantially increase productivity by reducing cycle time by as much as 50 percent. - Higher grinding speeds and infeeds - Longer wheel life - Lower power consumptions - Better surface finishes - Closer dimensional control Types of Grinding Fluids There are two basic types of grinding fluids: Grinding Oils - Straight mineral or fatty oils - Compounded oils (plus additives) Water-miscible (water soluble) fluids - Emulsifiable oils (soluble oils) - Chemical (synthetic) fluids - Semichemical (semisynthetic) fluids Waterbase Grinding Fluid Composition A list of several items or additives that may make up a typical water-miscible grinding fluid: Oils and water are usually the main ingredients. Extreme pressure additives help lubrication. Emulsifiers keep the oil suspended in the water. Bactericides destroy unwanted bacteria. Anti-foaming agents stop frothing. Corrosion inhibitor prevents rust. Chemical lubricants reduce the need for oil. Other additives such as water treatment may be added. Grinding Fluid Comparison These bar charts compare the relative performance of the three basic types of grinding fluids in terms of their ability to cool, lubricate and clean. Synthetics are excellent for cooling and cleaning but have low lubricating qualities. Water soluble runs about in the middle for all three functions. Straight oil is excellent for lubrication, average for cooling and has poor cleaning qualities. The "G" Ratio G = Grinding Ratio. The amount or volume or wheel wear in comparison to the amount of workpiece material that has been removed during the grinding process. m Volume of Material Removed from Workpiece Volume of Wheel Worn Away During Grinding MIL 000144 6-6 Straight Line Scallops Across Face of Part May create audible noise when product is run at high speed. Occasionally results in premature part failure usually as the result of fatigue. May disrupt lubrication Chatter standards should be set on basis of scallop height measurement Regenerative Chatter - Vibration 6 Scallops are usually very shallow - measured in millionths. Often need good light to see clearly. Various frequencies may be overlaid. Use Talyrond or wire and lift with tape. Count the number of complete cycles in a selected distance for a good estimate of wavelength rather than try to measure width of a single cycle. Usually seen in plunge operations without crossfeed. Spiral Regenerative chatter is a very important form of selfexcited vibration. Word "chatter" is usually used by vibration experts to designate self-excited, regenerative type vibration. Bumps may develop on wheel and work which become progressively larger with time Frequency of chatter depends upon resonant (natural) frequencies of the grinding system Resistance to Grinding Wheel Penetration Increases with Increased Work Material Hardness Usually present where there is crossfeed. Spiral pattern is actually pattern of short scallops which shift with successive workpiece revolutions. Wavelength is distance between successive scallops measured as shown. Importance of Chatter-Vibration Marks On Product Performance Unsightly, suggests good grinding practice was not being used. 34 42 52 67 81 Shore This graph shows that as you approach 50-60 Rc it gets very difficult to cause the grinding abrasive to penetrate into the surface of the workpiece. This results in very thin chips and considerable machine deflection, particu larly for weak grinding systems. Some of this behavior is due to the fact that the wheel itself, flattens out in the contact area -- sort of like the way a tire flattens against the road due to the weight of the car. MIL 000145 6-7 Roll Grinding Applications Miscellaneous Rolls Application Cast Iron Rolls - Regrinding Cold Mill Rolls: Backup Regrinding Tandem Rolls First Stand Other Stands Copper - Finishing Granite Rolls: Rough - New Regrinding Hot Mill Back-Up Rolls Regrinding Hot Mill Work Rolls Regrinding Roughing New Rolls Finishing New Rolls Recommendation CK36-I7-B320 H5AK30-J8-B320 H5AK30-J8-B320 AK80-I8-B320 C150-L8-B320 C36-K8-B320 C54-J8-B320 H5A30-J8-B320 CK36-I7-B320 AK30-L7-B320 C36-I7-B320 Application Aluminum Rolls Roughing Finishing Paper Mill Rolls: Chilled Iron, Granite, Rubber Covered Roughing Finishing Combination Copper, Brass, Wood Roughing ' Finishing Printing Rolls Rubber Print Rubber Rolls Soft - Roughing Soft - Finishing Hard - Rough or Finish Recommendation CK30-I9-EC CK60-J9-EC CK36-M9-E CK60-M2-E CK46-M10-E CK30-M9-E CK36-L7-B320 H5A20-L8-B320 CK46-M8-B320 CK36-J8-B320 MIL 000146 6-8 Wheel Related Problems problem Work shows discoloration Shiny appearance, slick feel Grit marks Isolated deep marks Wide irregular marks of varying depth. Widely spaced spots on work Chatter marks fairly long, wide, and evenly spaced at wide intervals, and generally discolored; wheel glazed or loaded Wavy traverse lines Long, regularly spaced chatter marks forming checkerboard pattern Deep, irregular marks Narrow and deep regular marks Regularly spaced chatter marks Chatter marks spaced synchronously with building vibration Regular or irregular chatter marks Chatter marks, long and widely spaced, regular in pattern, but may vary around body of work. Irregular chatter marks Cause Improper wheel Improper wheel Wheel too coarse or too soft Too much difference in grit size between roughing and finishing wheels Coarse grits or foreign matter in wheel face Wheel too soft Oil spots or glazed areas on wheel face Wheel grading too hard Remedy Use softer wheel, or manipulate to get softer effect. (See "Wheel Grading Effect"). Prevent glazing and loading; use more coolant; prevent chatter. Use coarser grit, softer bond; manipulate wheel to soften effect. (See "Wheel Grading Effect") Select correct wheel Use finer roughing wheel or finish out better with roughing wheel Dress out. Use harder grading. (See "Wheel Grading") Balance and true wheel; avoid getting oil on wheel face. Select softer grade, more open bond, or coarser grit. (See "Wheel Grading") Ragged wheel edges Wheel out of balance Wheel out of round Loose wheel flanges Wheel too coarse Round off wheel edges. Rebalance carefully on own mounting. Repeat after truing operation; if trouble persists, run wheel without coolant to throw off excess water; store on side to prevent water from settling at lower edge of wheel. True before and after balancing; true sides to face. Tighten flanges using blotters or lead washers. Use finer grit. General vibration Building vibration Faulty thrust bearings Check alignment and couplings; be sure motor and spindle are in balance. If a heavy grinder, provide a separate foundation, independent of the surrounding floor. If a light grinder, tighten or loosen anchor belts. Vibration dampers will often help. Moving the machine to a better location is sometimes the best solution. Replace thrust bearings. Back lash in drive gears Replace old gears or use belt drive; check lubricant. Work centers or work not true, or improperly lubricated Check fit of centers and rests; provide constant and even lubrication. On large jobs, such as in roll grinding, provide hold-down clamps on necks and arrange for adequate lubrication. MIL 000147 Belts Belts that whip, are uneven, or have poor splices will cause vibration. Belts that slip cause losses of power, speed, and removal capabilities, not to mention poor grinding results. Problem Regularly or irregularly spaced chatter marks of any width, but following one pattern Regularly but widely spaced chatter marks Uneven scratches on work Cause Metal belt lacing on spindle drive Uneven belt Whipping belt Remedy Use endless belt. Plane belt to uniform thickness and width; have all sections of uniform pliability. Take up belt. Spindle Bearings A reliable high quality bearing of babbit or bronze with the right oil and heat clearance will permit high quality finishes and excellent grinding wheel efficiency. Bearings should be allowed to heat up before attempting fine finishes since the bearing will expand from the heat, causing a tighter fit to the spindle. Problem Chatter marks -- short, close, and evenly spaced Cause Loose wheel spindle Remedy Reduce speed. Tighten or refit bearings, lap bearings to spindle. Increase quantity or improve quality of oil. Allow sufficient preliminary heating. Take up thrust bearings. Optimizing - Roll Grinding SPECIFICATION; H5AK36-J8-B320 Abrasive: 1. AK} 2. 10AK} Harder acting, less aggressive, better life Faster cut, less life, more aggressive Grit Size: 1. 367} 2. 46} Slightly softer, better finish, slower cut Same as above except to more of a degree Grade: 1. 18} 2. K8} Freer cut, may break down, more aggressive Slower cut, longer life, less aggressive Bond: 1. B70} Harder 2. B320M} Softer, more open F I N -TECH FINISHING TECHNOLOGIES Case History Application: Part: Material: Stock Removal: Surface Finish: Wheel Spec.: Coolant: Roll Grinding Steel Rolls 480mm dia. Forged Steel 95 shore hardness .1mm .04-.07 Ra 320 grit size Synthetic MIL 000148 6-10 7 Disc Grinding Wheels 7-1 Starting Grade Recommendations Specification Selection Guide In all types of grinding, the work area, stock removal, tol erances required and wheel speed can have a consider able effect on specification selection. This is particularly true in disc grinding. Hence, the following recommenda tions are general in nature. For further help, contact your Cincinnati Mllacron Marketing Company Sales Representative. Application Alnico-Magnets Aluminum Castings small-light work large-heavy work Asbestos clutch facings Brake linings woven moulded commercial finish moulded quality finish Brass and Bronze castings commercial finish Brick squaring ends-soft hard refractory Carbon Cast iron castings small-light work large-heavy work Chain saw blades Clutch plates Connecting rods Copper Dies (hardened steel) Fibre Gears (hardened steel) Golf club heads Grey Iron Knives Wheel Specifications C2A601-H9-B90 6C46-I9-B90 6C24-K11-B320 6C24-I11-B320 6C24-J11-B320 6C24-K11-B320 YC60-111-890 6C36-H11-B320 6C24-111-B320 6C24-J11-B320 6C24-L11-B320 6C46-K11-B90 6C36-J9-B90 BC24-J11-B320 97A601-J11-B90 97A601-I11-B90 97A601-H11-B90 6C46-H11-B90 97A801-H9-B90 6C24-I11-B320 97A801-H9-B90 97A461-L9-B90 6C46-J11-B90 97A461-I9-B90 Application Malleable iron castings Piston pin ends Piston rings roughing semi-finish finish Plumbing fixtures (vitreous) Porcelain (finish) Rails (surfacing) Roller bearing ends Roller bearing race cage surfacing Springs heavy wire medium wire small wire Steel - hard rough finish Steel - soft rough finish Steel forgings small-light work large-heavy work Tile (ceramic) Valve stem ends Wrenches roughing finishing Wheel Specifications 97A461-K9-B90 97A601-K9-B90 6C46-G9-B90 6C60-H9-B90 6C80-I9-B90 6C46-I11-B90 6C100-J9-B90 97A461-J11-B90 97A801-I9-B90 97A8Q1-I9-B90 97A241-N9-B320 97A241-N9-B320 97A461-N9-B90 97A801-G9-B90 97A1001-I9-B90 97A461-J9-B90 97A601-K9-B90 97A461-J9-B90 97A301-H11-890 6C80-K9-B90 97A601-N6-B90 C2A461-K9-B90 C2A601-M9-B90 The OD-ID size relationship usually determines the number of zones to be used (see example below): OD MINUS ID r~ MATERIAL Hard Steel Soft Steel Cast Iron (Hard) Aluminum (Soft) Aluminum (300 Series) Stainless Steel (400 Series) Stainless Steel Powdered Metal EQUAL TO GREATER THAN 24" 97A801-G/F/E9-BAM 2A601-L/K/J9-B90 6C601-J/I/H9-B90 97A801-K/J/I9-B90 6C60-G/F/E9-BAM 6C60-K/J/I9-B90 97A801-G/F/E9-BAM C2A801-G/F/E9-BAM GREATER THAN 12" LESS THAN 24" 97A801-G/F9-BAM 2A601-L/K9-B90 6C60-J/19-B90 97A801-K/J9-B90 6C60-G/F9-BAM 6C60-K/J9-B90 97A801-G/F9-BAM C2A801-G/F9-BAM EQUAL TO LESS THAN 12" 97A801-G9-BAM 2A801-L9-B90 6C6O-J9-B90 97A801-K9-B90 6C60-G9-BAM 6C60-K9-B90 97A801-G9-BAM C2A801-G9-BAM 7-2 MIL 000150 Bolt Hole Patterns 18" Disc 18 x T x ID IN5000 0 IN5100 4 IN5010 V, IN5110 5 IN5020 'k IN5120 6 IN5030 7- IN5130 7 IN5040 1 IN5140 8 IN5050 I'/. IN5150 9 IN5060 17* IN5160 10 IN5070 17. IN5170 11 IN5080 2 IN5180 12 IN5090 3 23" Disc 23 xTx ID IN5190 0 IN5320 7 IN5200 V. IN5330 8 IN5210 % IN5340 9 IN5220 7. IN5350 10 IN5230 1 IN5360 11 IN5240 I'/. IN5370 12 IN5250 Vk IN5380 13 IN5260 17, IN5390 14 IN5270 2 IN5400 15 IN5280 3 IN5410 16 IN5290 4 IN5420 17 IN5300 5 IN5430 18 IN5310 6 26" Disc 26 x T x ID IN5440 0 IN5450 V. IN5460 'k IN5470 7, IN5480 1 IN5490 I'/. IN5500 Vk IN5510 17. 1N5520 2 IN5530 3 IN5540 4 IN5550 5 IN5560 6 IN5570 7 IN5580 8 IN5590 9 IN5600 10 IN5610 11 IN5620 12 IN5630 13 IN5640 14 IN5650 15 IN5660 16 IN5670 17 IN5680 18 IN5690 19 IN5700 20 30" Disc 30xTx ID IN5710 0 IN5720 V. IN5730 'k IN5740 7, IN5750 1 IN5760 I'/. IN5770 Vk IN5780 17. IN5790 2 IN5800 3 IN5810 4 IN5820 5 IN5830 6 IN5840 7 IN5850 8 IN5860 9 IN5870 10 IN5880 11 IN5890 12 IN5900 13 IN5910 14 IN5920 15 IN5930 16 IN5940 17 IN5950 18 IN5960 19 IN5970 20 IN5980 21 IN5990 22 ID >0 <2 -2 <6 >6 <9 >9 Outer Row 10 on 147. 10 on 147. 10 on 147. 10 on 147. Next Row 5 on 11 5 on 11 5 on 11 -- Next Row 5 on 8 5 on 8 -- -- Next Row 3 on 4 -- -- -- ID 0 <3 >3 <6 >6 <12 >12 <16 >16 Outer Row 12 on 20 12 on 20 12 on 20 12 on 20 12 on 20 Next Row 6 on 18 6 on 18 6 on 18 6 on 18 -- Next Row 6 on 14 6 on 14 6 on 14 -- -- Next Row 6 on 8 6 on 8 -- -- -- Next Row 3 on 57, -- -- -- -- B ID SO <2 >2 <6 >6 <13 14 >14 Outer Row 14 on 227* Mon 227* 14 on 22V* 14 on 22V* 14 on 22'/* Next Row 7 on 167, 7 on 167. 7 on 167. 7 on 167, -- Next Row 7 on 15 7 on 15 7 on 15 -- -- ' Next Row 7 on 8V* 7 on 87* -- -- -- Next Row 3 on 4V. -- -- -- -- ID >0 <2 >2 <9 >9 <16 >16 <20 >20 Outer Row 16 on 26V* 16 on 26V* 16 on 267* 16 on 26'k 16 on 26V* Next Row 12 on 22 12 on 22 12 on 22 12 on 22 -- Next Row 12 on 18 12 on 18 12 on 18 -- -- Next Row 8 on 11 8 on 11 --, . -- -- Next Row 3 on 4V, -- -- -- -- MIL 000151 7-3 Disc Wheel Specification Selection Guide 1 Grain Type Information needed Material to be ground Hard Steel >50Rc Soft Steel <50Rc Cast Iron Aluminum (Hard) Aluminum (Soft) Stainless Steel 300 Series Stainless Steel 400 Series Alnico Powered Metal Nonmetallics 2 Grit size Slock Finished Removal Required <e3-ooK 97A 2A 6C 97A 6C 6C 97A 6C %E O<oo C2A C2A I Is issS jojn twmcoCc2Co 2cCn 8Ss CO s om 0 AJlT Al A VA V 801 801 1001 46 60 46 60 120 601 801 1201 46 60 46 60 801 801 1201 801 801 1201 80 80 1201 80 80 120 3 Grade Disc Size to determine the number of zones if OD minus ID is 4 Structure Part Size 5 Bone Always Resin O m ..CM 3 2J <o c (A to tA t O -- _J CM U1 Otw G/F G/F/E UK UK/J J/l J/l/H K/J K/J/l H/G H/G/l K/J K/J/l G/F G/F/E J/l J/l/H G/F G/F/E G/F G/F/E Zone Wheels -- Varying hardness across the grinding zone Purpose -- To maintain disc tllatness due to changes in the rate of stock removal and sur face speed across the grinding zone o2 c c cr Om O d CM c -- Jj cr >w O CM 11 11 11 11 11 11 11 11 11 11 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 Selection by numbers Refer to example below Example Valve Plate 1 Material Cast Iron 6C 2 Stock Removal .020 46 Finish Required 32 RMS 3 Disc Size 30 x 2 x 1 3 zone J/l/H 4 Part Size Approx. 4 x S x !/." 11 5 Bond B90 Roughing Finishing C9A 1201 1 11 B90 7-4 MIL 000152 6 Coolant Slots Type of Workfeed Slots are used on most thrufeed applications Purpose-- Coolant distribution Description-- standard pattern--4 radial slots '/" or '/*" wide (use V wide for parts that are less than V?" dia.) specify diameter on order (usually 2/3 of the disc diameter: i e, v<" slots to a 20" diameter on 30" wheel) (See the sample order below ) Basic Feed Methods Thrufeed -- Highest production rates possible in double disc grinding A continuous line of parts are fed through the machine Rotary Carrier-- High production lor small and medium sized parts and parts wth irregular shapes Oscillating and Reciprocating -- Generally used for short production runs, heavy stock removal, large workpieces. and when good accuracy is required 7 Perforations/Smooth Face Finish Required and Part Size Use smooth face disc when required finish is less than 15 RMS parts are less than !4" in diameter otherwise use perforated face Smooth face Purpose-- Used when grinding small diameter parts Produces fine finish Perforated face Purpose-- Aids in swarf removal and grain pene tration (free cutting) Coolant Slots Yes______ No Pedorations_____ Smooth Face. 6 Type of Workfeed Thrufeed Coolant Slots Yes__^ No. 7 Finish Required and Part Size Perforations Smooth Face. Recommended Specifications 6C46-J/I/H 11-B2 4 - %" slots to a 20" dia. Perforated MIL 000153 7-5 Machine and Wheel Sizes 18" Disc 18 xT x ID IN5000 0 IN5010 7. IN5020 7* IN5030 Vi IN5040 1 IN5050 17* IN5060 17* IN5070 IV* IN5080 2 IN5090 3 IN5100 4 IN5101 47* IN5102 4V* IN5110 5 IN5120 6 IN5130 7 IN5140 8 IN5150 9 IN5157 97* IN5160 10 IN5170 11 IN5180 12 ID >0<2 >2^6 >6<9 >9 Outer Row 10 on 147. 10 on 147* 10 on 147* 10 on 147* 10 on 147* Dowel holes - Dowel holes will be supplied as shown on sketch unless otherwise: specified. ` Slots - Standard pattern is 4 radial slots, 7a" or '/<" wide, to a specified diameter. : Perforations - Only one pattern is available. ; Perforations are 3/a" in diameter on ` 1 '/<" centers. Max. wheel thickness - 3" useable abrasive. Typical wheel description as it should appear on an order: ; Print #IN5040, 18x 1 x 1 -- 97A8O1-H/G/F9-B90 4 - '/<" slots to a 12" dia. "Perforated" Bolt Hole Patterns Next Row 5 on 11 5 on 11 5 on 11 -- Next Row 5 on 8 5 on 8 -- -- Next Row 3 on 4 -- -- -- 23" Disc 23 x T x ID IN5190 0 IN5200 7, IN5210 7* IN5220 7. IN5230 1 IN5240 IV, IN5250 17* IN5260 17. IN5270 2 IN5280 3 iN5290 4 IN5300 IN5310 IN5320 IN5330 IN5340 IN5350 IN5355 IN5360 IN5370 IN5380 IN5390 IN5400 IN5410 IN5420 IN5427 IN5430 5 6 7 8 9 10 107* 11 12 13 14 15 16 17 177* 18 ID >0<3 >3<6 >6<12 >12<16 >16 Outer Row 12 on 20 12 on 20 12 on 20 12 on 20 12 on 20 7-6 Dowel holes - Dowel holes will be supplied as shown on sketch unless otherwise specified. Slots - Standard pattern is 4 radial slots, 7a" or 7/ wide, to a specified diameter. Perforations - Only one pattern is available. Perforations are 78" in diameter on 1 V*" centers. Max. wheel thickness - 3" useable abrasive. Typical wheel description as it should appear on an order: Print #IN5230, 23 x 2 x 1 -- 97A801-H/G/F9-B90 4 -7*" slots to a 14" dia. "Perforated" Bolt Hole Patterns Next Row Next Row 6 on 18 6 on 18 6 on 18 6 on 18 -- 6 on 14 6 on 14 6 on 14 -- -- Next Row 6 on 8 6`on 8 -- ___ -- Next Row 3 on 57* -- -- -- -- MIL 000154 26" Disc 26xTx ID IN5440 0 IN5450 7. IN5460 7. IN5470 7. IN5480 1 IN5490 17. IN5500 17. IN5510 17. IN5520 2 IN5530 3 IN5540 4 IN5550 5 IN5560 6 IN5570 7 IN5580 8 IN5581 87. IN5590 9 IN5600 10 IN5610 11 IN5620 12 IN5630 13 IN5640 14 IN5650 15 IN5660 16 IN5670 17 IN5680 18 IN5690 19 IN5700 20 ID >0<2 >2<6 >6<13 14 >14 Dowel holes - Dowel holes will be supplied as shown on sketch unless otherwise specified. Slots - Standard pattern is 4 radial slots, 7a" or 7," wide, to a specified diameter. Perforations - Only one pattern is available. Perforations are 3/8" in diameter on 1 7." centers. Max. wheel thickness - 3" useable abrasive. Typical wheel description as it should appear on an order: Print #IN5480, 25 x 2 x 1 -- 97A801-H/G/F9-B90 4 - 7." slots to an 18" dia. "Perforated" Outer Row 14 on 227. 14 on 227. 14 on 227. Hon 227.0 14 on 227. Bolt Hole Patterns Next Row Next Row 7 on 167. 7 on 167. 7 on 167. 7 on 167. -- 7 on 15 7 on 15 7 on 15 -- -- Next Row 7 on 87. 7 on 87. -- -- -- Next Row 3 on 47. -- -- -- -- 30" Disc 23 xTx ID IN5710 0 IN5720 7. IN5730 7. IN5740 7. IN5750 1 IN5760 17, IN5770 17. IN5780 17. IN5790 2 IN5800 3 IN5810 4 IN5820 5 IN5830 6 IN5840 7 IN5850 8 IN5860 9 IN5865 97. IN5870 10 IN5880 11 IN5890 12 IN5900 13 IN5910 14 IN5920 15 IN5930 16 1N5940 17 IN5950 18 IN5951 187. IN5960 19 1N5970 20 IN5980 21 IN5990 22 ID >0<2 >3<9 >916 >16^20 >20 Outer Row 16 on 267. 16 on 267. 16 on 267. 16 on 267. 16 on 267. Dowel holes - Dowel holes will be supplied as shown on sketch unless otherwise specified. Slots - Standard pattern is 4 radial slots, V8" or wide, to a specified diameter. Perforations - Only one pattern is available. Perforations are 7a" in diameter on 17/' centers. Max. wheel thickness - 3" useable abrasive. Typical-wheel description as it should appear on an order: Print #IN5750, 30 x 2 x 1 -- 97A801-H/G/F9-B90 4 - 7." slots to a 20" dia. "Perforated" Bolt Hole Patterns Next Row Next Row 12 on 22 12 on 22 12 on 22 12 on 22 -- 12 on 18 12 on 18 12 on 18 -- -- Next Row 8 on 11 8 on 11 -- -- -- Next Row 3 on 47. -- -- -- ----. MIL 000155 7-7 Resinoid Disc Wheels Application and Selection Disc grinders are high production machines, used to grind flat and parallel parts. The machines can be hori zontal or vertical spindle, single or double disc. The abrasive discs that are used on these machines are manufactured with a pattern of nut inserts molded into the back of the disc. These inserts are used to mount the abrasive disc to the steel machine plate. (The nut inset pattern must exactly match the hole pattern of the steel machine plate.) Most common machines used: Gardner Besly Mattison Basic feed methods: 1. Thrufeed 2. Rotary 3. Oscillating 4. Reciprocating (gun type) Availability The abrasive discs are available in a variety of composi tions and styles that when properly selected and com bined will provide optimum grinding performance. Abrasive Alum. Oxide Silicon Carbide Combination Alum. Oxide Type 2A 4A 12A 9A 97A 29A 6C 7C CA C2A C4A C12A C9A Grit Size coarse 24 30 medium 36 46 54 60 70 80 fine 90 100 120 150 180 220 Grain Combination nominal 1 Availability -- MAX THICKNESS - 3" useable abrasive -- hardback - 5/8" thick (not used in describing wheel thickness) -- inserts - 3/8" - 16 unless otherwise specified -- dowel holes - will be furnished as shown on the sketches on page unless otherwise specified. 7-8 List of commonly ground parts: Alnico magnets Bearing parts Castings (various materials) Chainsaw blades Clutch plates Dies Gears Hand tools Insulating brick Knives Piston rings Plumbing fixtures Springs Valve plates Washers and many others See the selection guide for illustrations and information. Plate Mounted, NID Application Recommendation Alloy Steel R5A207-I7-BAM Alnico: Roughing A301-K6-BA Finishing E5A80-I7-B320 Grey Iron R5A24-M5-BC Malleable Iron R5A207-N5-BC Spring Steel A24-M5-BC Grade Structure Bond St. med. hd. dense open Resin DJO9 EKP F LO GMR HN 1 ii 890 Availability 1. Smooth face 2. Perforated face - see the selection guide for illustra tions and information. * 3. Slotted - 4 radial slots equally spaced - 1/8" or 1/4" wide to a specified diameter. 4. Zoned wheels or variable density MIL 000156 Availability And Ordering A. Availability 1. Grain Type - 2A, 4A, 9A, 12A, 97A, 29A.CA, C2A, C4A, C9A, C12A,6C 2. Grit Size - 24 thru 220 3. Grade (hardness) - D thru R 4. Structure - 9 and 11 are standard 5. Bond Type - B90, B320 only 6. Max. Useable Thickness - 3" 7. Hardback - All s/8" thick and not used in describing wheel thick ness (useable abrasive only in describing thickness). 8. Inserts 3/" - 16 unless otherwise specified B. Slots 1. Number: 4 radial slots from ID-Std. Width: V8" - 'A" available Length: to be specified on order Depth: fixed to hardback 2. Description of slots must appear on the order with the general wheel description. EXAMPLE: 4 - 'A" radial slots to 20 dia. Slots will not appear on any prints. C. Perforations 1. Available in 30", 26", 23", and 18" OD wheels. 2. Hole pattern is not variable and the hole diameter is fixed at 3. "Perforated" must be specified on the order with the general wheel description. Perforations will not appear on any prints. 4. A wheel can be both slotted and perforated. Data as it would appear on a typical order for a slotted wheel with a perforated face: 30 x 2 x 1 4-'A" slots to a 20 dia. "Perforated" D. Zoned Wheels 1. Disc wheel can be graded in the following ways: a. Single grade - EXAMPLE: 97A801-L9-B90 (B320) b. Two zone - EXAMPLE: 97A801-K/J9-B90 (B320) c. Three zone - EXAMPLE: 97A801-L/K/J9-B90 (B320) 2. Grit type or size cannot vary between zones: EXAMPLE: 60 grit inner zone 80 grit outer zone 3. Letter grades cannot vary more than one grade between zones: INCORRECT EXAMPLE: 97A801-K/I/9-B90 (B320) CORRECT EXAMPLE: 97A801-K/J/9-B90 (B320) 4. Grade breaks in zone wheels are fixed. Note: Some disc wheel manufacturers show the grade break along with the wheel size. EXAMPLE: 30 x 2 x 19* x 1 Grade break (Not used in any Cincinnati Milacron wheel description) *19" would be the diameter where the grade breaks 5. In most cases a suffix such as this follows the bond symbol. Below is the explanation. Single Disc Grinder Typical Wheel Size 18 x 3 x -- Nut inserted Disc Wheel Typical Wheel Grade -- C2A601-P9-B90 Necessary Ordering Information EXAMPLE 1. Print number IN5750 2. Disc dimensions OD x thickness x ID) 30x2x1 - 3. Disc specification 97A801 -G/F/E/11-B90 (B320) 4. Slots (if needed) 4-1/4" slots to a 20" dia. 5. State "Perforated" Perforated (if needed) MIL 000157 7-9 Basic Principles Background Disc wheels are used on disc grinders to grind flat sur faces. These wheels are resinoid bonded and usually used in sets of two. They are not mounted like most standard wheels. There is a series of nut inserts in the "back" of the wheel. Bolts are placed through a plate and screwed into the nut inserts in the wheels. There are single disc grinders (1 wheel set-up), double disc (2 wheel set-up), and triple disc grinders (3 wheel set-up, 1 roughing wheel and 2 finishing wheels). Disc grinders are normally high production grinders. In many applications, one disc grinder will feed a large number of other grinders or assembly operations. Disc grinders use a large number of wheels per machine because of the high production nature and softer wheel grades used for | this operation. Trouble Shooting Problem burning parts scratches Corrective Action Use softer abrasive spec Speed up dresser traverse If using a diamond dressing tool check its condition Consider different type of dressing tool (e.g., star cutter) Increase coolant capacity Reduce disc speed if possible Increase feed rate Use perforated disc Use finer abrasive spec Use smooth face disc Clean coolant tanks and check filters Add finish pass scratches (cont.) sizing Slow down dresser traverse Consider different type of dressing tool (e.g., diamond cluster) Vary feed rate Disc may be too hard or soft; adjust abrasive spec accordingly Increase coolant capacity Reduce feed rate Speed up dresser traverse Consider different type of dressing tool (e.g. star cutter) 7-10 MIL 000158 8 Internal Grinding Wheels Machine -- 1EF70 Internal Grinding Machine Material -- Rockwell "C" 58-62 Operation -- Finish grind recessed hub OD Grinding wheel -- 12A-80-J6-VFME 29A801-J6-VFME 3MSB801-I6-VSAE Machine -- 2EF CINTERNAL Multisurface CNC Grinding Machine Material -- Rockwell "C" 60-62 Operations -- Plunge grind inner ID, face plunge inner face, recip. center bore, vector plunge lip and ID, recip. face. Grinding Wheel -- 12A-80-J6-VFME 29A801-J6-VFME 3MSB801 -16- VSAE 8 Machine -- 2EF90 Internal Grinding Machine Material -- Rockwell "R" 60-64 Operation -- Finish grind bore Grinding wheel -- 4A-60-J4-VFM 9A60-J4-VFM 3MSB601 -14-VSAE Machine -- 273A Universal Internal Grinding Machine Material -- Rockwell "C" 56-62 Operations -- Finish grind roller path Grinding Wheel -- 2A-60-K6-VFM 9A601-K6-VFM 3MSB601 -18-VSAE MIL 000159 8-1 Starting Grade Recommendations Wheel Grades For Internal Grinders Material Type 1 and 5 Alnico Aluminum Aluminum Alloys Ball and Roller Bearings Bearing Races (Form Gr.) Brass Bronze (Soft) Bronze (Hard) Cast Iron Bushings (Cast Iron) Bushings (Steel - Hard) Carbide (Ring Gages, Etc.) Cemented Carbide (Dies, Etc.) Roughing Finishing Chromium Plated Parts (Small) (Large) Connecting Rods Glass Dies - Blanking & Drawing Carbon Steel High Carbon - High Chrome Meehanite Motor Stators Laminated Silicon Steel Steel (Casting) Miscellaneous Forgings Gears Soft Hardened High Speed Steel Hardened Green Grind Monel Metal Molybdenum Cylinders (Aircraft) Roughing Finishing Regrinding Nitrided Steel Cylinders (Aircraft) Before Nitriding After Nitriding Regrinding Rocker Arm Sprayed Metal Steel - General Purpose Castings & Forgings Soft Hardened Nitrided Stainless Steel 300 Series 400 Series Titanium Universal Joint Cups Valve Seats Cast Iron Inside Diameter Stellite Seats Valve Lifter Bodies 12A60-J6-VFM 6C46-K6-VSC 2A60-H6-VFM 97A801-K6-VFM 3MSB801-J6-VSA 6C46-J6-VSC 6C46-J6-VSC 97A601-K6-VFM 97A461-J6-VFM 12A60-H6-VFM 3MSB601-I4-VSA 3MSB601-J6-VSAE 5C120-J6-VSC 5C60-K6-VSC 5C120-J6-VSC 12A80-K4-VFM 12A80-J4-VFM 97A601-L6-VRW 6C80-J6-VSC 12A60-J6-VFM 12A80-J6-VFM 12A46-J4-VFM 2A60-L4-VFM 2A60-L4-VFM 12A60-L4-VFM 2A60-L6-VFM 3MSB601-J6-VSA 9A801-J6-VRW 2A60-L4-VFM 6C60-J6-VSC 12A46-J4-VFM 9A60-I4-VFM 12A46-J4-VFM 12A46-I6-VFM 97A461-J4-VFM 6C60-J6-VSC 6C60-J6-VSC 2A60-L6-VFM 6C60-J6-VSC 2A601-K6-VFM 97A461-M4-VFM 9A60-K6-VFM 12A80-K4-VFM 6C60-K6-VSC 97A601-J4-VFM 6C60-L6-VSC 3MSB1001-K4-VSA 6C46-I6-VSC 9A60-N4-VFM 9A60-04-VFM 12A80-L6-VFM To substitute VRW for VFM, go 1 grade softer. 8-2 Mounted Wheel 9A60-N-V6 6C60-K-V7 9A60-K-V6 9A60-L-V6 6C60-L-V7 6C60-L-V7 6C60-L-V7 2A60- N-V6 2A60-K-V6 9A60-L-V6 5C80-L-V7 5C120-K-V7 5C80-L-V7 5C120-K-V7 9A60-L-V6 9A60-K-V6 9A60-N-VFM 6C80-K-V7 9A80-L-V6 9A80-K-V6 2A60-K-V6 2A60-M-V6 2A60-M-V6 2A60-M-V6 2A60-N-V6 9A60-L-V6 9A601-K-V6 9A60-M-V6 6C60-L-V7 Diamond Wheel i ]) MD120-N100-B 1/8 MD220-N100-B 1/8 MD120-N100-B 1/8 MD220-N100-B 1/8 2A60-N-V6 2A46-N-V5 9A60-L-V6 12A80-L-V6 6C60-L-V7 9A60-K-V6 6C80-M-V7 2A80-M-V6 MIL 000160 Wheel Size & Speed Specification Selection Guide Wheel size recommendations. Wheels should be ordered as close to "ready grind" size as possible. Some allowance for truing the wheel must be made. For pro duction internal grinding operations, wheel can be ordered with decimal sizes to minimize oversize and decrease the amount of truing. Wheel Speeds Due to the size of the hole ground and the necessarily small size of the grinding wheel, it is advisable to use as large a wheel as possible that will enter the hole and still allow coolant to enter the grinding zone to cool the part and benefit the grinding operation. The chart at the right indicates the maximum recommended wheel diameter for a given hole size. Hole diameter to be ground 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/64 3/4 13/16 7/8 15/16 1 1-1/8 1-1/4 1-3/8 1-1/2 1-5/8 1-3/4 1-7/8 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4 4-1/2 5 5-1/2 6 6-1/2 7 7-1/2 8 8-1/2 9 9-1/2 10 . Wheel Diameter Ordered Trued before using 1/8 3/16 1/4 5/16 3/8 7/16 1/2 1/2 5/8 11/16 3/4 3/4 7/8 7/8 15/16 1 1 1-1/8 1-1/4 1-3/8 1-3/8 1-3/8 1-1/2 1-3/4 2 2 2-1/4 2-1/2 2-1/2 3 3 3-3/8 4 4 4-1/2 5 5-1/4 5-3/4 6 6-1/2 6-1/2 7 7 7/64 11/64 7/32 9/32 11/32 13/32 7/16 1/2 17/32 19/32 21/32 23/32 3/4 13/16 7/8 31/32 1 1-1/8 1-1/4 1-3/8 1-5/16 1-3/8 1-1/2 1-11/16 1-7/8 2 2-1/4 2-7/16 2-1/2 2-13/16 3 3-3/8 3-3/4 4 4-1/2 4-7/8 5-1/4 5-5/8 6 6-3/8 6-1/2 7 7 Wheel Width Average 3/16 1/4 5/16 3/8 7/16 1/2 1/2 1/2 5/8 5/8 3/4 3/4 7/8 7/8 1 1-1/8 1-1/4 1-1/4 1-3/8 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1 1 1 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 Standard range 1/8-3/16 5/16-1/4 1/4 5/16 5/16-3/8 5/16-7/16 3/8 -1/2 3/8 - 1/2 1/2 - 5/8 1/2 - 5/8 1/2 - 5/8 5/8-1 5/8 -1 3/4 -1 3/4 - 1 3/4 -1 3/4 - 1-1/4 1 -1-1/4 1 - 1-1/4 1 -1-1/2 1 - 1-1/2 1 -1-1/2 1 -1-1/2 1 -1-1/2 1 -1-1/2 1 -1-1/2 1 -1-1/2 1 - M/2 3/4 -1-1/2 3/4-1-1/2 3/4-1-1/2 3/4 -1-1/2 3/4 - 1-1/2 3/4 - 1-1/2 3/4-1-1/2 3/4- 1-1/2 3/4-2 3/4-2 1 -2 1 -2 1 -2 1 -2 1 -2 1 -2 Diam. Of Wheel in Mm. Inches (Approx) Vb V. 7. % V. '/, 7, 1 I'/. I'/, 13/4 2 27. 2'/, 2'/. 3 37, 4 5 6 3 6 9 13 16 19 22 25 31 37 44 50 57 63 69 75 88 100 125 150 4000 Ft. 20.3M 122,230 61,116 40.744 30.558 24,446 20.372 17,462 15,279 12,275 10,185 8,725 7,639 6,790 6,110 5,560 5,093 4,360 3,820 3,056 2,546 4500 Ft. 22.9 M 137,510 68,756 46,594 34,378 27,502 22,918 19,645 17,189 13,750 11,460 9,820 8,594 7,640 6,875 6,250 5,729 4.910 4,297 3,438 2,865 Peripheral Speed in Feet per Minute and Meters per Second 5000 Ft. 5500 Ft. 6000 Ft. 6500 Ft. 7000 Ft. 7500 Ft. 25.4M 27.9M 30.5M 33.0M 35.6M 38.1 M 152,790 76,392 50,928 38,196 30,557 25,464 21,826 19,098 15,300 12,730 10,920 9,549 8,490 7,640 6,940 6,366 5,460 4.775 3,820 3,183 Revolutions per Minute 168,060 84,032 56,021 42,016 33,615 28,011 24,009 21,008 16,800 14,005 12.000 10,504 9.340 8.405 7,640 7,003 6,000 5,252 4.202 3,501 183,350 91,672 61,115 45.836 36,669 30,557 26,192 22,918 18.350 15,280 13,100 11,459 10,190 9,165 8,340 7,639 6,550 5,729 4,584 3,820 198,624 99,312 66,208 46,656 39,724 33,104 28,374 24,828 19,862 16,552 14,187 12,414 11.034 9,931 9,028 8,276 7.093 6,207 4,965 4,138 213,903 106,951 71,301 53,475 42,780 35,650 30,557 26,737 21,390 17,825 15,278 13,368 11,883 10,695 9,722 8,912 7,634 6,684 5.347 4.456 229.182 114,541 76,394 57,295 45,836 38,147 32,740 28,647 22,918 19,098 16,370 14,323 12,732 11,459 10,417 9,549 8,185 7,161 5,729 4,774 8000 Ft. 40.6M 244,461 122,230 81,487 61,115 48,892 40,743 34,923 30,557 24,446 20,371 17,461 15,278 13,581 12,223 11,111 10,185 ' 8730 7,639 6,111 5,092 8500 Ft. 43.2M 259,740 129,870 86,580 64,935 51,948 43,290 37,105 32.467 25,974 21,645 18,552 16.233 14,430 12,987 11,806 10,822 9,276 8,116 6,493 5.411 MIL 000161 Basic Principles A. Types of Parts Bearing races, bushings, inserts, valve lifters, etc. B. Selection and Application of Wheels 1. Plunge Grinding - Usually on ball groove or simi lar parts. Usually hard. Use finer grain 60-80 because roughing and finishing are often done on same cycle. Finish is obtained by spark out and frequency of dress. 97A801-L6-VFM would be a good general purpose grade. 2. Oscillating Grind - Usually used on bushings, inserts, lifter bodies, and other parts with straight bores. Parts can be done individually or grouped. In both cases it is a good idea to start with a wheel near the size of the bore for two reasons: to establish a good line contact and to minimize wheel change time. A good general purpose wheel grading would be 29A601-M6-VFM or 3MSB801-L6-VSA or 29A801-M6-VFM. 3. For larger diameter work, use softer grades and more open structure (6). 4. For smaller diameter work, use harder grades and closer structure (4). 5. For small hard parts where down time for wheel change is critical, CBN should be investigated. C. Trouble Shooting 1. Coolant is very important in guarding against heat. Part should be flooded inside, and on sen sitive parts an extra nozzle flowing on outside of part is helpful. 2. Due to line of contact, very good RMS values can be generated with medium grit sizes, simply by slowing down oscillation or increasing spark out. 3. Chatter - Usually the result of a hard wheel, weak quill, or possibly the wheel has worked loose. 4. Rules of thumb - Use friable grain 9A, 12A, 97A, 29A, WA, JA. Try to control stock to a minimum. Use good wetting coolant; lubrication is not as important as wettability and volume. i 4j Internal Grinding { Internal grinding is a method whereby the inside diame- j ter of a hole is enlarged with a grinding wheel to an i accurate size and desired finish. The work is usually mounted in a chuck or fixture which fits on the work head spindle so it can be rotated while grinding the I.D. The wheel head or spindle is mounted on a cross slide ) to give the wheel adjustment to grind the diameter of the work. The wheel head assembly is mounted on a recip- ' rocating table that will traverse the wheel thru the bore - while grinding. It is common for holes to be ground to a , tolerance of plus or minus .0001 and under special con- ' ditions, tolerances of .000025 of an inch, with finishes that seldom require lapping. Hole sizes range from approximately 1/16 inch diameter to the maximum capacity of the machines available. When the work becomes too large and awkward to rotate, the holes can be ground with a planetary type grinder. In this type of machine, the spindle and the wheel revolve about their own axis and also revolve ; about the axis of the hole in the work. The work is > mounted on the table and the table traverses toward the -. wheel. There are three standard styles of wheel heads for most grinders, a wheel head with a solid projection spindle, a wheel head with a removable quill type of spindle, and a sleeve or enclosed type of spindle. On miscellaneous work, toolroom and small lots, the quill type wheel head is generally used because several size quills can be used in the same head. The proper quill is the shortest and most rigid one avail- able that will work satisfactorily in the hole to be ground. If too large a quill is used, it will prevent the wheel from being worn down to a small stub and will block the flow of coolant, allowing the work to become too hot. Long quills must be larger in diameter for a given hole than short stubby quills, to help prevent deflection and vibration. If it is necessary to use a long, thin quill, the selection of the correct grade becomes more critical. The wheel must be soft enough to cut freely with the light pressure that can be applied without springing the quill and still hard enough to remove stock without too much breakdown. ; The sleeve or enclosed style spindles are recommended for use when grinding holes 2'h" diameter or larger. MIL 000162 work speed is generally 150 to 200 SFPM for most e- classes of work. The work speed can be used to vary the grinding action of the wheel. If the wheel acts hard, increasing the work speed will help the wheel to break down faster and cut more freely. If the wheel is breaking 0. down too fast, decreasing the work speed will make the le wheel act harder. the Always true a new wheel before staring to grind. It is P- very important to use a sharp diamond on small wheels. e The small phonopoint diamonds are recommended for a use on small wheels on long slender quills. ma The length of the grinding stroke in relation to the length of the hole to be ground generally controls the straight ness of the hole. On open or thru holes, the wheel ster should withdraw an equal amount from each end of the hole to avoid a tapered hole, the stroke should be adjusted to allow the wheel to withdraw from both ends of the hole approximately 1/4 inch for wheels 1/2 to 3/4 inch wide, and 1/4 to 3/8 inch for wheels wider than 3/4 inch. The wheels should never be withdrawn more than half the wheel width. If the wheel is wider than the the length of the hole, the wheel should remain in the hole approximately the length of the work. nost On blind holes, the wheel should not be withdrawn from 5, a the open end of the hole during the grinding cycle, if id a possible, to prevent grinding a tapered hole. If a recess or relief is not provided at the bottom of the hole, the stroke should be adjusted to reverse the stroke just before touching the bottom of the hole on the roughing ^I vail- und. Internal Grinding om Starting Grade Only low Ceramic (MSB) Recommended for Steels Harder >le Than 50RC nd I he | Wheel Diameter Wheel Grade I. e the 00 1 1" 2" 3" 4" 5" 5MSB1201-M4-VSAE 3MSB1001-L6-VSAE 3MSB801-K6-VSAE 3MSB801-J6-VSAE 3MSB601 -16-VSAE -nde?1 part of the grind cycle. When finish grinding, the wheel can be fed manually past the reversing dog to clean up the stock left in the bottom corner of the hole. Traverse speeds and feed are generally controlled by the characteristics of the job, the material, hardness, length and diameter of the hole, tolerances, etc. The tra verse speed should be in proportion to the finish required and the width of the grinding wheel. The wheel infeed or depth of cut will vary with the material, hard ness and finish required. As a general rule, feeds of .0005 for each pass is satisfactory, except when rigidity of quill, or lack of it, makes it necessary to reduce feed or makes it possible to take heavier cuts. Whenever possible internal grinding should be done wet. The coolant will help keep the wheel clean, improve finish and cool the work and wash away the grinding swarf. The conventional automatic internal grinder has a con stant rate of feed per stroke or pass of the wheel, regardless of the stock in the work or the resistance to penetration of the wheel. In the controlled force system of internal grinding, the cross feed screw and constant feed per stroke is replaced by a hydraulic cylinder, dur ing the infeed part of the grinding cycle, which keep a controlled force or pressure against the grinding wheel. The rate of stock removal per pass is controlled by the ability of the wheel to grind the material at a given pres sure. With this method of grinding, the problem of spin dle or quill deflection is greatly reduced or eliminated. 8 MIL 000163 * MywffliiMMMii Internal Centerless Grinding This method does not use a chuck and has no fixed centers; the work rolls on its own O.D. The bore is gen erated from the O.D., producing good concentricity between I.D. and O.D. The set-up consists of a regulat ing wheel, a support roll, and a pressure roll, the work must be cylindrical on the outside. The regulating roll drives the work and also acts as a brake, preventing the work from being driven by the grinding wheel. The support roll is fixed below the work, and the pressure roll is mounted on a swinging arm that holds the work in contact with the regulating roll and support roll. When work support shoes are used instead of rollers, the work is driven by a rotating back plate. The internal centerless grinders are generally classified as "On-center work roll arrangement" or "Off-center work roll arrangement." On-center machines have the rolls positioned so that the work, grinding wheel and regulating roll are all on the same centerline (note Sketch #1). Off-center machines have the work support rolls posi tioned so that the grinding wheel centerline is above the work regulating roll centerline (note Sketch #2). Due to the angular relationship of the regulating roll and support roll, successively loaded parts even with some variation in O.D., are on the same vertical centerline, making it possible to grind such parts to close tolerances. This type of internal grinder works exceptionally well to grind rings, sleeves, bearing cups and cones, cylinder liners, etc., and can be equipped to operate automatical ly when grinding small parts. Parts too large to be loaded automatically can be ground, but must be insert ed manually one at a time. Wheel Selection: MSB wheels have shown tremendous improvements on most internal applications. The same rules for determin ing size still apply and most grades are in 3 or 5MSB, 80-120 Grit, I thru N grades, depending on the part size. With this set-up the maximum support is given to the work and you can accurately grind parts that have a thin wall section with very little or no distortion. MIL 000164 8-6 Internal Grinding Since the commercial introduction of CBN by General Electric in 1969, the use of this abrasive has grown at a steadily expanding rate. After considerable research and experimentation, it was found that CBN wheels could be used successfully for internal grinding operations. Cincinnati Milacron was a pioneer in bore grinding development with vitrified CBN. Today, Milacron contin ues its leadership position by introducing new products such as Marathon 2. The advantages which CBN abrasives bring to other forms of grinding also apply to internal grinding operations: High stock removal Long wheel life / High G-Ratio Greater precision, better quality Increased productivity Lower total cost per piece Machine Specifications Modem abrasives (superabrasives) and machines have developed the art of grinding into a highly efficient pro duction tool. Work tolerances on a production basis have gradually been reduced from one thousandths of an inch to a few millionths of an inch. Surface quality is now consistently measured and pro duced in microinches. All this has been possible because of the new abrasive products which were devel oped and the special grinders which were designed for superabrasive wheels to produce accurate parts and reduce grinding costs. Internal machines should be complete with the following capabilities to optimize the use of CBN: Rigid designed spindle and work fixture Higher than normal wheels speeds >6500-12,000 SFPM Accurate feed systems Grinding fluid Rotary diamond dresser If possible, in process and post process gaging Wheel Selection Any successful grinding operation depends on choosing the right wheel for the job. The wheel selected will affect the material removal rate and the life of the grinding wheel, the selection of a CBN wheel should be thought out carefully. Like conventional wheels there are several factors to consider. With CBN there are two additional items to decide upon -- concentration and depth of useable abrasive. Wheel Grade Variables I. Grain Type 2BN uncoated crystal -- CBN vitrified XBN* microcrystalline crystal -- CBN IBN nickel coated -- CBN resin RD uncoated crystal -- diamond/vitrified MD uncoated crystal -- diamond/resin CMD nickel coated crystal -- diamond/resin DMD nickel coated crystal -- diamond/resin EMD nickel coated crystal -- diamond/resin AMD copper coated crystal -- diamond/resin Listed above are the most common diamond and CBN crystals used by Milacron. However, for internal grinding of ferrous materials 2BN is used in vitrified bonds exclu sively. RD diamond is used in vitrified bonded diamond of grinding non-ferrous materials. II. Grit Size CBN abrasive grit size greatly influences material removal rates and surface finishes. For high material removal rates, use coarse grit size wheels. For good sur face finishes use finer mesh size. 8 CBN Mesh Size Range 46 60 80 100 120 150 180 220 240 280 320 400 Finer 400 Finer 400 1200 Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Vitrified Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin Bonds Resin 8onds Expected Finish 35 RA 32 24-30 22-24 20-22 18-20 16-18 14-16 12-14 10-12 8-10 6-8 4-6 4-6 2-4 'XBN used largely for alternate CBN types. MIL 000165 8-7 I 4? III. Hardness Hardness is determined by the percentage of bond pre sent in the wheel composition. Hardness dictates the strength or tenacity of grinding action. Marathon and Marathon 2 have different ranges of hardness which enhance the performance. MARATHON PRTU SOFT -<------------- HARD MARATHON 2TM M N O P Hardness should be varied depending upon the stock removal rate required, wheel life expected and De (arc of contact). IV. Concentration Concentration can be described as the number of superabrasive particles per cubic inch of resin material. The higher the concentration the longer the wheel life. Higher concentration will also increase the normal and tangential grinding forces. A rule of thumb is to use low concentration wheels for low stock removal and large areas of contacts while using high concentration for high stock removal and smaller areas of contact. Vitrified Range 80 20% by volume 57.6 cts/in3 100 25% by volume 72 cts/in3 125 31.25% by volume 89.9 cts/in3 150 37.5% by volume 107.9 cts/in3 164 41% by volume 118.0 cts/in3 175 43.75% by volume 125.9cts/in3 200 50% by volume 144 cts/in3 Resin Range 44 11% by volume 31.6 cts/in3 66 16.5% by volume 47.4 cts/in3 80 20% by volume 57.6 cts/in3 88 22% by volume 63.3 cts/in3 100 25% by volume 72 cts/in3 * 125 31.25% by volume 89.9cts/in3 IV. Bond Type The four bonds used with superabrasive wheels are resin, metal, electroplated, and vitrified. Vitrified bonds are used for most production bore grinding operations. Resin and metal are used where fast removal and dura bility are required. Electroplated is used where high stock removal is needed with no significant requirement on tolerances and/or surface finish. Vitrified bonds provide the best bond type for production bore grinding applications. Vitrified bond is the only type which contains porosity and the necessary chip clear ance while yielding extremely tight tolerances and finish es below 32RA. C.M.P.D. Vitrified Bond Types Marathon VHA -- AI2O3 as secondary abrasive VHC -- SiC as secondary abrasive V -- no secondary abrasive { \ \ Marathon 2 VEA -- Open structure with Ala03 as secondary abrasive VEC -- Open structure with SiC as secondary abrasive VEB -- Open structure with no filler ' i j j Marathon 2 with patented filler ^ VMA -- Open Structure with Al203 and patented filler < VMC -- Open structure with SiC and patented filler t VMB -- Open structure with no filler and patented filler Depth of Abrasive } Normally a wheel for bore grinding <.500" will be ? made as a solid superabrasive wheel. Wheels larger jj than .500 will generally have a '/,s or 'U useable rim. * This is designated with a depth marked on the end of a I wheel specification. EXAMPLE: 2BN100-R100-VHA7e. 1 MIL 000166 8-8 1^ Trouble Shooting problem 1. Feed lines or spirals on workpiece 2. Scratching of work Possible Causes Poor wheel dressing. Wheel too hard. Wheel head tipped. Wheel too soft. Faulty wheel dressing. Wheel too coarse. Dirty coolant. 3. Burning of Wheel too hard. f workpiece Work speed too slow. Wheel infeed too fast. f Poor coolant flow. 4. Wheel glazing Wheel too hard. (shiny appearance) Wheel too fine. Poor wheel dressing. r Poor quality/quantity coolant. 5. Wheel loading 1 (metal lodged in wheel pores) Wheel too fine. Wheel too hard. Wheel too finely dressed. Poor coolant flow. Insufficient wheel breakdown. 6. Bell-mouthed hole Tipped workhead. Misalignment of center heights. Overtraveling of wheel. 7. Tapered hole Wheel too soft. Uneven travel past each end of hole. 8. Out-of-round hole Overheated during previous rough grinding and became distorted. Rotating fixture out of balance. Hole distorted after front face grinding. 9. Chatter marks Wheel too hard. Spindle material not rigid enough. Defective belt. Wheel out of balance or truth. Dust or other particles inside wheel pulley. Worn spindle. Machine not on solid foundation. Suggested Correction Redress wheel carefully. Use softer wheel or reduce wheel feed. Realign wheel head. Use harder grade wheel. Check for cracked or loose diamond and redress. Use finer grit wheel. Change coolant. Use softer grade wheel. Increase work speed. Reduce wheel infeed. Ensure coolant directed at grinding contact. Use softer grade wheel. Use coarser grit wheel. Check diamond sharpness - redress. Reduce oii level - increase amount of coolant. Use coarser grit wheel. Use softer grade wheel. Give a more open dressing to wheel. Increase supply and clean coolant. Increase work and traverse speed. Realign workhead. Carefully "zero" centers. Reduce overtravel from both ends. Use harder grade wheel. Adjust overtravel to be equal on both ends. Before finish grinding loosen clamps and retighten one at a time. Balance rotating fixture. Grind front face before grinding the hole. Use softer wheel. Replace spindle. Replace belt. Balance and/or true wheel .. .avoid use of bushed wheels. Clean inside surface of pulleys. Replace spindle. Assure machine is properly aligned and not adjacent to heavy vibrating machines. MIL 000167 MICRO-CENTRIC and Chucking Grinders Brief Specifications' Work Capacity Work Diameter Range.............. Grinding Wheel Maximum Diameter................... Minimum Diameter.................... Hole Size.................................. Width (Max.)............................. Motor.......................................... Surface Speed With New Wheel Headstock Speed Range............................ Orientation................................ Motor.......................................... 1 Specifications subject to change without notice Consult factory for wider wheel widths 0.5 to 7.1" (12 to 180 mm) 24" (609 mm) 17" (431 mm) 12" (304 mm) 4" (102 mm)2 20 hp (15 kW) 8500 sfpm (43 m/s) Variable. 30 to 600 rpm 0 or 30' 1 hp (0.7 kW) MIL 000168 rK Series Cincinnati Milacron's new RK Series 220-HS ChuckingType Grinder brings precision, high-volume infeed grind ing to round parts whose flanges and other irregularities make centerless and centertype grinding impractical. Built to complement the proven RK Series Centerless Grinders, our standard 20 hp (15 kW) 220-HS, featuring a variable speed headstock (HS) work drive system, is ideally suited for grinding diameters, shoulders, tapers, radii, grooves and similar operations without sacrificing high production. And like the RK Centerless, the simplicity designed into the 220-HS contributes directly to its overall reliability, durability and ease of operation. Simple modular build and mechanical design combine with advanced features to make these machines remarkably accurate and affordable. Sturdy, Smooth Running Headstock The variable speed servomotor work drive system has a broad range of part rotational speeds programmable in revolutions per minute. To assure a high degree of grind ing accuracy, the drive plate rotates on precision taper roller bearings that are lubricated for life. No mainte nance required here. "Standard" 220-HS models feature 0 or 30 headstock orientation though machines can be built to any custom angle within this range. Work can be mounted in chucks or draw-in collets. Precision Components RK Series 220-HS machines are built on an epoxy gran ite base, selected for its superior rigidity, vibration damp ing and thermal characteristics. Infeed axis feed slide combines anti-friction ways, brush less AC servomotors, precision ballscrews and digital feedback. The result gives you compensation with 0.000004" (0.1 micron) resolution. The FILMATIC cantilever-style grinding wheel spindle bearing system with hydrostatic lift provides long-lasting, hydrodynamic, self-centering support which is consistent under varying grinding loads. High dynamic and static rigidity provide 0.000004" (0.1 micron) rotational accuracy. CNC or cam-type anti-friction profile grinding wheel tru ing with selectable rate servomotor-driven traverse and diamond axes provide 0.000004" (0.1 micron) resolution. DMC Grinding Control The Multi-Axis DMC (Dedicated Motion Controller) is the standard system for all RK Series Grinding Machines. It's a small unit with relatively few controls -- easy to learn, easy to set up and easy to operate -- yet packed with flexibility. Comprehensive diagnostics and cycle status display provide detailed operator information. Simple, direct con trols give you the accuracy, speed and consistency of servo control with the common sense operation of a manual machine. Commonality and Support Incorporating many of the same components as the RK Centerless, the 220-HS uses 95% identical and inter changeable electronics, truing unit, feed motor and ballscrews to make maintenance easy for users of exist ing RK machines. Milacron has the machines, controls, wheels, fluids, training, service, parts and process expertise, providing a total support package that's second to none. Grinding Wheel Grades General Purpose -- 97A601-K6-VFME Precision Finishing -- 29A801-J4-VRWE Ceramic --3MSB801-J6-VSAE Larger diameter parts require slightly softer grades. Standard Machine Features Epoxy granite machine base Anti-friction slide-way systems throughout Simple, precise DMC (Dedicated Motion Controller) 0.000004" (0.1 micron) machine resolution Multi-axis servomotor machine motions FILMATIC grinding wheel spindle bearings Externally mounted grinding wheel motor Isolated stand-alone hydraulics Machine mounted electrical cabinet Variable speed servomotor work drive system 0 or 30 Headstock orientation Totally enclosed grinding zone Optional Equipment Various work holding devices CNC grinding wheel truing Rotary diamond roll grinding wheel plunge dresser Variable frequency grinding wheel drive Automatic grinding wheel balancer Automatic gaging systems Coolant filtration and refrigeration equipment Auto-loaders Various Programmable Controller alternatives MIL 000169 9-2 Starting Grade Recommendations MICRO-CENTRIC 29A1001-J6-VAE Grinding two track bearings simultaneously requires special radius truing unit. 3MSB1001 -16-VSAE 29A801-K4-VAE A variety of bearing races are ground on this No. t MICRO-CENTRIC. 3MS8801-J4-VSAE 29A801-J4-VFM Shoe-type centerless grinding a variety of automo tive front wheel spindles. 3MSB801-J4-VSAE Chucking 29A1001-K4-VFME Face and 00 of large outer bearing are ground simultaneously. 3MSB1001-J4-VSAE 97A1001-K4-VRWE Formed wheel automatic grinds centering balls 3MS81001-J4-VSAE 9-3 MIL 000170 Application Know-How Numerous applications have been effectively processed on MICRO-CENTRIC Grinders. The following illustra tions show some examples of the machine capability and factory-based process knowledge which support your Cincinnati Milacron Marketing Company Field Engineer's recommendation for a machine to tackle your production requirements. Bail Tracks Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: Common Carrier Radius, 0 to .875" convex or Rotary Diamond Cartridge Part Range: 2" to 10" diameter Machine: No. 2 MICRO-CENTRIC Truing: Common Carrier Radius, 0 to .875" convex or Rotary Diamond Cartridge Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: Common Carrier Radius, 0 to .875" convex (Reciprocator for lateral spindle feed) Part Range: 2" to 10" diameter Machine: No. 2 MICRO-CENTRIC Truing: Common Carrier Radius, 0 to .875" convex Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: Dual Position Radius, 0 to .750" convex or Rotary Diamond Cartridge 7^777?7?^ Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: Dual Position Radius, 0 to .750" convex or Rotary Diamond Cartridge Tapered Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: Profile -- Sine Bar Attachment (straight or crowned taper) Part Range: 2" to 10" diameter Machine: No. 2 MICRO-CENTRIC Truing: Profile -- Sine Bar Attachment (slight or crowned taper) Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: 30 Angular-Double Diamond Holder Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing.-Double Angle Part Range: 2" to 10" diameter Machine: No. 2 MICRO-CENTRIC Truing: Double Angle 9 Part Range: .5" to 4.5" diameter Machine: No. 1 MICRO-CENTRIC Truing: Profile Part Range: 2" to 10" diameter Machine: No. 2 MICRO-CENTRIC Truing: Profile Part Range: 2" to 10" diameter Machine: No. 2 MICRO-CENTRIC Truing: Ball Bushing Profile (4 operations) MICRO-CENTRIC & Chucking Grinder Wheels Commonly In Stock In Various Grades -- 29A, 97A, MSB 24x3x 12 24x2x 12 24x 1 x 12 24 x V2 x 12 20x2x 12 20 x 1 x.,12. 20 x 7z x 12 20 x '/2 x 12 18 x 1 x 12 18 x 72 x 12 MIL 000171 9-4 Machine And Wheel Data Race Grinding (Bearings) Race Grinding refers to the precision form grinding of outer and inner ball of roller bearing "Raceways" (usually referred to as the "Ball Track" and the "Roller Path"). Wheels used for internal grinding the raceway in the outer ring are normally Type 1 straight wheels with spe cial faces formed to the contour of the raceways. Wheels range from approximately 1/2" to 6" in diameter, thick nesses are determined by the width of the raceways, and are always specified decimally. One special applica tion, called "Cross-Axis" grinding, involves grinding the inside diameter of large spherical roller bearing "outers." This employs the use of the rim (outer edge) of a Type 6 Cup Wheel where the axis of the wheel is at 90 to the axis of the workpiece. External grinding of the matching raceway in the "inners' is usually performed with wheel sizes ranging from 14" to 24" diameter. The wheel face thickness (specified decimally) is again determined by the width of the race way. Type 1 straight wheels, or wheels with a hub on one side, are used with formed faces to suit the raceway form. Hubbed wheels are used where the required face thickness cannot be manufactured in a straight wheel and/or where the grinder requires a certain minimum thickness for mounting. Standard operating speeds are 6500 SFPM and 8500 SFPM, with special high production applications on high performance machines operating as high as 16,000 SFPM on external grinders. Where speeds above 8500 SFPM are required, special speed approvals are neces sary. Consult your Cincinnati Milacron Marketing Company Sales Representative. Specification Selection Guide For AISI-52100 and AISI-8620 Heat Treated (Rc 62 to 64) Internal (I.D. ol Outers) Application Ball tracks (plunge) Ball tracks Roller paths Cross-Axis (cups) tor high finish Wheel Specifications Less Than Diameters over 3" Diameter 3"thru 6" 97A1201-L4-VFMD2E 97A1201-L6-VFM 97A801-K6-VFMD2E 97A1001-K6-VFMD2E 97A1001-K6-VFM 97A801-J6-VFMD2E 9A70-I6-VFM 9A70-I6-VFM Set-Up Hints for MICRO-CENTRIC Grinding 1. Check for proper offset. 2. Good starting point .010" down .015" forward. 3. Remember that as the part is ground to size down ward offset increases -- forward offset decreases. 4. The larger the diameter of the part the greater the offset. The smaller the diameter of the part the smaller the offset. 5. Set rear shoe approximately 15 to 20 down from centerline of part. 6. Set front shoe as close to grinding wheel as possi ble. 7. Remember that on larger diameter parts, the front shoe must be moved away from grinding wheel to prevent chatter. 8. Be sure that face of driver is square with axis of grinding wheel spindle. 9. Lowering headstock RPM will decrease chatter. 10. Raising headstock RPM will increase roundness. External (0.0. ofInners) Application Ball tracks (plunge) Ball tracks . Roller paths Wheel Specitications 1Z" thru 24" dia. wheels '/" thick & less Over 'If' thick 97A1001-L4-VFM 97A1201-K4-VFM 97A1001-K4-VFM 9711001-K4-VFM 97A801-J4-VFM 97A1001-J4-VFM When using VRW or VQC go / grade softer. Alternate Grades 29A1201-L4-VRWE 3MSB1201-K4-VSAE 29A801-K4-VRWE 3MSB801-J4-VSAE 29A1001-L4-VRWE 3MSB1001-K4-VSAE For parts 3"-6" diameter use 6 structure MICRO-CENTRIC Set-Up Diagram 1 J5 k* J ? 1 T 9-5 MIL 000172 I Typical Machine Manufacturers Bryant Landis Cincinnati Internal Race Grinding Machines (Refer to Internal Grinding Section) External Race Grinders Bryant Grinder Corp., Springfield, VT Machine/Model MCM External Chucker CENTRA-FORM Wheel Size DT H 6-20 17. max. 17,-12* 20 17. max. 12* SFPM 8,500,12,000, 16,000 8,500.12.000, 16,000 *Note:Wheels with 12" nominal holes frequently have decimal oversize based on wheel speed: 8,500 SFPM and less -- 12.000 hole; 12,500 SFPM --12.050 hole Bryant's new model Ultraline Internal Grinder. Metal bond diamond cup dresser capable of using vitrified and resinoid CBN grinding wheels. Typical grade for this type of grind is 2BN150-MI 64-VMB Cincinnati Milacron, Cincinnati, OH Machine/Model Wheel Size SFPM DT H MICRO-CENTRIC #1 20 1 max. 12 6,500 MICRO-CENTRIC #2 20 2 max.. 12 6,500 MICRO-CENTRIC #1MM 6-20 1.5 max. up to 12* 12,000 & 16.000 MICRO-CENTRIC #1MD 20 2 max. 12 8,500 & 12,000 and #2MD 24 3 max. 12 8,500 ,f% -`Note: 20" diameter wheels for the Model #1MM may also be supplied with 11" holes. *%&** \ Landis Tool Co., Wayneboro, PA Machine/Model ___ f2 RACE-A-WAY ^acentric Type R [^jugate 4.8 type R Wheel Size DT H 12 3/16-1 5 16 1 8 61 17. SFPM 11,200 Special* Special* Cincinnati Milacron's RK Series 220-HS Chucking-Type Grinder. 9 MIL 000173 9-6 Basic Principles Of MICRO-CENTRIC And Chucking Grinders 1. Type of parts. Bearing parts, races, rollers, cups, small pistons, gears, nozzles, etc. Micros and chuckers are a necessity on high production of parts difficult to hold. Most micros use the shoe type holder; most chuckers employ some type of chuck. 2. Selection of Grinding Wheel A. Things to consider: 1. Roughing or finishing 2. Hardness of part 3. Cycle time 4. Type of dresser 5. Finished part criteria B. Steps to take: 1. For roughing, use 60-80 grit; for finishing use 80-120 grit. 2. For soft material, coarse grain and harder grades can be used, i.e. 46-60 in K-M grades. Tough abrasive may also be used (2A). 3. For hard material, finer grain and softer grades must be used, i.e. 80-120 in l-K grades. Most work on Micros is hard and requires more fri able grain (29A). 4. Cycle times are usually short, thus the need for this type of grinder. This is especially valu able in bearing plants where production runs may consist of hundreds of thousands of parts. 5. Listed below are 2 sets of conditions one may encounter and the proper Cincinnati wheel and coolant. Recommendation To Do The Job Soft Part Part: Race Hardness: 35-40 Stock: .025 RMS Finish: 32 micro inch Waveometer: N/A on soft parts Machine Speed: 8500 SFM Wheel: 97A701-N4-VFME Cimstar 60 LF CIMPERIAL 20 at 1-20 Hard Part Race 60-62 .010 12 micro inch 4-5 hi band 8500 SFM 29A1001-L4-VFME Cimstar 60 LF CIMPERIAL 20 at 1-20 The part size has a direct effect on the wheel grading. A smaller part with sharper arc of contact may require a harder wheel. A larger part with more contact area, may require a softer wheel. Trouble Shooting Precision grinding with micros and chuckers employs a unique set of variables. Part sizes can range from 1/4" to 10" or 12" in diameter. Wheel diameters can vary from 6" to 24". Wheel speeds can vary from 6500 SFM to 16,000 SFM. Any of these factors have a noticeable effect on the grinding operation. For large diameter parts, you must use sharp grain, softer grades, and more open structures. Listed below are some problems and some helpful hints for solving them. PROBLEM Poor Finish -- Out of Round -- CAUSE Wheel too soft Diamond traverse too fast Cycle time too short (add sparkout) Not enough grinding fluid or wrong grinding fluid Check hardness of part Wheel too hard Cycle time too short (add sparkout) Not enough grinding fluid Dull diamond Check hardness of part Check Helpful Hints Guide on back cover. MIL 000174 10 Surface Grinding Recommended Starting Grades For Surface Grinding Horizontal Spindle Reciprocating Table Surface Grinders. Material Cast Iron Nonferrous Metal Soft Steel Malleable Iron & Steel Casting Hardened Steel Broad Contact Narrow Contact or Interrupted Cut Form Grinding Crush Dressing-Roughing Crush Dressing-Finish General Purpose Cemented Carbide Roughing Finishing Finishing Wheels Less Than 16" Diameter 97A361-H10-VA 6C36-J6-VSC 12A46-J6-VA 97A461-J4-VFM 12A46-H6-VA 12A601-F10-VA 12A461-I6-VA 97A801-K4-VFM 97A1201-J4-VFM 12A36-I6-VA 5C60-J6-VSC 5C120-J6-VSC MD150-N100-B 1/8 Wheels 16" Diameter and Over 97A361-G10-VA 6C36-J6-VSC 12A46-J6-VA 97A361-J4-VFM 12A36-H6-VA 12A461-F10-VA 12A461-H6-VA 12A801-K4-VFM 97A1201-J4-VFM 12A36-H6-VA 5C60-I6-VSC 5C120-I6-VSC MD150-L100-B 1/8 10 Vertical Spindle Rotary Table Or Reciprocating Table Surface Grinders. Material Cast Iron Nonferrous Metal Soft Steel Malleable Iron & Steel Castings Hardened Steel Broad Contact Narrow Contact or Interrupted Cut Cemented Carbide General Purpose Type 2 Cylinder Wheels 12A301-G10-VA 6C24-I6-VSC 12A30-H6-VFM 12A301-H6-VFM 12A241-G10-VA 97A241-H6-VFM 12A301-F10-VA 97A461-H6-VA 97A461-F10-VA 12A461-H6-VFM 97A461-H6-VA 5C60-J6-VSC 97A301-G10-VA 12A301-G10-VA Type 5 Cup Wheels 12A301-G10-VA 6C24-I6-VSC 6C24-I6-VSC 12A30-H6-VFM 12A241-I6-VA 97A301-I6-VFM 97A301-H6-VFM 12A241-G10-VA 12A461-H6-VFM 12A601-F10-VA 12A461-H6-VFM 971461-H6-VFM 5C60-J6-VSC 97A301-H6-VFM 12A30-H6-VFM Segments 97A241-G10-VA 6C24-H10-VSC 6C24-I6-VSC 12A241-G10-VA 97A301-G10-VA 12A241-H6-VFM 2A301-F10-VFM 97A301-F10-VA 12A361-F10-VA 12A361-H6-VA 971461-16-VA 12A361-G10-VA 5C60-J6-VSC 97A301-G10-VA 12A341-G10-VA MIL 000175 10-1 Surface Grinding MATERIAL ALUMINUM BOILER PLATE & SOFT STEELS 1018,1020 BRONZE CAST IRON STEEL 1034 STEEL 4140 Tool Steel 55 to 62 RC STAINLESS STEEL Non-Magnetic 300 Series Heat Treated 400 Series Fine Finish 2 to 8 RMS GENERAL PURPOSE CERAMIC GRAIN SEGMENTS MEDIUM WORK AREA NO 3WB247-F12-VC4 If Hard Scale Only NO 3WB247-E12-VC2 3WB302-E12-VC2 W836-F12-VC 3WB302-E12-VC4 3WB302-E12-VC2 3WB302-F12-VC4 SEGMENTS SMALL WORK AREA LARGE WORK AREA WA242-G12-VC4 C54-G7-B290-XS (for 60 RMS) WA242-G12-VC C54-G7-B290-XS WA242-B12-VC4 WA242-F12-VC2 WA242-G12-VC4 WA242-G12-VC4 WA242-G12-VC4 JA46-G10-VP4 WA462-E12-VC2 WA242-F12-VC2 WA242-F12-VC2 WA242-F12-VC2 JA46-G10-VP WA462-E12-VC4 WA309-E9-V4-B WA301-H12-VC4 C180-B200-XS WA242-G12-VC4 WA301-G6-VR-B WA301-G12-VC2 WA242-F12-VC2 RING & WHEELS MEDIUM WORK AREA LA301-H8-VP LA301-G9-VP2 ~~ LA301-G9-VP2 LA301-G9-VP2 LA301-G9-BP2 LA301-G9-VP2 WA462-E12-VC4 ~~ WA301-G6-VR-B WA301-H8-VP2 WA301-G9-VP2 Okamoto Column Type ACC 28-60 Typical Wheel Size: 20 x 3 x 8 Typical Wheel Grade: WA461-F12-V4 or 9A461-G10-VA 10-2 MIL 000176 Horizontal Spindle Rotary Table Surface Grinders Material Cast Iron Nonferrous Metal Soft Steel Malleable Iron & Steel Castings Hardened Steel Broad Contact Narrow Contact or Interrupted Cut Carbide Roughing General Purpose Grade Grade 12A361-G10-VC 6C36-I6-VSC 97A461-G10-VC 97A361-H6-VFM 12A46-H6-VC 12A461-F10-VC 12A46-I6-VFM 5C60-J60-VSC 12A461-I6-VC Form Grinding Stainless Steels 300-400 Series Heat Resistant Ni Base Super Alloys A 286 Inconel Rene Udimet Waspalloy General purpose wheel grading for these materials would be: 12A60-J6-VRW 12A54-J6-VRW Specification Guide Horizontal Spindle Grinders Vertical Spindle Grinders (cylinders, cups, and segments) Application Wheel Specifications Application Wheel Specifications Alnico 9A80-H6-VA Aluminum Aluminum 6C36-J6-VSC plate 7C361-H10-VSC Brass 6C36-J6-VSC cast 9A361-H10-VA Bronze 6C36-J6-VSC Brass 6C36-I6-VSC soft 6C36-J6-VSC Bronze hard 97A461-K6-VA soft 6C24-I6-VSC Cast Iron hard 9A36-G6-VA ductile 9A46-J6-VA Cast Iron gray chilled Nihard Chrome plate Die steel hardened annealed Steel soft hard tool and high speed 300 series stainless 9A46-J6-VA 6C46-J6-VSC 9A46-I6-VA 12A70-I6-VFM 9A60-F10-VA 9A46-I6-VA 9A36-J6-VA 9A60-I6-VA 9A60-G6-VA 9A46-J6-VA ductile gray chilled Nihard Steel hard (broad contact) hard (narrow contact) soft tool and die 300 series stainless 400 series stainless 97A301-G10-VA 97A301-G10-VA 6C361-I6-VSC 9A36-F10-VA 9A36-E10-VA 9A46-G6-VA 971241-G10-VA 9A46-I6-VA 9A46-F10-VA 9A24-G10-VA 400 series stainless Stellite Titanium Tungsten 9A46-J6-VA 6C54-I6-VSC 7C601-K6-VSC 7C601-K6-VSC MIL 000177 Machine and Wheel Data Typical Machine Manufacturers Abrasive Machine Heald Arter (Sundstrand) Hill Acme Blanchard KOLee Blohm Magerle Boyar-Schultz Mattison Bridgeport Norton Worcester Brown and Sharpe (Surface Grinders) Cone Blanchard Phinney Diamond Pratt & Whitney DoAII Speedfam Elb Sundstrand Excello Taft-Pierce Gallmeyer and Livingston Thompson Grand Rapids Universal Vise Hanchett O.S. Walker Machine and Wheel Data Segments, Cylinders And Cup Wheels Abrasive Machine Tool Co., E. Providence, R.l. Machine/Model No. 33 No. 34 No. 34 and M34 (with 6" CORTLAND Chuck) Wheel/Segment Size 5x3x3 W = 5/e", E = '// 6x3x3 W = 7/', E = '!z 5 x 3 x 37.. Rim 7a" Plate Mounted (5 X 7a X 17a) 6 x 3 x 47* Rim 7, Plate Mounted (6 X V, X 17a) 4 Segments 3% X 7a x 4 10-4 Type T-6 T-6 1P289 IP 420 CD-6 -. MIL 000178 Cone Blanchard, Windsor, VT (formerly Blanchard Machine Co.) Machine/Model No. 10 (with type 2 wheel) No. 10 (with STERLING Chuck) No. 11 (with type 2 wheel) No. 11 (with 11" BLANCHARD Chuck) No. 11 (with 12" CORTLAND Chuck) No. 11 (with 12" STERLING Chuck) No. 16 (with type 2 wheel) No. 16 (with 18" BLANCHARD Chuck) No. 16 (with 18" CORTLAND Chuck) No. 16 (with 18" NORTON Chuck )1 'k Segments No. 16 (with 18" NORTON Chuck) 2'A Segments No. 16 with 18" STERLING No. 16A, 16-A Dual and 16A2 (Automatics) No. 18 (with type 2 wheel) See Note No. 18 (with 20" BLANCHARD Chuck) NO. 18 (with 20" CORTLAND Chuck) No. 18 (with 20" NORTON Chuck) No. 18 (with 20" STERLING Chuck) Wheel/Segment Size 10x4x8, 1" Rim 6 Segments 4-15/16 x 1 x 4 11x5x9,1" Rim 4 Segments 6'Ax 1 'A x 5 4 Segments 7'k x 1 'k x 5 6 Segments 5-15/16 x 1'/x5 18x5x15,1 V/ Rim 6 Segments 7-1/16 x 13A x 6 4 Segments 11 'A x 2'A x 5 8 Segments 5 x I'/iX 6 8 Segments 5-9/16 x 2'k x 6 8 Segments 6-13/16x1 'k x 5 or 6-13/16 x 17* x 6 18 x 5 x 10, 4" Rim 18 x 5 x 15, 17/Rim 8 Segments 5-11/16x2x6 6 Segments 8 x 17, x 6 5 segments 107a x 2 x 6 9 Segments 5 x 1 'k x 6 9 Segments 6-13/16 x 17* x 5 6-13/16x2x5 6-13/16 x 2 x 6 Segment Number T-2 STG 10 T-2 BL 11 CD12 STG 12 T-2 BL18 CD18 N018 N018A STG 18 STG18A T-2 T-2 BL20 CD20 old style CD20A new style NOPO . STG20 STG20A STG20B 10 MIL 000179 10-5 Cone Blanchard (cont'd) Machine/Model No. 27 (with 27" BLANCHARD Chuck) No. 27 (with 32" BLANCHARD Chuck) No. 27 (with 36" BLANCHARD (Chuck) No. 42-72 (with 42" BLANCHARD Chuck) No. 42-72 (with 42" CORTLAND Chuck) No. 48-96 (with 48" CORTLAND Chuck) Wheel/Segment Size 8 Segments 77, x 272 x 7 8 Segments 9-9/16x2-11/16x7 16 Segments 472 x 3Va x 9 10 Segments 8-7/16x3x8 18 Segments 472 x 3% x 9 10 Segments 10'/b x 3 x 8 20 Segments 4'/j x 372 x 9 10 Segments 117, x 3 x 6 117, x 3 x 8 11 Segments 117, x 3 x 6 117, X 3 X 8 Hanchett Mfg. Co., Big Rapids, Mi Machine/Model No. 24* & 24A2 (with ring wheel mounting) No. 36 (with 18" chuck) No. 36, 36A and 36A2 (with 20" chuck) No. 72 (with 20" chuck) `Serial nos. 1-33 take 10 hole Wheel/Segment Size 16x4, 2" rim nut inserted type 8 Segments 5 x 172 x 6 8 Segments 5'7.6 x 2 x 6 8 Segments 5'7,s x 2 x 6 10-6 M im m m iim e is tti Segment Number BL27 BL32 BLA32 > i \ BL36 BLA36 BL42 BLA42 CD42 CD42-3 CD42H-3 CD48 CD48-3 CD48H-3 Segment Number Eight 7a" inserted nuts on 14" circle HM18 HM20 HM20 MIL 000180 L Hanchett (cont'd) Machine/Model Wheel/Segment Size Piano Vertical Spindle 18" Chuck Planer Type 8 Segments 5 x 27, x 6 NOTE: HANCHETT Model No. 3000 Horizontal Spindle Type Vertical Reciprocating No. 300 (with 14" chuck) 6 Segments 5'It x 1 % x 6 No. 400 (with 22" chuck) 8 Segments 6-11/16x2x6 No.400S 32"chuck 12 Segments 6% x 2 x 7 Face Grinders No. 500 (with 30" chuck) 12 Segments 7-3/32 x 2 x 7 No. 600 (with 4" chuck) 15 Segments 8x3x7 No. 900 (with 36" chuck) 12 Segments 8x2x7 No. 1000 (with 30" chuck) 12 Segments 7-3/32 x 2 x 7 NOTE: HANCHETT Model No. 500 Horizontal Spindle Type Hill Acme Co., Cleveland, Ohio Machine/Model 23" Chuck 26" Chuck 32" Chuck Wheel/Segment Size 8 Segments 77. x 2 x 77, 9 Segments 77. x 2 x 77, 11 Segments 77. x 2 x 77, Segment Number HM18 HM14 HM22 HM32 HA30 HA44 HA36 HA30 10 Segment Number HI23 HI26 HI32 MIL 000181 10-7 Mattison Machine Works, Rockford, IL Machine/Model No. 24D Duplex Rotary 24A & 24A2 Vertical Spindle Rotary Table 24 Vertical spindle Rotary Table 36", 36-48" 36A & 36A2 Vertical Spindle Rotary Table 36", 36-48" 36A & 36A2 Vertical Spindle Rotary Table 60 Vertical Spindle Rotary Table No. 72 and No. 100 Vertical Spindle Rotary Table No. 200 and 200A Series Vertical Spindle Reciprocating Wheel/Segment Size 18" Chuck 8 Segments 5 x T/z x 6 18x6x 15, 1 Vs" Rim Nut Inserted Type 18 x 4 x 14 Nut Inserted Type - 2" Rim 18" Chuck 8 Segments (5 x 17, x 6) 18" Chuck 8 Segments 20" Chuck 9 Segments 22" Chuck 10 Segments 18x2 x 14, 2" Rim Nut Inserted Type 20 x 4 x 16, 2" Rim Nut Inserted Type 26 x 4 x 22, 2" Rim Nut Inserted Type 18" Chuck 8 Segments (5 x IV, x 6) 20" Chuck 8 Segments (5-5/16x2x6) 26" Chuck 10 Segments (6`/a x 2 x 6) 26" Chuck 12 Segments 32" Chuck 14 Segments 36" Chuck 16 Segments 26" Chuck 6 Segments 32" Chuck 7 Segments 36" Chuck 8 Segments 42" Chuck 10 Segments 48" Chuck 11 Segments 20x3x 16 20 x 3 x 16, 2" Rim Nut Inserted Type 20" Chuck 8 Segments (5-5/16 X 2 X 6) 10 x 4 x 8, 1" Rim Nut Inserted Type 10-8 Segment Number HM18 T-2 T-2 HM18 MA 18 NO 18 MA20 T-2 T-2 T-2 HM18 HM20 HM26 MA26 N026 MA32 N032 MA36 N036 CD26 CD32 CD36 CD42 CD48 HM20 - MIL 000182 Pratt & Whitney Co., Div. Nlles-Bement-Pond Co., West Hartford, CT Machine/Model 8" Vertical Spindle Rotary 12" Vertical Spindle Reciprocating 1" Vertical Spindle Reciprocating (Cup Wheel) or Cylinder Wheel (with 14" NORTON Chuck) 14" Vertical Spindle Hydraulic Model D Wheel/Segment Size 8x3x4 8 x 3 x 6, 1" Rim 8 x 4 x 6, 1" Rim 10x4x8, 1" Rim 12x4x8% 14 x 4 x10% 14 x 5 x 11 11/2" Rim 6 Segments 5 x 1 72 x 6 8 Segments 5 x 1'/2 x 6 Thompson Grinder (Waterbury Farrel Div. of Textron, Cheshire, CT) Type Type 2 Cylinder Wheels Segment Number T-1 6Y-1537 6Y-1047 N014 N018 Machine/Model Type "C" HYDROVERT Vertical Spindle 12", 18", 28" Universal Vise and Tool, Parma, Ml Segment Size For 12" Cortland Chuck 4 Segments Tk x 1 % x 5 For 14" Cortland Chuck 4 Segments 878 x 174 x 5 For 18" Cortland Chuck 4 Segments 1174 X 274 X5 Segment Number CD12 CD14 CD18 Machine/Model SWISHER Old New Wheel Size 7 x 3 x 3.3, 72" or 7e" Rim 8 x 3 x 3.3, V" Back Type T-6 Thompson Grinder (Waterbury Farrel Div. of Textron, Cheshire, CT) Machine/Model 6" x 18" Vertical Spindle Reciprocating Wheel Size 5x3x2 7s" Rim, 72" Back 6x3x3 7a" Rim, 'k" Back Type T-6 T-6 T-6 MIL 000183 10-9 Surface Grinding Horizontal Spindle Straight and Recessed Material ALNICO ALUMINUM BRASS and SOFT BRONZE BRONZE, Hard CAST IRON CEMENTED CARBIDES Roughing Finishing COPPER GRANITE, Contour MEEHANITE STEEL D2 Air & Oil Hardened Hardened over 60 RC Soft & Stainless Very Hard 65 RC Form Grinding GENERAL PURPOSE GENERAL PURPOSE 18" through 24" diameters LA462-H9-V2 LA54-G10-V WA54-H12-VC2 WA54-E12-VF LA1001-J11-V WA543-Super LA364-H8-V LA462-I9-V WA54-G12-VC WA54-F12-VC2 WA54-F12-VC2 LAI 001 -K11-V WA54-I12-VC 2WB362-H9-V Specification WA54-G12-VC C37-I7-V8 C36-I7-V8 WA543-I12-VC C46-I7-V8 GC60-J9-VP GC102-I7-V8 C30-I7-V8 C36-K7-V8 C30-J7-V8 3WB462-H9-V 3WB542-F10-V 3WB54H-12-VC 3WB100-I11-V2 3WB100-I11-V2 3WB54H-12-VC Vertical Spindle Rotary Table Surface Grinding Machines Helpful Hints Vital Statistics for Popular Segments and Wheels Shape Size Area Length Width Height Sq. In. per Segment AA1 AA2 BL18 BL20 CD18 CD18-8 CD18XT8 HI26 N018 N018A STG18 STG18A STG20S Ring Wheel Ring Wheel Ring Wheel Ring Wheel Ring Wheel Ring Wheel 11 ,s/,6 X 2*/a X 6 672 X 17la X 572 77,6 X17.X6 5'7,6 X 2 X 6 117, X 27, X 6 117. X 27, X 8 117, X3X8 778 X 2 X 7'/, 5 X 17j X 6 57,6 X 2'/, X 6 6*7,6 X Vk X 5 6*7,6 X 17j X 6 6*7,6 X Vk X 5 11 x 5 x 9 18 x 5 x 10 18 x 5 x 12 18x5x15 20 x 5 x 16*/a 20 x6 x 1672 20.9 10 11.81 10.5 18.4 18.4 26.8 12.48 6.86 11.65 9.7 9.7 9.68 31.4 175.92 141.37 77.75 100.34 100.34 Volume Cu. In. per Segment 125 55 71.4 63.1 110.4 110.4 177.9 90.5 41.18 68.2 48.6 58.3 58.1 157.1 879.6 706.85 388.75 501.7 602 MIL 000184 Machine and Wheel Data Though all grinding could be called surface grinding, the term "surface grinding" is used to describe the grinding of flat surfaces. Surface grinding applications range from heavy, rapid stock removal operations to precision grinding jobs. Among the numerous makes of surface grinders that are manufactured today, there are five principal types: 1. Vertical Spindle, Rotary Table uses segments or cylinder wheels. Most common type of machine is the single spin dle machine. Roughing, semi-finishing and finishing of flat surface can be performed on small to very large work pieces on these machines. 2. Horizontal Spindle, Rotary Table uses wheel types 1, 5, or 7. Work pieces are mounted on a rotary table and grind ing is performed on the periphery of the wheel. Grit sizes from 36 to 80 are commonly used and vitrified wheel grades of F to K are used. 3. Horizontal Spindle Reciprocating Table uses wheel types 1, 5, or 7 with grit sizes 36 to 80. Soft wheels with grades F to K are generally used. Workpieces move back and forth under the wheel and all grinding is done on the periphery of the wheel. 4. Vertical Spindle, Reciprocating Table uses cylinder or cup wheels, like 3 above, the work moves back and forth but all grinding is performed on the face of the wheel. Soft grades and coarse grit size wheels are normally used. 5. See disc grinding section for disc applications and theory. Surface grinding is widely used in toolroom applications. See toolroom section for details on toolroom surface grinding. Type I And Recessed Wheels Abrasive Machine Tool Co., East Providence, R.l. Machine/Model No. 3 No. 3B and 3S No M3, M3S and 17* No. 5 No. 1218 HVDRABRASIVE Wheel Size 8 X 7: x 17* 10 x 7* x 3 10x7. x 3 10x1x3 12 x 7* x 3 12 x 7. x 3 12 x 1 x 3 14 x 17* x 5 12 x 1 x 3 12 x 2x 3 12x3x3 Type 1 Blohm (Germany) Machine/Model HFS 6-9-12-15 SIMPLEX 5-7-9-1175 Wheel Size 12X2X76MM (300 MM x 50 MM x 76 MM) 12x2x76 MM (300 MM x 50 MM x 76 MM) Type Rec. 2/Sides 57. x 7. Rec. 2/Sides 57* x 7* Brown & Sharpe Mfg. Co., Providence, R.l. Machine/Model No. 2 No. 2B No. 5 Wheel Size 7 x 7* x 17. 7 x 7* x 17. 10x7. x 3 Type 1 DoAII Company, Minneapolis, Minnesota Machine/Model D6-1.G-1 D8-1. G-10 D8-3, D-10-1 D-10-3 Wheel Size 7 x V* x 11/4 10x3/4 x 3 12x1x3 14 x 1 x 3 Type 1 MIL 000185 Elb (Germany) Machine/Model SWH RUBIN SWN. SWE, SWBE SWE-O SWBEO SWBDO Wheel Size 8 x 1 X 51 MM (200 MM x 25 MM x 51 MM) 10x1 x 51 MM (250 MM x 25 MM x 51 MM) 10 x 1 x51 MM (250 MM x 25 MM x 51 MM) 12 x 2 x 76 MM (300 MM x 50 MM x 76 MM) 12x2x76 MM (300 MM x 50 MM x 76 MM) 14x4x 127 MM (350 MM x 100 MM x 127 MM) 16 x4 x 127 MM (400 MM x 100 MM x 127 MM) 20 x 6 x 203 MM (500 MM x 150 MM) Type 1 1 Rec. 2/Sides 77, x V. Rec. 1/Side 12 x 7. O/Side 12 x 17. Hanchett Mfg. Co., Big Rapids, Michigan Machine/Model 18" Chuck Planer Type Wheel Size 20 x 3 x 12 to 20x4 x 12 Heald Machine Co., Worcester, MA Machine/Model No. 20 and 22 8" Old Style No. 20 and 22 12" Old Style No. 22 New Style 8" & 12" No. 261 & 361 No. 25A 8", 12" and 16" For Serial 14700 & Up Furnish 18" Dia. No. 25A 24" and 30" Wheel Size 10 x 1 x 37i 12 x 1 x 5 12 x 1 x 5 14 x 1 x 5 16 x 2 x 8 18x2x8 18 x 2 x 8 Excello, Detroit, Michigan Machine/Model Style 85-Two Wheel Form Style 84-Single Wheel Form Angular Twin Head Wheel Size 24 x X 12 12 x O x 5 12 x O x 5 Type 1 1 1 Gallmeyer & Livingston Co., Grand Rapids, Michigan Machine/Model Wheel Size Type No. 3V 5x3x3 6Y-171 No. 4 10 x3/. x 2 No. 5, 15 and 18 10 x 1 x 2 No. 20 No. 25 No. 28 7 x'/iX 17, or 8 x 7s x 1/, 10 X 7. x 17, 1 No. 35 and 38 10x1x2 No. 45, 45A. 45B. 55, 55A 55B, 65. 65A 12x1 x3 14x1x3 A-12" and 14" F-12" and 14" 14x3x5 Rec. Two Sides 8x V, F-16", 18" 20". 24" & 30" A-12" and 14" Table 20 x 4 x 10 20 X 4 x 12 20 x 6 x 12 14x3x5 14 x 3 x 5 Rec. Two Sides 14 x 7 Rec. Two Sides 8x7, The Hill Acme Co., Cleveland, Ohio Machine/Model Wheel Size Horizontal Spindle Reciprocating Table 20 x 2 x 10 20x3x 10 20 x 4 x 10 20 x 5 x 10 20 x 6 x 10 Wheel Size 12 x 1 x 3. WA46-G12VC: 9A461-H10-VA. This machine designed and built for ceramic grind ing wheels. 3MSBS41-H8-VSA Type 1 Type 1 Rec. Two Sides 107, x 7, 7 Type 1 Rec. 1 Side 127, x 1 Rec. 2 Sides 127, x 1 Rec. 2 Sides 127, x 17, Rec. 2 Sides 127, x 17, { 4 * t * \ 1 l > 10-12 MIL 000186 Machine and Wheel Data (cont.) K.O. Lee Co., Aberdeen, S.D. Machine/Model S 600 Series S 700 Series Wheel Size 8 x V, x 17. Type 1 Above: Typical Reciprocating Surface Grinder Wheel Size: Wheel Grades Hard Steel Soft Steel 9A54-F6-VA 29A461-H10-VA WA543-E10-V LA463-G12-VC 3MSB601-D8-VSA 3MS8461 -F10-VSA Magerte (Switzerland) Machine/Model Reinforced Surface Grinder F10/12/15-V Large Surface Grinder FI 00/120 Wheel Size 300 MM x 100 MM x 127 MM 400 MM X 100 MM X 127 MM 400 MM x (50 to 90 MM x 127 MM 500 MM x (50 to 90 MM x 203 MM Type 1 Various Recesses 1 Various Recesses Mattison Machine Works, Rockford, Illinois Machine/Model 12" and 14" Old Style 12" and 14" New Style Wheel Size 14x3x4 16x6x10 16x6x5 16x3x 10 16", 20" 24" Old Style 16x6x 10 20 x 2 x 10 20 x 3 x 10 20 x 3 x 10 20x4x 10 22x3x 10 16", 18", 20" 24" and 30" New Style 22x6x10 20x6x 10 Type Rec. 2/Sides 7 x 7 Rec, 1/Side 127, x 1 O/Side 127, x 2 Rec. 1/Side 8 x 1 O/Side 8x2 Rec. Two Sides 1272 xV, Rec. 1/Side 1272 x 1 O/Side 127j x 2 1 Rec. 1/Side 127. x 'k Rec. O/Side 127. x 1 Rec. 1/Side 127. x 1 Rec. 1/Side 127. x 1 Rec. 1/Side 1272 x 1 O/Side 1272 x 2 Rec. 1/Side 127> x 1 O/Side 127j x 2 10 Norton Co., Worcester, MA Machine/Model 6" x 18" ' Horizontal Spindle Reciprocating 8" x 24" Horizontal Spindle Reciprocating Wheel Size 7 x 7, x 17, 7x7. x 17. 8 X 7; x 17, 8x7. x 17. 10x1x3 10" 10" for Die Grinding 6" x 10" x 36" Old Style 12" x 36" S-1 15" x 15" Old Style 10 TS 6" S3 8 x 24 S3 10 x V4X3 20 x 17: x 3 10 x 3 x 3 14 x 1 x 5 14x3x5 14x4x5 14 x 5 X 5 14x6x5 12x7. X 3 8 x 7. x 17. 10 x 1 x 3 or 12x1 x 3 S-1 12x48 14x36 14x48 16x36 16x48 Type N10 x 18 or 10x24 14x1x5 or 14x2x5 ' 10 x 1 x3 or 12x1x3 ' Type 1 Rec. Two Sides 5V, x 7. 1 1 Rec. 2/Sides 8 x 7, Rec. 2/Sides 8 x 1 1 1 1 1 1 MIL 000187 10-13 i yjt Machine and Wheel Data (cont.) Sundstrand Machine Tool Co., Rockford, Illinois (formerly Arter Grinding Machine Co.) Machine/Model Old Slyle 8" and 12" Old Style 16" A-8" D12 A-12" D12 A-16" B-20" B-24" B-30" B-40" C-8" C-12" C-16" H Rotary H-16" H-20" H-24" H-30" Wheel Size 12x 1 xS 12x1'/. x 5 14x1x5 14 x I'/, x 5 14 x 17, x 5 12x1x8 14 x 1 x 8 14 x 1 x 8 14 x 17. x 8 20x2 x 12 20 x 2 x 12 20 x 2 x 12 20 x 2 x 12 16 x 17, x 8 16 x 17, x 8 16 x 17, x 8 16 x 2 x 8 Type 1 Taft-Pierce Co., Woonsocket, R.l. Machine/Model No. 1 Precision Surface Gr. 6" Rotary Wheel Size 7 x 7,x 17. Type 1 Thompson Grinder (Waterbury Farrel Oiv. of Textron, Cheshire, CT) Machine/Model F-6 F-6 B-1 B-2 B-6 8-8 B-3 B-4 B-8 B-5 B-6A B-7 B-8A B-9 B-48 B-49 B-50 B-51 8-631 B-10 B-12 C-12 BB-12 BB-10 BB-12 BB-615 BB-616 BB-617 BB-633 BB-636 BB-629 BB-640 BB-641 BB-642 BB-661 BB-662 BB-634 BB-635 BB-637 BB-638 BB-663 BB-664 C-12 C-14 C-16 C-18C-20C-24 Wheel Size 12 x 7, x 17. 12x7. x 3 12x1x5 12 x 17 x 5 12x2x5 B-627 12 x 17, x 5 12 x 2 x 5 12x3x5 20x11/2x8 20 x 2 x 8 20 x 3 x 8 Type 1 1 Rec. 1/Side 77, x 7, Rec. 2/Sides 77, x 7, B-628 Rec. 1/Side 77, x 7, Rec. 2/Sides 77, x 7, Rec. 2/Sides 77. x 7Rec. 1/Side 77, x 7, Rec.2/Sides 117, x 7, Rec. 2/Sides 117. x 7, 10-14 MIL 000188 L. Hanchett Segment Shape HM E Norton Segment Shape NO MIL 000189 10-15 Segment Shape And Sizes Style Number AA-1 BL-11 BL-18 BL-20 BL-27 BL-32 BL-36 BL-42 CiBLA-32 0BLA-36 B LA-42 CD-6 CD-8 CD-12 CD-14 CD-16 CD-18 CD-18L CD-20 CD20A *CD20B *CD22 *CD24A *CD26 *CD27 'CD30A CD32 "CD32A *CD36 *CD42 *CD44 *CD48 *CD54 *CD60 *CD120 Chuck Dia. in inches All Dia. 11 18 20 27 32 36 42 32 36 42 6 8 12 14 16 18 18 20 20 20 22 24 26 27 30 32 32 36 42 44 48 54 60 120 A-Length 11-5/16 67, 7-1/16 5-11/16 77, 9-9/16 8-7/16 107. 4% 4'k 4% 37* 47, 77* 87. 107. 117, 117, 8 107. 117, 117, 117, 117, 117, 117, 8 117, 117, 117, 117, 117, 117, 117, 117, * Identical shape (CD Universal) C Identical BLA shapes CD Universal segments are also available in a 3' thickness and 8" in length. Possible combinations are: Size in Inches B-Width 27, 17, 17, 2 27* 2-11/16 3 3 37* 37* 37* 7. 17, 17* 17, 2 27, 27, 17, 2 27, 27, 27, 27, 27, 27, 17, 27, 27, 27, 27, 27, 27, 27, 27, C-Height 6 5 6 6 7 7 8 8 9 9 9 4 4 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 Pieces Per Set As ordered 4 6 8 8 8 10 10 16 18 20 4 4 4 4 4 4 4 6 5 4 5 5 6 6 7 10 7 8 10 10 11 12 or 13 14 30 Size 11V.x2V<x6 11 'A x 3 x 6 11 'A x 27, x 8 11 'A x 3 x 8 Designation (Example) CD221 CD22-3 CDH22 CDH22-3 'Any style no. which uses substituted Universal segment can be 10-16 4 MIL 000190 Style Number CR-42 DIA-30 DIA-36 HA-16 HA-20 HA-24 HA-30 HA-36 HA-36A HA-48 HA-44 HI-23 HI-26 HI-30 HI-32 HM-14 HM-18 HM-20 HM-22 HM-26 HM-32 NO-14 NO-18 NO-18A NO-20 NO-22 NO-24 NO-26 NO-27 NO-32 NO-36 NO-42 STG-10 STG-12 STG-14 STG-14A STG-16 STG-16A STG-16B STG-18 STG-18A STG-18B STG-18D STG-20 STG-20A STG-30 Chuck Dia. in Inches 42 30 36 16 20 24 30 36 36 48 44 23 26 30 32 14 18 20 22 26 32 14 18 18 20 22 24 26 27 32 36 42 10 12 14 14 16 16 16 18 18 18 18 20 20 30 A-Length io3/, 6'/2 67* 5-5/16 5-5/16 5-3/16 7-3/32 778 8-9/32 8-33/64 8 77s 77s 77s 77s 57s 5 5-15/16 6-11/16 672 67, 5 5 5-9/16 5 5 5 5 5 5 5 5 4-15/16 5-15/16 5-5/16 5-5/16 6 6 6 6-13/16 6-13/16 6-13/16 67s 6-13/16 6-13/16 8 Size in Inches B-Width 27s 2 2 17, 2 2 2 2 3 3 3 2 2 2 2 1 '/z 17, 2 2 2 2 172 17s 27, 17s 17s 17s 17s 17s 17s 17s 17s 1 174 17, 17, YU 174 17, 17s 17s 2 4 17s 2 2 C-Height 67, 77, 77, 6 7 7 7 7 7 8 7 77, 77, 77, 77, 6 6 6 6 6 7 6 6 6 6 6 6 6 6 6 6 6 4 5 4 5 4 5 6 5 6 5 5 5 5 6 Pieces Per Set 12 12 15 8 10 12 12 12 12 16 15 8 9 10 1 6 8 8 8 10 12 6 8 8 9 10 11 12 12 14 16 20 6 6 8 8 8 8 8 8 8 8 8 9 9 12 MIL 000191 10-17 <D 0) x: (7) ra C3 <D Q Eo co G3O O 10-18 {II IlI jg "co Q <5 c 2" Observed By: _ _ ______ ___ _____ __ ____ _ _ Coolant U s e d :_____ ___________ __ _ _ _ _ _ _Table R.P.M.: _ _ _ _ ___ _ _~ ------- _ Machine Specifications Make: ______ ____________ Spindl e R.P.M. __ . .. H.P. Table Size _ wheell/Seqment (A) Size/Shaoe (B) Grade (C) Area (in.2) Table Load No. Parts Per Table Part Area ( in .2) Material Type Feed Rate in ./m in . Total Infeed (.001) M o to r Load % FI. Grind Cycle Time Metal in .000 A b ra s iv e Loss Abrasive Loss in.2 G Ratio - MIL 000192 Some Basic Formulae Area of a rectangle = Base x Height Area of a square = Base2 Area of a parallelogram = Base x Height Area of a triangle = 1/2 Base x Height Area of a trapezoid = 1/2 Base + Basel x Height Area of a circle = 3.1416 x radius2 Circumference of a circle = 3.1416 x diameter A = BH A = B2 A = BH A = 1/2BH A= 1/2 (B+B1)H A = rrR2 C = ttD General Recommendations Vertical Spindle Rotary Table The large contact areas encountered in this type of grinding make the wheel or segment selection very criti cal. The general rule is to use a soft open specification on large work areas and to use harder specifications if work areas are decreased. We find a maximum efficient work area for general use on a 36" table to be about 450 square inches. However, workpiece dimensions, loading and handling time may dictate the use of larger or small er work areas. Whenever possible, do not load the cen ter of the table, but it is advantageous to pass the workpieces through the center of the wheel or segment assembly. Use relatively low table speeds when grinding large area parts in order to minimize heat generation. Higher table speeds are recommended for small area parts to keep them from moving. High horsepower machines will usually require harder wheels and seg ments than those generally recommended. To minimize heat distortion when grinding thin work, it may be necessary to add auxiliary coolant lines to blast coolant into the primary grinding zone. You will note the specification change for large and small work areas. Likewise, we go softer for large seg ment areas in square inch per piece, such as for CD 18xT8, and harder for small segment areas, such as N018. These specifications consider AA1 and CD18 segments as normal areas of contact. 10 GENERAL PURPOSE NOTE: A. To obtain segment volume (In.3) Segment Area x Segment Height B. To obtain segment "usable volume" (In.3) Segment Height - Stub Height x Segment Area C. To obtain metal volume, simply measure the area of one part then multiply by number of parts. Then mul tiply total area by amount of metal removed in deci mals. This gives you cubic inches of metal. D. To obtain abrasive lost: Find your segment area on the chart on page 24, and multiply by inches (in decimals) the abrasive lost during the grind, i.e., if you feed down .040" and remove .015 from the part, obviously you lost .025 from the segments. E. Divide metal removed by abrasive lost and you have "G" ratio (cubic inches of steel removed by cubic inch of wheel). MIL 000193 10-19 Basic Principles Of Surface Grinding 1. Type of Parts A. Soft Parts - Boiler plates, blocks, gates, punch outs, misc. B. Hard Parts - Gears, dies, washers, piston rods, etc. 2. Grading the Wheel Horizontal Spindle Reciprocating The main variable in surface grinding is the hardness of the part. This will necessitate a change in wheel grading; however, most soft parts can be roughed and finished with the same wheel and the same rule applies to hard parts. Stock RMS Grinding Rate GR Wheel Soft .025 - .040 25-40 Medium 2A46-I6-VL Hard .004 - .010 12-17 Slow 97A701-J4-VFM This information pertains mainly to horizontal spindle reci procating surface grinding. 3. Grading the Wheel Vertical Spindle Rotating Table This is another popular type of surface grinding. This requires segments largely and Type 2 cylinder wheels. A. Soft Material = Parts are usually large -- intermit tent, and stock removal is high. A good segment grade is 97A241-G10-VL, VA, V, VC. B. Hard Material = Stock removal quite less. Grinding time is longer accordingly, and the RMS is improved by finer grit sizes and spark out time. A good grade for hard material is 97A461-F10-VL, VA, V, V or WA461-D12-VC. 4. Trouble Shooting A. Horizontal Spindle 1. Chatter - Wheel too hard - Wheel out of balance - Setup not rigid. 2. Burn - Wheel too hard and/or too fine - Poor coolant application - Grinding rate too fast. 3. RMS too rough - Wheel too soft - Grinding rate too fast. B. Vertical Spindle (Segments) 1. Chatter - Segments too hard - Interrupted cut and setup not rigid. 2. Bum - Segments too hard - Grinding rate too slow - Poor coolant application. 3. RMS too rough - Segments too soft or grinding rate too fast. Producing flat surfaces with surface grinding machines is extremely important. No other method can produce an accurate flat surface as quickly and economically, and at the same time handle a variety of work ranging from small instrument parts to large castings. From flat locating surfaces subsequent machining operations can be per formed accurately. Surface grinding also encompasses 10-20 contoured surfaces on soft and hard materials. Surface grinding wheels must be cool cutting to avoid burning and warping parts. To minimize tedious wheel dressing and wheel changing, surface grinding wheels must be as close to self-dressing as possible and each wheel must be able to grind a wide variety of jobs. CINCINNATI Surface Grinding Wheels are quick-cutting, cool-grinding, versatile, and virtually self-dressing when correctly graded. Correct grading to your surface grinding application is easy with the help of your Cincinnati Milacron Marketing Company representative. Once on grade, successive wheels that you order will give you the same grinding action. Through our manufacturing system featuring unvarying, in process quality control, duplication of the original wheel is assured with each reorder. On grade with a CINCINNATI Surface Grinding Wheel means that all future wheels will act and grind alike. Most horizontal spindle surface grinding requires straight or recessed wheels. Vertical spindle surface grinding requires (depending on the grinder) segments, cup wheels and cylinder wheels. Cincinnati has a wide variety of surface grinding wheels to meet your needs. We can also recommend a CIMCOOL grinding fluid featuring rapid grit setting and exceptional cleanliness. Rotary surface grinding was the original abrasive machin ing (fast, heavy stock removal by grinding competition with other metal removal processes), and the only significant one, until 1963, when the bridge-type centerless grinder was introduced. Now high-speed, high-efficiency centertype grinders have joined the abrasive machining parade too, but surface grinders are still a big part of it. Some big surface grinding machines, such as one with a 250 h.p. head, a 48" grinding wheel in the form of 11 segments held in a chuck, and a 96 work-holding mag netic chuck cost considerably more to operate than the smaller machines. But they can often beat planers and milling machines on overall cost in spite of the lower cost per machine-hour operated of these machines, because ( they frequently remove metal at least 41/2 times faster. They can hold tolerances more easily and get a better finish; finishes of 63 rms are routine. Ease of workpiece clamping (magnetic chucks) is another advantage rotary < surface grinders have over planers and milling machines in operations that can be done by abrasive machining. Surface grinders give minimum distortion, no induced stress, a burr free operation and freedom from complex fixtures. Whether your surface grinding is complex or a simple toolroom operation, you can counfon us. We'll use our experience in making and servicing grinding machines. CINCINNATI MILACRON Grinding Wheels and CIM COOL Cutting Fluids, plus a spirit of innovation, to help you make the job run smoothly and profitably. MIL 000194 Height And Area Per Set Seg. Shape AA-1 AA-2 BL-11 BL-18 BL-20 BL-27 BL-32 BL-36 BL-42 BLA-27 BLA-32 BLA-36 BLA-42 CD-6 CD-8 CD-12 CD-14 CD-16 CD-I 8 CD-18L CD-20 CD-20A CD-22 CD-221 CD-24 CD-26 CD-27 CD-30 CD-30A CD-32 CD-32A CD-36 CD-42 CD-48 CR-42 DIA-30 DIA-36 GO-12 GO-16 HA-16 HA-20 HA-24 Pieces Per Set As Req. As Req. 4 6 8 8 8 10 10 8 16 18 20 4 4 4 4 4 4 4 6 5 5 5 8 6 6 10 7 10 7 8 10 11 12 12 15 8 10 8 10 12 Hgt. 6" 57/ 5" 6" 6" 7" 7" 8" 8" 7" 9" 9" 9" 4" 4" 5" 5" 5" 5" 6" 6" 6" 5" 6" 7" 6" 6" 6" 6" 6" 6" 6" 6" 6" 67/ 77/ 77/ 37/' 7" 6" 7" 7" Area Per Set (In/) 20.0 31.2 71.7 84.8 145.8 217.7 235.7 287.1 145.8 221.7 249.4 277.1 9.7 18.9 33.3 44.3 58.4 74.1 74.5 76.8 72.7 92.6 93.1 89.6 111.7 111.7 130.7 130.3 128.0 130.3 148.9 186.2 204.8 263.6 143.5 181.7 45.1 78.9 102.1 Seg. Shape HA-30 HA-36 HA-36A HA-48 HI-23 HI-26 HI-30 HI-32 HM-14 HM-18 HM-20 HM-22 HM-26 HM-32 NO-14 NO-18 NO-18A NO-20 NO-22 NO-26 NO-32 NO-36 PE-11 PE-12 PE-12A PE-18 PE-22 RO-12 RO-14 RO-16 RO-20 RO-20 STG-10 STG-12 STG-14 STG-14A STG-16 STG-16A STG-16B STG-18 STG-18A Test Form And Procedure For Computing "G" Ratio. See Page 10-18 and 10-19 Seg. Shape Pieces Per Set STG-18B STG-18D STG-GAP STG-20 STG-20A STG-20B STG-20C 8 8 8 9 9 9 9 'Special STG-18 "GAP Type" Hgt. 5" 5" 5" 5" 5" 6" 6" Area Per Set (In/) 98.1 173.0 67.8 84.7 110.3 109.7 85.2 Pieces Per Set 12 12 12 16 8 9 10 11 6 8. 8 8 10 12 6 8 8 9 10 12 14 16 6 6 6 8 10 7 8 8 10 8 6 6 8 8 8 8 8 8 8 Hgt. 7" 7" 7" 7" 77/' 77/ 77/ 77/ 6" 6" 6" 6" 6" T 6" 6" 6" 6" 6" - 6" 6" 6" 4" 6" 6" 5" 6" 4" 4" 4" 47/ 47/ 4" 5 4" 5" 4" 5" 6" 5 6" Area Per Set (In/) 137.8 166.0 242.4 336.6 98.7 111.0 123.3 135.6 43.4 55.2 87.2 101.2 217.2 151.8 41.4 55.2 90.0 62.1 69.0 82.8 96.6 110.4 27.2 41.3 50.0 48.0 56.4 56.9 56.9 75.7 75.7 MIL 000195 10-21 11 Creepfeed Grinding ELB's Cam-Master Machine features 5 grinding heads with automatic wheel change. Typical wheel grade for turbine blades would be WA603-D15-VF or 9A601-E12-VCR. A typical wheel size is 24 x 2 x 8. Starting Grade Recommendations Straight Grind Form Soft Steel Hard Steel Inconel Alloys Stainless LA4P1-F15-VC4 WA541-D12-VF4 WA601-E12-VF4 WA531-D15-VF4 WA541-E15-VF4 LA601-F12-VF4 WA601-E12-VF4 WA603-D12-VF4 WA543-D12-VF4 WA601-E12-VF4 MSB is applicable for most creepfeed applications. Call Cincinnati's Abrasive Engineering Group for MSB grade recom mendations. MIL 000196 11-1 What Is Creepfeed Grinding? Creepfeed surface grinding is like formed milling except the wheel, instead of the cutter, removes the stock in one pass at a slow table speed. Creepfeed gives high accuracy, high production and good finish, and works well on many difficult-to-cut metals. The picture shows sample parts which have been creepfeed. ground. Parts vary from the size of a needle to 10" wide forms 3" deep. The method lends itself to CNC tapes and can have different axes on both the work and the grinding spindle. Will any machine do the job? Creepfeed machines are specially made for high velocity of fluid flow, rigidity of table, grinding spindle and dress er mechanism. They have high horsepower, hold a con stant SFPM as the wheel wears down, and have a slow table speed 2 IPM to 80 IPM. The dress mechanism varies with the production needed. Highest production is with diamond rolls and continuous dress (CD measured in millionths infeed per revolution of the grinding wheel), or with intermittent dress. Shorter run jobs can use crush dressing, or single point dressing. What kind of parts are creepfeed ground? Very small parts tend to use finer grain grinding wheels and high wheel speeds, like 8500 SFPM. This reduces pressure and permits the fluid, at high psi (70 to 200 psi), to penetrate the arc of contact. Larger parts with deeper cuts can run at wheel speeds of 3000 SFPM to 6500 SFPM to reduce total heat. 6000 SFPM is generally the most efficient speed. The type of fluid, volume, velocity and direction are very critical in creepfeed grinding. How is creepfeed done? Most creepfeed is done in the down cut or climb mode, to put pressure on the table and to make fixturing easier. In down-cut, the wheel and table are going in the same direction at the point of contact. But on large cuts or where burn is critical, up-cut with the table going oppo site to the wheel at contact brings heat up and away from the work surface, allowing higher table speeds. The variables in creepfeed grinding are: depth of cut, table speed in IPM, wheel speed in SFPM, type of dress, amount of dress, ratio roll to wheel in SFPM (.8 ratio opens the wheel to cut aggressively. A ratio of 1 would be a crush dress). The grinding wheels are very soft in grade, high in rupture strength and extremely open in structure. Sample wheel specifications are given above. These vary with the method of dressing and work radii needed. What fluids are used for creepfeed grinding? Water soluble oil such as CIMPERIAL 1011 metalwork ing fluid gives lubricity to the cut and helps the G ratio while removing heat. This is especially helpful in large cuts where huge volumes of chips, like steel wool, are removed with special filters. Variable and short run jobs often run with clear solutions such as C1MTECH 500 metalworking fluid for easy in handling. Sample Wheel Specifications Aircraft Blade (Inconel) Aircraft Blade (Stainless) Aircraft Blade (Inconel Root) Steel Forgings WA603-E12-VF WA543-D15-VF WA603-C15-VF WA702-F15-VF MIL 000197 11-2 Creep Feed Data Sheet CUSTOMER AOORESS CITY STATE ZIP WHEEL SIZE MATERIAL TYPE DRESSER MACHINE HARONESS FINISH CREEP FEED HP SIZE RADIUS SPECIFICATION COOLANT TYPE Wheel Dia. Cut Width Cut length Depth of Cut Ratio SFPM Roll/Whl Table Speed 1.P.M Wheel SFPM Roll Infeed Dress Mil/Rev Amount" Time Grd. Cut Up or Down Amps or % load Comments - 'If intermittent dress, amount of dress if C.D. (continuous dress) = RPM x time x roll infeed 11-3 - Abrasive cost in; S R Machine cost in' S.R. Total cost in1 S.F- MIL 000198 r = Grinding Wheel Radius - pi = (R2 - (R - (PG + PS2)))3 PL = Part Length PK = Part Over Travel Typical .04 PG = Depth of Cut PS = Stock Remaining Over Finish PI PL PI PK PART LENGTH Dress Length = (2xP1) + PL + PK 1 Creep Feed Grinding Wheels VCR Product Availability Abrasive Types Abrasive Sizes Grades Aluminum Oxide 9A, 4A, 12A, 29A, 97A, 2A *46, 54,60, 70, 80, 90,100, 120 *C, D, E, F, G Silicon Carbide 5C, 6C, 7C '46, 54, 60, 70,80, 90,100,120 C, D, E, F,G Structures Wheel Size *10,12,14,16 6" through 30" O.D. 10,12,14 3/4" through 6" thick 'Exception: C grade is not available in 46 grit, 10 structure. C grade is available in 46 grit, 12, 14 and 16 structures. Standard Maximum Wheel Speeds -- SFPM Grit Size and Grade Wheel Type 36 and Finer ***C-0-E F, G 6 4500 5000 2 5000 5500 Other *6500 6500 "See special speed chart for overspeed applications. 'Maximum operating speed for a 46 qrit, C12 Specification is 6000 SFPM. i i L_ ii MIL 000199 11-4 Deep Cut and Creep Feed Grinding On the American metalworking scene creep feed grind ing is an exciting development that is changing the industry's views about grinding productivity. Most suc cessful creep feed operations are being done with prod ucts that have been produced expressly for creep feed applications. Most of the development work for creep feed grinding has been conducted in Europe, although the first actual creep grinding was done in the States. One of the prob ably causes for this lies within the name itself. Creep, to most people, means slow and slow is not a popular word around most of our high-production grinding shops. A word which has and is gaining popularity is productivi ty. When American manufacturers took an indepth look at creep grinding they were surprised to learn that although the machine tables were moving slow, the pro ductivity was greatly increased. They were also sur prised to learn that the parts were burn free and required no deburring operation after the grind. This first caught the eye of the aircraft industry whose part speci fications required perfect parts with no burn, burr or heat distortion. Thus, the early stages of creep feed grinding in the U.S. were done in aircraft plants. What exactly is creep feed grinding, and how does it work? Creep feed grinding is a milling operation per formed with an abrasive wheel. Different from customary reciprocating grinding, creep feed is a grinding tech nique capable of removing metal from a solid workpiece -- up to 1" of stock removal in a single pass! Because creep feed grinding demands the use of a soft, open wheel, It is especially appropriate for applications where burr and burn-free parts are absolutely vital, as they are in the electronics, ceramics and aerospace industries. Creep feed grinding is capable of reducing as much as 50% of your machine cycle time since it eliminates the need for rough'machining, milling, de-burring and other finishing steps; and this lowers material handling as well as inventory costs. Furthermore, creep feed grinding minimizes heat distortion and cracks thereby curtailing -- even eliminating re-work costs! Still, another advan tage to creep feed grinding is that the operator no longer needs to (repeatedly) sharpen a mill cutter; so, time and money are also saved. Not only will creep feed save money and time, it will improve production, efficiency and yield a better finished product at a lower cost per piece. This all adds up to what it's all about -- PRODUCTIVITY! Even with all of its' advantages creep feed grinding has been slow to be recognized in the metalworking industry -- but why? To answer this question let's take a brief look at its origin. From its' inception, in America's 1940s, 11-5 creep feed grinding quickly acquired an unfair reputation simply because its' very name implied that the process was too slow, especially for our nation's production demands. A table speed of 1 to 2 inches per minute failed to impress a very time conscious industry like ours. Another reason why creep feed grinding failed to make a positive impression was that a few industries, however remotely interested in it, attempted to perform various creep feed operations on their existing equip ment and failed because their machines were not specif ically designed for the creep feed application. Successful creep feed grinding essentially requires three things: 1. A creep feed grinder 2. The correct wheel 3. The correct metalworking fluid Once you have obtained the proper creep feed grinder to suit your needs, you will need the proper grinding wheels and metalworking fluids to make your creep operation a great success! Creep feed grinders are unique when compared with conventional grinders in that they have: -- Higher horsepower motors -- Larger fluid tanks with cyclone filters and pumps capable of adequately flooding the workpiece with high velocity fluid. -- A rigid table with a rigid feed control To properly and effectively creep feed grind the following rules must always apply: Rule #1:The wheel, part and fluid should travel in the same direction (or downcut). Rule #2: Both the sharp abrasive wheel (featuring a very open structure) and the metalworking fluid should travel up to 73 MPH (This is 6500 surface feet per minute). Rule #3: The key to success with creep feed grinding is high velocity fluid 100-200 gallons of coolant per minute is required, depending upon the size of the job and the wheel. Rule #4: An adequate fluid system pipe must be used, one that is at least 1V2" coming to a constantly reduc ing nozzle (to increase pounds per square inch), there by maintaining gallons per minute (G.P.M.'s). Operators must be aware that burr and burned parts are a result of an inadequately applied or misapplied fluid. Creep Feed grinding should be accomplished in the "down grind" or "climb-grind" mode. Climb-grinding auto matically eliminates the burr. Chips are not formed, pushed, or rolled to the edges, but pulled through the cut and devoured or reduced to a fine wiry swarf. MIL 000200 Feed rates are determined by the depth of the cut, width of the cut, hardness of the material, and, of course, the difficulty of the job. The deeper the cut, the slower the procedure. In some applications where burn is persis tent. the up-arind mode mav be helpful. At this point a word about creep feed tables is appropri ate. Small hydraulic cylinders do not provide rigidity, power or a stable force, elements vital to creep feed appli cations. Preferred creep feed table drives feature a heavy duty ball nut feed screw and heavy duty motors to facili tate the positive feed control required for its application. Grinding wheels are specifically designed to meet creep feed grinding's harsh demands. They key to their suc cess lies in the term "S.O.S." -- meaning soft, open and sharp. These wheels are composed of sharp aluminum oxide or tough silicon carbide abrasive. Creep feed wheels are produced by a process that results in a prod uct that is extremely open in structure. There are some very good reasons for this: first, the open structure pro vides a place for the chip to go until it can be thrown out. Second, it facilitates the transportation of the metal working fluid through the cut. Third, it lowers unit pres sure and reduces the risk of burning. These grinding wheels feature a soft grade which per mits the sharp grains to do their job in an effective man ner without damaging the part. As pressure increases the wheel simply fractures before part damage can occur. The result: no scrap, no heat and no distortion. Producing burr and burn-free parts, when creep feed grinding, requires the application of the proper metal working fluid. There is no better fluid to use than a pre mium soluble oil with EP additives. These fluids at 20:1 and 30:1 ratios permit you to creep feed grind on ferrous materials quickly, accurately and economically. It is important to point out that, because of its slower speeds and deeper cuts, creep feed grinding requires a high gallon per minute (G.P.M.) fluid system with piping arranged in such a way as to increase pressure as the fluid nears the wheel. The fluid nozzle and its placement are also critical, most jobs require a custom designed nozzle to fit the shape of the part to be ground. To eliminate any chance of burning, the fluid must be applied in the same direction that the part is traveling, pulled into and through the cut by the open-structured creep feed grinding wheel. Most creep feed grinding technical specialists will be happy to show you how to set up your creep feed grinding system. Finally, you might be interested in knowing some of the manufacturers of quality creep feed grinders: ABA Excello ELB Gallmeyer & Livingston Hauni-Blohm Jung Mattison Magerle Niagara Grinding of Flat Surfaces Surface Grinding In peripheral surface grinding, the wheel axis of rota tion lies parallel to the surface being ground. In face surface grinding, the wheel axis of rotation is perpendicular to the surface being ground. Peripheral Grinding Face Grinding Comparison of peripheral surface grinding and face surface grinding. Up Grinding Less sensitive for burn Rougher finish (less rubbing) Increased Fn MIL 000201 11-6 Down Grinding Heat flow and thermal conductivity are important. On super alloys (low thermal conductivity) CBN wheels are conducting heat widening the constraint. Selection of table feed V,,and depth of cut is important and critical. Select wheel grades soft to avoid constraint for thermals. More rigid Less burr More apt to burn Slightly better finish Thermal Damage Constraint Thermal damage constraint depends on: Depth of cut and creepfeed rate Thermal conductivity of material Grinding wheel grading Truing technology Metalworking fluid and application For a given set of conditions it is essential to generate the thermal constraint diagram which defines the areas of non-thermal and thermal damage. Creepfeed Grinding Thermal Damage CBN Wheels Conductive materials Good fluid application Good sharp truing Softer wheels Lower thermal conductivity Harder grinding wheel Bad metalworking (luid Bad truing conditions Variables effecting thermal damage constraint 11-7 MIL 000202 12 Tool Room Grinding NOTE: Always consult the Cimform Grinding Wheel Stock Catalog for wheels in these size and grade families. Always try to utilize wheels which are in stock and encourage the customer to order quantities instead of one or two pieces. MIL 000203 12-1 Recommended Starting Grades For Toolroom Grinding Job Hobs Tool & Cutter Milling Cutters Tool & Cutter Gr. Face Mill & Side Mill End Mills Formed Cutters Shell End Mills (Large) Shell End Mills (Small) Side Mills (Small) Lathe & Planer Tools Tool & Cutter Gr. Large Tools Small Tools Chip Breaker Reamers Cylindrical Gr. Backing Off Taps Sharpening (Grind Chamfer) Squaring End Touch Up Flutes Broaches (Round, Spline, Etc.) Cylindrical (Wet) Sharpen Backing Off Broaches (Flat & Keyway) Sharpening Backing Off Boring Tools Tool & Cutter Gr. Counterbore & Spot Facers Small Large Drills -- Sharpening Off Hand - Under 'A" Dia. Off Hand - V." to 1" Dia. Off Hand - Over 1" Dia.' Drills (Machining Sharpening) Under V." Dia. 'A" to 1" Dia. Over 1 " Dia. Point Thinning Wheel Type H.S. Steel and Alloys Carbon Tool Steel Carbide (Green Grit) 12 9A60-H6-VRW 9A60-H6-VRW 5C60-J6-VSC Carbide (Diamond) 1-1A1-6A9 11-11V9 12-12A2 6-11V9 1-11V9 1-6-11V9 9146-16-VRW 9A60-H6-VRW 9A60-H6-VRW 9A46-H6-VRW 9A60-H6-VRW 9A60-H6-VRW 9A46-I6-VFW 9A60-H6-VRW 9A60-H6-VRW 9A46-H6-VRW 9A60-H6-VRW 9A60-H6-VRW 5C60-J6-VSC 5C60-J6-VSC 5C60-J6-VSC 5C60-J6-VSC 5C60-J6-VSC 5C60-J6-VSC CMD120-P100-BY V, CMOI20-PI00-BY 7. CMD150-P100-BY 7, CMD120-N100-BY 7, CMD120-P100-BY 7, CMD120-PI 00-BY 7, 6-11V9 6-11V9 1A1 9146-H6-VRW 9A46-H6-VRW 5C60-J6-VSC 9A60-H6-VRW 9160-H6-VRW 5C80-J6-VSC CMD150-R100-BY 7, CMD220-R100-BY 7a CMD120-P100-8Y 7 1-1A1 1-6-11V9 9A60-J6-VRW 9146-16-VRW 9A60-J6-VRW 9A46-I6-VRW 5C80-I6-VSC 5C60-I6-VSC CMD220-N100-BY 7a CMD220-N100-BY 7a 1 9A60-I6-VRW 9A60-I6-VRW 1 9A60-I6-VRW 9A60-I6-VRW 1 9A60-H6-VRW 9A60-H6-VRW 1 6-12 6-11 9A80-J6-VRW 9A60-H6-VRW 9A60-I6-VRW 9A80-J6-VRW 9A60-B6-VRW 9A60-I6-VRW 12-12V9 6-11V9 9A80-I6-VRW 9A60-I6-VRW 9A80-I6-VRW 9A60-I6-VRW 5C60-J6-VSC 5C60-J6-VSC CMO150-N100-BY 7a CMD 150-PI 00-BY 7a 6-11V9 9A60-H6-VRW 9A60-H6-VRW 5C60-J6-VSC MD150-N100-BY 7, 1-11V9 1-11V9 9A6Q-I6-VRW 9A60-I6-VRW 5C60-J6-VSC 9A46-H6-VRW 9A46-H6-VRW 5C60-J6-VSC MD150-N100-BY 7a MD150-N100-BY 7a 1 9A80-H6-VRW 9A80-H6-VRW 1 9A60-J6-VRW 9A60-J6-VRW 1 9A46-J6-VRW 9A46-J6-VRW 6A2H-P.M. RA2H-P.M. 6A2H-P.M. 1 9A80-H6-VRW 9A60-J6-VRW 9A46-J6-VRW 9A80-K6-VRW 9A80-J6-VRW 9A60-J6-VRW 9A46-J6-VRW 9A80-K6-VRW CMD 180-R100-BY 7. CMD150-P100-BY 7, CMD 120-N100-BY 7a To use VFM go 1 grade higher. Use VSA on burn sensitive material. Use 3MS8 for general purpose tool steel, wet. If grind is dry, use 5MS8. 12-2 Toolmaster^Toolmaster wheels are available in both diamond and CBN. Most common sizes are available from stock, ready for immediate delivery. MIL 000204 TOOLMASTER Diamond & CBN Wheels nnxTHKxlD 3V, x 1'/ x 1 V, 4064-D 4 x 0.032 x 3A 4 x 0.032 x 3A 4 x 0.032 x IV. 4 x 0.032 x I'/. 5 x I3/, x IV. 4065-D 6 x 0.032 x 1V. 6 x 0.032 x 1V. 6 x 0.062 x 1V. 6 x 0.062 x 1V. 6x V, x I'/. 6x V. x IV. 6 x 7 x 1V. 6 x 'Ax IV. 6x7. x I'/. 1012-D 7." Rim Width 6 x 7. x 1V. 1014-0 7." Rim Width 6x7. x IV. 1092-D 7." Rim Width 7 x 0.032 x 1V. 7 x 0.032 x IV. 7 x 0.062 x 1V. 7 x 0.062 x 1V. 7 x V. x 1V. 7 x 7 x 1V. 7 x 7. x 1V. 7 x 'A x 1 Vs 7 x 'A x IV. 10 x 0.060 x IV. 10 x 0.060 x I'/. 12 x 'A x 5 12 x 'A x 5 1x1x5 12 x 1 x 5 14 x 'A x 5 14 x 'A x 5 14x1 x5 14 x 1 x 5 GRADE BN150-W-BBL-V* BNIOO-W-BBL-'A BN150-W-BBL-V, NCD150-R100-BDL-'A, NCD100-R100-BDL-V, NCD150-PI OO-BDL-'A NCD150-R1 OO-BDL-'A BNIOO-W-BBL-'A NCD100-R100-BDL-V BNIOO-W-BBL-'A NCD100-R1 OO-BDL-'A BN150-T-BBL-V, BN150-W-BBL-'/. NCD150-R1OO-BDL-'A, NCD150-R10O-BDL-'A NCD150-R75-BDL-'A BNIOO-W-BBL-'A NCD100-R 100-BDL-V, BNIOO-W-BBL-'A NCD100-R 10O-BDL-'A NCD150-R1 OO-BDL-'A BN150-W-BBL-V, NCD150-PI OO-BDL-'A NCD150-R100-BDL-'A NCD220-R75-BDL-V, NCD150-P75-BDL-V. NCD100-P75-BDL-V, BN150-W-BBL-V, NCD100-R1 OO-BDL-'A BNIOO-W-BBL-'A, NCD100-P75-BDL-V,, NCD220-P75-BDL-V., NCD220-P1 OO-BDL-'A, NCD150-P75-BDL-'A, TYPE 11V9 11V9 11V9 11V9 11V9 11V9 11V9 1A1R 1A1R 1A1R 1A1R 11V9 11V9 11V9 11V9 11V9 1A1R 1A1R 1A1R 1A1R 1A1 1A1 1A1 1A1 1A1 1A1 1A1 1A1 1A1 6A2C 6A2C 6A2C 6A2C 6A2C PROD CODE 6017VH1 607211 6017K1 6017G1 608281 611851 6017J1 8137A1 8137D1 8137E1 8137F1 6194X1 6017P1 6017L1 6017M1 6258T1 8137G1 8137H1 8137J1 8137K1 6014D1 601781 601721 6128D1 6101D1 613351 601731 6017A1 601741 6183E1 602721 602741 602751 602711 NCD150-P75-BDL-V,, NCD220-P1 OO-BDL-'A, 6A2C 6A2C BNIOO-W-BBL-'A NCD100-R1 OO-BDL-'A BNIOO-W-BBL-'A NCD100-R1 OO-BDL-'A NCD150-R75-BDL-V, NCD150-R75-BDL-V, NCD220-R1 OO-BDL-'A BN150-T-BBL-V, NCD150-R75-BDL-V. BNIOO-W-BBL-'A NCD100-R 10O-BDL-'A BNIOO-W-BBL-'A NCD100-R1 OO-BDL-'A BNIOO-W-BBL-'A NCD220-P75-BDL-V, BNIOO-W-BBL-'A NCD100-R1 OO-BDL-'A BN220-W-BBL-V, NCD220-P75-BDL-V, 1A1R 1A1R 1A1R 1A1R 1A1R 1A1 1A1 1A1 1A1 1A1R 1A1R 1A1 1A1 1A2 1A1 1A1 1A2 1A1 1A1 602701 6513X1 8137L1 8137M1 9137N1 8137P1 601751 601761 6177Q1 6017F1 601771 8137Q1 8137R1 813711 813721 813731 813741 813751 813761 813791 813781 MOS 9669 9669 9669 9669 9669 9669 9669 9072 9072 9072 9072 7257 7257. 7257 7257 7257 6048 6048 6048 6048 6048 6048 6048 6048 6048 6048 6048 6048 6048 6048 6048 6043' 6043 6048 UPC CODE 662506-10188 662506-10184 662506-10189 662506-10150 662506-10143 662506-10147 662056-10151 662506-84830 662506-84831 662506-84832 662506-84833 662506-12345 662506-12346 662506-12327 662506-12328 662506-12326 662506-84834 662506-84835 662506-84836 662506-84837 662506-12881 662506-13091 662506-13080 662506-13081 662506-13082 662506-13153 662506-13151 662506-13510 662506-13488 662506-13955 662506-13902 662506-13926 662506-13927 662506-13914 APPLICATION Tool Steel-Med. Finish Tool Steel-Roughing Tool Steel-Med. Finish Non-Ferrous Med. Finish Non-Ferrous Roughing Tool Steel-Med. Finish Non-Ferrous Med. Finish Ferrous Cut-Off Non-Ferrous Cut-Off Ferrous Cut-Off Non-Ferrous Cut-Off Tool Steel-Med. Finish Tool Steel-Med. Finish Non-Ferrous Med. Finish Non-Ferrous Med. Finish Non-Ferrous Med. Finish Ferrous Cut-Off Non-Ferrous Cut-Off Ferrous Cut-Off Non-Ferrous Cut-Off Non-Ferrous Med. Finish Tool Steel-Med. Finish Non-Ferrous Med. Finish Non-Ferrous Med. Finish Non-Ferrous Fine Finish Non-Ferrous Med. Finish Non-Ferrous Rouqhinq Tool Steel-Med. Finish Non-Ferrous Rouqhinq Tool Steel-Roughing Non-Ferrous Roughing Non-Ferrous Fine Finish Non-Ferrous Fine Finish Non-Ferrous Med. Finish 6048 6048 662506-13915 662506-13928 Non-Ferrous Med. Finish Non-Ferrous Fine Finish 5184 5184 5184 5184 5184 5184 5184 5184 5184 3629 3629 3024 3024 3024 3024 2592 2592 2592 2592 662506-84838 662506-84839 662506-84840 662506-84841 662506-15388 662506-15494 662506-15497 662506-16048 662506-16044 662506-84842 662506-84843 662506-84821 662506-84822 662506-84823 662506-84824 662506-84825 662506-84826 662506-84829 662506-84828 Ferrous Cut-Off Non-Ferrous Cut-off Ferrous Cut-Off Non-Ferrous Cut-Off Non-Ferrous Med. Finish Non-Ferrous Med. Finish Non-Ferrous Fine Finish Tool Steel-Med. Finish Non-Ferrous Med. Finish Ferrous Cut-Off Non-Ferrous Cut-Off Tool Steel-Roughing Non-Ferrous Rouqhinq Tool Steels Roughing ` Non-Ferrous Fine Finish Tool Steel-Roughing Non-Ferrous Rouqhinq Tool Steel-Fine Finish Non-Ferrous Fine Finish MIL 000205 12-3 Machine And Wheel Sizes CINCINNATI MONOSET Cutter and Tool Grinder (Older Model Machines) Supplied as Standard Equipment Wheel Size 3x'/<x 7. 3 X 7. X 7. 3 X '/: X 7, 3 X 7, X 7. 3 X % X 7, R 1/S IV* XV, 3% X '/,, X V. 37, X 7. X V. Products Div. Shape S/S S/S s/s 12Y100 Type 5 S/S S/S 9 CiSO cg v> .59- S iS" 1 CO (Newer Model Machines) 37, x 17, x % 4 X 7,6 X V, 4 X 7. X V, 4 X 7. X V. 4 X 7, X V, 4 X V. X 7, R 1/S 2 X V. 4 X 7, X V. Complete Set of Above Wheels-------- 11Y172 S/S S/S S/S S/S Type 5 12Y302 Specifications 12A120-I6-VRW 12A60-I6-VRW 12A60-I6-VRW 12A60-H6-VRW 12A60-H6-VRW 2A60-Q9-B2 2A60-Q9-B2 C.M. Co. Catalog No. 102757 102758 102759 102760 102761 10676 102756 'iORRO7 12A60-I6-VRW 2A60-Q9-B2E 2A60-Q9-B2E 12A120-I6-VRWE 12A60-I6-VRWE 12A60-H6-VRWE 12A60-I6-VRWE 325535 325529 325530 325531 325532 325533 325533 ----- 325609 CINCINNATI MONOSET Cutter and Tool Grinder Mounted Wheels Supplied at Extra Cost Wheel Size 7,6 x 7. Mandrel 7.x 17. V. X 7. Mandrel 7,x 17, V. x 7,, Mandrel 7,x 17. 7, X 7, Mandrel 7,5 x 17. 7. X 7. Mandrel 7,6x17. 17.X 7. Mandrel 7, x 17. Products Div. Shape W152 7.x 17, Mandrel W160 7.x 17. Mandrel B-81 7.x 17, Mandrel . W183 7..X17. Mandrel W201 7,6x17. Mandrel W225 7, x 17. Mandrel Specificatins 12A80-L-V6 12A80-K-V6 12A120-R-V6 12A80-K-V6 12A80-K-V6 12A80-0-V6 C.M. Co. Catalog No. 102751 102752 102755 102753 102754 107326 Speed (RPM) 8276 8276 8276 8276 8276 13096 13096 6547 13096 13096 8276 8276 8276 8276 MIL 000206 12-4 Tool Room General Recommendations Straight and Type 12 Wheels End Mills High Speed Steel Type 6 and 11 Cups Broaches High Speed Steel Wheel Type Conventional Type 1 Wheels WA462-J4-V2 Type 4 Wheels Ingersoll WA462-J9-V 6" and 7" 10'' Type 1 Automatics Type 6 Cup Wheels LA603-J4-V Type 11 Cup Wheels LA603-J4-V Type 12 Dish Wheels WA542-I9-V2 For Cast Alloy Types, we suggest one grade softer. Milling Cutters High Speed Steel Open Structure WA54-I12-VC WA54-I12-VC WA60-I10-V WA60-I10-V 2A54-H11-VF2Q Cylindrical Backing Off Reamers Fluting Small Taps Large Taps Squaring Ends Cylindrical Grinding of Shanks Taps Toolroom Cut-Off 7 x 1/16 x 1-1/4 7 x 1/32 x 1-1/4 Single Point Lathe and Planer Tools High Speed Steel Rough Bench and Pedestal Grinding-Straight Wheels Wheels up to 8" LA603-J4-V Wheels over 8" LA603-I4-V Plate Mounted, Easy-Mount and Recessed Wheels Wheels 6'' and 7" HA36-J9-V Wheels over 7" HA36-I9-V Cemented Carbide Rough Bench and Pedestal Prefer diamond wheels Grinding-Straight Wheels Wheels up to 8" GC60-J9-VP Wheels over 8" GC60-J9-VP Plate Mounted, Easy-Mount and Recessed Wheels Wheels 6" and 7" GC60-J9-VP Wheels over 7" GC60-I9-VP2 WA60-I5-V WA60-I10-V Cemented Carbide Prefer Diamond GC60-J9-VP GC80-I9-VP GC601-K5-B1XS GC461-J5-BXS GC601-K5-B1XS GC60-J9-VP GC601-K5-B1XS GC60-I9-VP2 WA543-I9-V2 WA46-I10-V2 WA543-I9-V2 WA60-J9-V LA603-J4-V LA603-J4-V 2A60-N6-B90 2A60-N6-B90 Finish WA603-I9-V2 WA603-I9-V2 HA60-I9-V HA60-H9-V Finish GC1002-17-V8 GC1002-17-V8 GC1002-I7-V8 GC1002-I7-V8 MIL 000207 12-5 Tool Room General Recommendations (cont'd.) Wheel Type 7 x 1/2 x 3/4 B Face 65 10X 1 Offhand Resharpening Machine Resharpening Hobs Barber-Colman Machines Conventional Open Structure WA60-I9-V2 LA602-I13-V2 WA60-I13-V LA60-H11-VF2 Drills 3/8" and Smaller LA702-K9-V LA702-L9-V Ceramic 3WB602-H13-V 3WB602-G11-VF2 Over 3/8" LA462-J9-V LA462-K9-V Grain Conversions Company Regular SemiFriable Friable Green Black Mix FMR A FA HA JA LA WA 36A 13A GC C RC CIN MIL 2A 2A 97A/29A 32A BAYSTATE A 3A 8A NORTON A 57A 19A 32A 9A 9A 38A 12A 17A 25A 5C 1C 39C 6C C 37C 7C 3C 74C CERAMIC GRAINS Regular 1WB 3WB 4WB WB 6WB BG 1MSB 3MSB 3MSB 5MSB 5MSB MSB IGA 3GA 3GA 5GA 5GA GA 1SG 3SG 3SG 5SG 5SG SG Use V-VC-VF Bonds with WB Grain. In general, we grade on grade softer thane ompetitors with WB or MSB. 3 WB-WB 3MSB and 5MSB are the most popular selections. To reap the full benefits of MSB or WB you must be able to vary grind cycles, pieces per dress and dress depth. For dry grinding, use WB or 5MSB. 3WB-V is softer than 3MSB-VSA. Reischauer Gear Tooth Grinder Wheel Size: 13% x 4V& x 6'9/ Typical Wheel Grade: 9A80-J8-VAE 3MSB801-H8-VSAE MIL 000208 12-6 J i j j CINCINNATI No. 1, No. 2 Plain, And No. 2 Universal Cutter & Tool Grinders Wheel Size 37s x1'/,x 17. 5 x V/z x 1 7. 6X 7.X 17. 6 X 7? X 17. 6 X V. X 17. Onmplpte Ret Of Above 37s X 17s X 17. 37s x 17s x 17. 5 X 17s X 17. 5 X 17s X 17. 6 X Y. X 17. 6 X Y. X 17. 6 X 7s X 17. 6 X 7s X 17, Y, X 7s X 7. Y. X 7s X 7. Y, X 7, X 7. 1 X 7s X Y, 8 x 7.6 x 17. 8X 7, X 17. Products Div. Shape 11Y120 6Y112 S/S S/S 12Y155 #23 #24 #28 #25 #21 11Y120 11Y120 6Y112 6Y112 12Y155 12Y155 S/S S/S S/S S/S S/S S/S S/S S/S #23 #24 #21 #25 #29 #26 #30 #27 Specifications 9A60-I6-VRW 9A60-H6-VRW 2A60-K9-B2 9A54-I6-VRW 9A60-I6-VRW 5C60-I6-VSC 5C80-H6-VSC 5C60-I6-VSC 5C80-H6-VSC 5C60-I6-VSC 5C80-H6-VSC 5C60-I6-VSC 5C80-H6-VSC 9A80-J6-VRW 9A60-J6-VRW 9A80-J6-VRW 9A80-J6-VRW 2A60-K9-B2 9A46-H6-VRW C.M. Co. Catalog No. 67783 62277 67782 60479 60481 w. 325608 102843 102844 102845 102846 102847 102848 102849 102850 158178 158179 99796 158180 74012 65613 No. 2 MT Cutter and Tool Grinder with power table traverse. MIL 000209 12-7 Wheel Shapes And Sizes Common Dimensional Standards The most popular tool room wheel types are straight (type 1), tapered two sides (type 4), straight cup (type 6), flaring cup (type 11), dish (type 12) and saucer (type 13). Common blueprints for Type 11 and Type 12 wheels are as follows: 12-8 Type 1 Wheels Wheel Size Shape 6 x '/i x 1 '/< 7 x V, x 1'/, 7 X 7; X 1 V, 8 x 'A x 1 'A 8 X '/. X 1V. Straight Grades Available From Stock 9A46 H H,l G.H.I.J H H,l 9A60 H,l H.I.J G.H.I.J H,l H,l 9A80 1 l,J H.I.J 1 Wheel Size Shape Grades Available From Stock 10 x'/.x3 10x1x3 12x1 x 3 12x1 x5 Straight 9A46 1 H,l H,l H 9A60 H H,l H H.l 9A80 Type 11 blueprints (hole size usually '/2 to VU) Print Ho. Dimensions 0 H wK A E VT j t1Y34t-Z 3 V, Yi 1-9/16 V, V, 30 17. 2Y. 11Y126-Z 3Y. V, 7. 17, V. V. 30" 17. 2 V, 11Y179-2 37, V, 7. 2Y. V. V, 30" 17; 2/. 11Y213-Z 4 7/16 7. 27, V, V, 30 17; 3 11Y237 47, r/. Vi 2V..3 V. V, NO UY- 2V-.3 /. 11Y146 4V, V, 7. 3V, 2V. V, NO 37. 1IY243-Z 5 V, 7. 3-1/16.3V. V, V, 30 17. 3V. 11Y161-Z 6 V, V, 37,. 37, V, V, 30 2 47; 11Y297 7 V. 7, 3/. 2V. V, NO 5 Type 12 blueprints (hole size usually '/2 to IV.) Print No. Dimensions HDAK 12Y116 7. 3 V. IV, 12Y305 V. 37, 3/16 IV. 12Y120 7, 4 3/16 2 12Y280 7. 4Y, V. 27. 112Y131 V. 5 V. 27, 112Y140 7i 6 V, 3 112Y150 7: 6 V, 3 12Y363 17. 7 7/16 3/, 12Y231 1 A 7 /.V. 3V. 2V. 12Y123 7. 8 /, 4 12Y308 7; 8 / 4 12Y208 4 10 2 37, 12Y324 1 /. 10 2.27, 37. J EUT 17, 5/16 1/16 7; IV. 5/16,7. 3/32 7.- 2 5/16 3/32 / 27. 5/16 7, 7 27, 5/16 7, 7; 3 5/16 7, 7; 3 V. 7, 7. 2V, 11/32 7, 7. 27. 7, /, 2 4 ' "7. 7. 7. 4 7, /, 1 37,.4 11/16 7, 1 6V..6 11/16 7,-. 1/16 1.1/16 Additional Sizes & Shapes Available Stocked in Cincinnati MIL 000210 Type 11 And 12 Wheels Available from Stock Eliminate flat (Va inch) and 30 angle from Types 6 & 11 prints. These wheels are put in stock with a straight rim. If stan dard "X" face (Type 6) or standard "Y" face (Type 11) are required, program prices are not applicable. PLAIN CUP WHEEL TYPE 8 Wheel Size 5 x 1'Ax I'A R 1/S 4'A X IV, Shape Grades Shown Are Available From Stock 9A46-G6-VRW 9A46-H6-VRW 9A46-I6-VRW 9A60-H6-VRW 9A60-I6-VRW 12A60-I10-VA 12A60-J6-VA 5C60-J6-VSC DISH WHEELS TYPE 12 FLARING CUP WHEELS TYPE 11 Wheel Size 6 X 'A X 1'A Wheel Size 6 X V. X 1 'A Wheel Size 3'A X 1 'A X 1 'A Shape 12Y145 Shape 12Y155 Shape 11Y120 Grades Shown Are Available From Stock 9A46-G6-VRW 9A46-H6-VRW 9A46-I6-VRW 9A46-J6-VRW 9A60-G6-VRW 9A60-H6-VRW 9A60-I6-VRW 9A60-J6-VRW 12A60-I10-VA 12A60-J6-VA 5C60-J6-VSC 9A80-H6-VRW 9A80-I6-VRW 9A80-J6-VW 9A100-H6-VRW 9A100-I6-VRW 9A120-H6-VRW 9A120-I6-VRW Grades Shown Are Available From Stock 9A46-G6-VRW 9A46-H6-VRW 9A46-I6-VRW 9A46-J6-VRW 9A60-G6-VRW 9A60-H6-VRW 9A60-I6-VRW 9A60-J6-VRW 12A60-I10-VA 12A60-J6-VA 5C60-J6-VSC 9A80-H6-VRW 9A80-I6-VRW 9A80-J6-VW 9A100-H6-VRW Grades Shown Are Available From Stock 9A46-G6-VRW 9A46-H6-VRW 9A46-I6-VRW 9A46-J6-VRW 9A60-H6-VRW 9A60-I6-VRW 9A60-J6-VRW 12A60-I10-VA 12A60-J6-VA 5C60-J6-VSC 9A80-H6-VRW 9A80-I6-VRW Wheel Size Shape Grades Shown Are Available From Stock 4 X I'A X I'A Wheel Size 5 X PAXI'A 11Y128 Shape 11Y148 9A46-G6-VRW 9A46-H6-VRW 9A46-I6-VRW 9A46-J6-VRW 9A60-G6-VRW 9A60-H6-VRW 9A60-I6-VRW 9A60-J6-VRW 12A60-I10-VA 12A60-J6-VA 5C6Q-J6-VSC 9A80-H6-VRW 9A80-I6-VRW Grades Shown Are Available From Stock 9A46-G6-VRW 9A46-H6-VRW 9A46-I6-VRW 9A46-J6-VRW 9A60-G6-VRW 9A60-H6-VRW 9A60-I6-VRW 9A60-J6-VRW 12A60-I10-VA 12A60-J6-VA 5C60-I6-VSC 5C60-J6-VSC 5C60-H10-VSC - 9A80-H6-VRW 9A80-I6-VRW ^A80-J6-VRW 5C80-I6-VSC 5C100-I6-VSC All wheels have glued-on blotters MIL 000211 12 12-9 Grinding Wheels For SPIROPOINT Drill Sharpening Machines (Numbers in Parenthesis are Cincinnati Milacron Part Numbers) Collet Mounted Wheels (Old Model) Drill Size Wheel Grading #60 - V. 4A220-N4-VFM '/j - Vs 4A100-M6-VFM 7* - 7. 4A60-L6-VFM 7, - 1 4A46-K6-VFM Wheel Shape* 1075-Y and 1076-Y (710816) (710817) 1013-Y and 1014-Y (710715) (710717) 1013-Y and 1014-Y (710716) (710630) 1013-Y and 1014-Y (710134) (710135) NOT APPLIED TO MACHINES AFTER AUG. 1960. *NOTE: Blotters not used 1013-Y 1014-Y 1075-Y Arbor Mounted Wheels (New Model) Drill Size Wheel Grading #60 - '/a 4A220-N4-VFM '/a - Vs 4A100-M6-VFM V2 - 7a 4A60-L6-VFM 7a - 1 4A46-K6-VFM Wheel Shape* 1720-Y and 1721-Y (710335) (710345) 1420-Y and 1421-Y (710123) (710128) 1420-Y and 1421-Y (710144) (710146) 1420-Y and 1421-Y (710145) (710147) 1420-Y issp 1421-Y 1720-Y Wl v\vi' . 1721-Y czzmm "NOTE: Use blotters when mounting wheels 12-10 \i MIL 000212 Cincinnati Projecto-Form Grinding Machine Wheel Size Products Div. Shape 6 x 'A x 1 'A 7 x .040 x 1 'A 3'A x I'A x 7s S/S S/S 11VI23 Special Wheels for GLEASON Gear Cutter Grinders Specifications 4A120-J6-VFM MD150-R100-B1/8 9A60-H6-VFM C.M. Co. Catalog No. None Assigned None Assigned None Assigned Typical Grade 9A70-I6-VRW Easy Mount Wheels Available Grades Bond Type VFM Grain Types 2A, 4A, 9A, 12A, 97A VL 2A, 4A, 9A, 97A VSC 5C, 6C, 7C STERLING Easy Mount Wheels D H ! 'AR -12-7*A- I__30 9"/* Typical Grade 9A80-J6-VRW 740' / TIR .020 Max 'W FROM O.D. 4 St. 36-46 H-R 54-80 G-R 90-150 F-S 180-220 F-R 24-60 P-U 70-220 N-T Grades 6 St. 24-30 H-N 36-46 G-N 54-80 F-N 90-120 F-M 24-80 N-T 90-100 L-T 120-150 K-S 180 l-R 220 J-P 24-36 G-U 46-60 F-U 70-220 E-T lost. 24 E-K 30-150 D-K 24 E-0 30-46 D-N 54-80 D-M 90-100 D-L 24-36 F-N 46 F-M 54-120 D-L 12 Hard Side For Mounting MIL 000213 12-11 Reishauer Gear Grinding Wheels A Reishauer (pronounced Rye-Shower) Gear Grinder is essentially a gear hobbing machine with a grinding wheel used in place of teh customary gear hob. The wheel has a thread cut into the O.D. that corresponds to the "Diametral Pitch (DP)" of the gear being ground. Typical sizes would be: 350 x 104 x 160 mm (13.780 x 4.094 x 6.299 in.) 400 x 104 x 160 mm (15.750 x 4.094 x 6.299 in.) A typical grade would be 9A80-H6-VRW Cincinnati has the capability of generating the spiral thread form required for these wheels. In order to facili tate orders for these wheels a blank drawing should be requested from Cincinnati so that the customer can sup ply the information needed to accurately generate the desired form. The minimum information needed is: 1. Diametral Pitch - D.P. 2. Pressure Angle - P.A. 3. Right Hand or Left Hand Threads 4. Number of Starts 5. Thread Lead Machine Type HSS60, HSS60/80 HSP-80 HSS60, HSS 60/80 HSS-90P HSS-90S SHS-150S HSS-360 Wheel Size 280 X 33 X 90 mm (11.024 x 1.299 x 3.543 in.) 280 x 257a x 40 mm (11.024 x 1.004 x 1.575 in.) 340 x 27 x 55 mm (13.386 x 1.063 x 2.165 in.) 340 x 29 x 150 mm (13,386 x 1,142 x 5.906 in.) 450 x 29 x 127 mm (17, 716 x 1,142 x 5 in.) 500 X 41 X 160 mm (19.685 x 1.614 x 6.299 in.) Standard Rim Widths 4 or 8 mm 3, 6 or 9 mm 6, 8 or 12 mm 6, 8 or 12 mm 5, 10 or 12 mm 10 mm Side Relief Angle 13 5 6 10 5 10 AS MFG. REF. ONLY 12-12 MIL 000214 Special Wheels For Barber Colman HOB Grinders Prints shown above are typical. Other prints of varying design and overall dimensions are on file in Cincinnati. 9A46-H6-VRW would be a typical grading. Special Wheels For Maag Gear Grinders Maag, a Swiss company, manufactures a number of these machines. Some machine types and wheel infor mation associated with these machines are listed below. There are some Maag prints on file in Cincinnati. Fully and accurately dimensions drawn are needed to gener ate Cincinnati prints for new items. A typical wheel grade wouid be 9A60-G6-VRW. Machine Type HSS-10, HSS-30 HSS-10, HSS-30 Wheel Size 220 X 20 X 90 mm (8.661 x .787 x 3.543 in.) 220 x 17 x 40 mm (8.661 x .669 x 1.575 in.) Standard Rim Widths 2, 4 or 6 mm 2, 4 or 6 mm Side Relief Angle 12 5 Model 21 Drill Pointer Wheel Size: 5 x 2 x 5/8 Recessed or Plate Mounted Typical Grade: 9A60-J4-VFM 29A801-J4-VA MIL 000215 12-13 Toolroom Applications Rough grinding the chamber of a sin tered carbide face mill--cutter is rotated by the cylindrical grinding attachment. AMD100-R100-B5 -- dry CMD100-R100-B -- wet Grinding a relief angle on a carbide lathe tool--the tool shank is held in the surface grinding attachment, equipped with an intermediate swivel support. AMD120-P100-B5 CMD120-P100-B A typical setup to grind a plain milling cutter--the cutter clearance angle is obtained by lowering the toothrest below the center of the cutter. 9A80-I6-VRW 3MSB801-I6-VSA 1BN100-W-B7 Sharpening the teeth on a 10" diam eter saw--this setup is greatly simpli fied by the tilting wheelhead and uni versal toothrest plate. 9A80-I6-VRW 1BN100-W-B7 3MSB801-I6-VSA Ecccentric wheelhead and swivel table provide added range to grind the face of this extended shell end mill. 9A60-H6-VRW 1BN80-Q100-B4 3MSB801-H6-VSA The No. 2 radius grinding attachment includes a micrometer device, used to accurately determine the correct radius. 9A80-I6-VRW 1BN100-Q100-B4 3MSB801-I6-VSA All grinding operations on this large face mill are performed using the face mill grinding attachment. This setup provides ample vertical range and rigid table support. 9A80-H6-VRW 1BN120-W-B7 3MSB801-H6-VSA 12-14 Grinding the tooth face of a form relieved milling cutter, using the gear cutter charpening attachment. 9A100-I6-VRW 1BN120-S100-B4 3MSB801-I6-VSA The internal grinding attachment is ideal for light toolroom operations, such as grinding the I.D. of this bushing. 9A100-K6-VFM 1BN120-Q100-B4 3MSB1001-K6-VSA MIL 000216 Gleason Cup Wheel Cup wheels used on Gleason grindes range in diameter from 3" thru 22" and are generally 47a" thick, this is a low speed (generally 4000-6000 SFPM) and light stock removal operation. The cup rim will normally be angled 20 to 30 from the sides of the rim wall to either a sharp point or a flat, '/" wide in most cases. The inside corner of the recess has either a radius or bevel at the base for added support because of the relatively long length of the rim wall. On occasion, the inside wall of the recess is sulfur painted to help retain coolant in the cutting. These wheels are identified as a 6Y type with a num bered suffix. Example: 6Y-1620 is used to describe the wheels hown above. Many prints of Gleason cup wheels are on file in Cincinnati. Contact for information about other sizes and designs. Gleason Gear Tooth Grinding Wheel i MIL 000217 12-15 Machine and Wheel Sizes Toolrooms are found in almost all manufacturing plants throughout the country. They may be called by other names, such as storeroom, machine shop, or repair shop, but the work done is virtually the same: the main tenance and repair of the cutting tools used in the man ufacturing operation. Various types of grinding are done in tool rooms, such as: 1. Tool and cutter grinding -- milling cutters, ream ers, end mills, etc. 2. Surface grinding -- generally wheels 10" diameter and smaller. 3. Cylindrical grinding -- generally wheels 16" diam eter and smaller. 4. Internal grinding. 5. Drill grinding. 6. Off-hand grinding with mounted wheels and grind ing of the lathe and planer tools. 7. Cutting-off of drills and reamers. Wheels of all sizes and shapes are used. Most wheels are vitrified in grit sizes 36 to 220 and in grades H through N. Most toolroom grinding is done with friable abrasives, 9A-12A-WA-VA and many of these jobs require CBN. A typical toolroom wheel grade for grinding tools shown on the preceding page would be 9A60-I6-VRW for roughing and 9A80-H6-VRW for finishing. Carbide grinding requires diamond wheels. Typical Machine Manufacturers Alina American Drill Baldor Barber-Coleman Black & Decker Black Diamond Blake Blount Brown & Sharpe Cawi Cincinnati Covel Delta Detroit DoAII Dunmore Ex-Cell-O Gallmeyer & Livingston Geometric Gleason Gisholt Grand Rapids Hammond Heald Hisey-Wolf Hybco Ingersoll Jones & Lamson Jones & Shipman Landis LaSalle K.O. Lee Mohawk Norton OKTool Oliver Omark Winslow Royal Oak Sellers Sundstrand Wickman Winslow Chaser Grinding Geometric Tool Co., New Haven, CT Machine/Model Wheel Size Type No. 1G (Old Style) and No. 20 No. 1G 9 x '/2 x 1V. 12Y224 9X1/, x 17. 9 x V, x 7 T-1 T-12 T-1 Jones and Lamson Machine Co., Springfield, Machine/Model Wheel Size Type J & L Bench Chaser Gdr. 6 X 7, X 7; 6 x 17, x 7, R 1/S 5V. x 17 T-1 T-6 12-16 A A / Landis Machine Co., Waynesboro, PA Machine/Model Wheel Size Type "O" "Y" "1" `T* "17," "nr "2" 7 x 7, X 7a 6 x 2 x 7, 12 x 17,x 1 12 x 27, x 7 12 x 1 x 1 12 x 27, x 7 14x1x1 14 x 27, x 7 12 x 17, x 1 12 x 27.. x 7 14 X 17; x 1 14 x 27s x 7 . 18 x2x 17; 18 x 27a x 117, . T-1 R 1/S 5 x 17. T-6 T-1 T 1/S 9 x 17a T-6 T-1 R 1/S 9 x 17, T-6 T-1 R 1/S 9 x 17a T-6 T-1 R 1/S 9 x 17, T-6 T-1 R 1/S 9 x 17, T-6 T-1 T-6 R 1/S 157, x 17, MIL 000218 Machine and Wheel Sizes (cont.) Drill Grinding Machines Alina Corp., Plainville, NY Machine/Model Wheel Size 2-32 SELECT-O-POINT 03-6 05-8 57. x 17. x 50MM 47. x 17, x 50MM R 1/S 47, x 1 Type T-1 T-6 F-Pt. FO-Pt. WFJ WFL No. 44 7, to 4" 12 x 17, x 17, 7. to 4" No. 30 to 4" No. 30 to 17," 7x 1 x I1/,. R 1/S 4'/a x 7, Dunmore Company, Racine, Wl no Cin. print T-5 01-2 3x7. x 16MM R 1/S 27, x 7, T-6 Machine/Model DUNMORE Drill Gdr. Wheel Size 2 x 7a x .250 Type T-1 Black & Webster, Waltham, MA (formerly Black Diamond Saw and Machine Works, and Worcester Drill Grinder.) Machine/Model Wheel Size Type BLACK DIAMOND Drill Gdr. WORCESTER Drill Gdr. Black & Webster Models BW-70 BW-75 BW-80 Black & Webster Models BW-55 BW-60 BW-65 Black Diamond Models 1.2.3 7 x 7. x 7, 6x7. X 17, 6 X 1 7. X 1 7a R 1/S 37. x 7. 97, x 17, x 17, R 1/S 67, x 7, 10 x 1 x7. 6 x 7. x 7, 6 X 7. X 7, 7 X 7a x Q 829-Y T-1 T-6 T-6 T-1 T-1 T-1 T-1 2 x 7a x .250 2 x 7,6 x .250 T-1 for web grinding Gallmeyer and Livingston Co., Grand Rapids, Ml Machine/Model Wheel Size Type A7T, B7T, 20-BB6T, 87, x 17, x 1 B5T, A5T R 1/S 57, x 1 C6A,D6A,C6T,D6T,C5T 107, x 17, x 1 10A, 10B, 10C R 1/S 67, x 1 CWA, DWA 12 x 17, x 1 R 1/S 8 x 1 Grob & Tesker, Grafton, Wl (formerly Ted Grob) T-5 T-5 T-5 Machine/Model Wheel Size Type #300 #100 15x27,x5 R 1/S 77. x 1 8 x '7.6 x 3 R 1/S 47, x 7, 8x17. x 3 R 1/S 47a x 7/16 T-5 T-5 T-5 Brierly Drill Grinder, Des Plaines, IL (Machine & Fixtures) Machine/Model Wheel Size Type Model ZB Point Thinning ZB New Model 7 x 1 x 37, 67, x 7. x 1 10 x 4 x 57. R 1/S 77, x 3 T-1 T-1 T-6 Covel Mfg. Co., Benton Harbor, Ml (YANKEE Drill Grinders) Machine/Model Drill Capacity Wheel Size Type JB-Pt. A JBP-Pt. F-Pt.A FD-PtA WPLA 7. to 17, 7, to 27," No. 30 to 27," 97, x 17, x 17, T-6 R 1/S 67, x 7, Gallmeyer & Livingston VRT Rotary Surface Grinder Wheel Size: 8x3x3, R1/S7x 27. WA461-F12-VC 29A461-G10-VA MIL 000219 12 12-17 Machine and Wheel Sizes (cont.) Hisey-Wolf Machine Co., Cincinnati, OH (Heavy Duty Drill Grinders) Machine/Model Wheel Size Type IJA and IJD Max. 11/4" drills 2JA and 2JD Max. 27/ drills 3JA and 3JD Max. 2'/a" drills 3JJA and 3JJD 3/8" to 27/ 3JWA and 3JWD No. 60 to 27/ 3JJWA and 3JJWD 1/8" to 27/ 6 x 17z x 7i 6 x % x 7* 7 x 17z x V# 7x1x7# 10 x 17a x V# 10 x 1 x 710 x 7a x 7# 10 x 17a x 7# 10 x 1 x 7# 10 x 17s x 7# R 1/S 37# x 7a T-5 T-1 R 1/S 4Va x 7a T-5 T-1 R 1/S 6 x 7? T-5 T-1 R 1/S 6 x 7i T-5 R 1/S 6 x 7a T-5 T-1 R 1/S 6 x 7a T-5 Bench Drill Grinders JA and JD No. 60 to 3/8" 6 x 17# x 7a 6 x 7# x 7a R 1/S 37. x 7a T-5 T-1 Holland Co., Cleveland, Ohio and J & A Machinery, El Paso, TX Machine/Model Wheel Size Type "THE CHAMP" 7 X 1 % X 1 7# R 1/S 4 X 1 T-6 Kurt Orban Co., Inc., New York, NY Machine/Model Drill Capacity Wheel Size Type CAWI Drill Gdr. 7a tO 1" 10 x 1 x * 7a to 7a" 12 to 1" 10 X 17a x * 7# to 7a" Web Thinning High Speed 6 X 7.6 X Va Only 'State whether wheel with 2 or 5 hole is required. LaSalle Tool Co., Ottawa, Canada T-1 T-1 T-1 Machine/Model Wheel Size Type AMERICAN Drill Gdr. 87a x 17a x 1 R 1/S 57a x 1 Lisle Corporation, Clarinda, Iowa T-6 Machine/Model Wheel Size Type DG3 5 x V, x 7. T-1 McDonough Mfg. Co. Machine/Model Wheel Size STERLING DADB-DFDV 6 X 17a X 7a R 1/S 4 x 1 Mohawk, Montpelier, Ohio Machine/Model Wheel Size 48 49, 100 71 302 308 8 X 7. X Va 8 X 17a X 47a Rim 17#" 1P293 8 X 1 7a X 47a Rim 17#" 1P293 12 x 1 x3 12 x 7# x 3 12 X 7a x 3 12 x 1 x3 408 14 x 7# x 5 14 x 27a x 5 Oliver Instrument, Adrian, Ml It/lachine/Model Wheel Size No. 21 Drill Pointer Drill Point Thinner No. 5 or No. 51 Drill Pointer No. 4 Drill Pointer 124/32 No. 510 Drill Pointer Rim 11/32 No. 510 or No. 600 Drill Pointer 5 x 2 x V8 6 X 7a X 17# 6 X 7a X 1 7# 9 X 27# X 47a 8 x 27# x 57a 7 x 2 x 47,a Plate Mounted (7 X 7a x 2) 8x2x5 Rim 17/ Plate Mounted (8 x 7# x 2) 9 x 2 x 47,6 Rim 27aa" Plate Mounted (9 x 7, x 2) Omark Winslow Co., Arcadia, CA) Machine/Model Wheel Size HC Drill Pointer ESACTAMAIC 800 12 x 7# x 5 12 x 7# x 5 3 x 7,6 x 2.015 Type T-6 Type T-1 T-1 T-1 T-1 T-1 T-1 T-1 Type R 1/S 4 x 17s T-1 T-1 S-119 R 1/S 57a x 1P232 1P230 1P131 Type 1 1 1 12-18 MIL 000220 Machine and Wheel Sizes (cont.) S.R.D. Cone Grind Drill Point Grinder - U.S.A. (import) Machine/Model Wheel Size Type DG-76M 1V, x 1 7, x 7.-16 R 1/S 1 x 1 T-6 William Sellers Div. Consolidated Mach. Tool Corp. Rochester, NY Machine/Model Wheel Size Type 1G (Old Style) Formerly 05D) 4G 6G (New Style) 6GA (New Style) 5 X 1 V; X 1 'W Rim 7<'\ 7," back 6 x 17, x 4'/>" Rim 7a" Plate Mounted (6 X 7,a X 17a ) 8 x 3 x 57," Rim 1V Plate Mounted (8 x 7,6 x 376) 10 x2x7V," Rim 17 Plate Mounted 10 x 7a x 3.750" R 1/S 37, x 1 1 P119 1 PI 61 1P180 Hob Grinding Klingelnberg, Germany Machine/Model Wheel Size Type AGW 160 77, x "/,, x 2 AGW 231 10x7, x 2 Lathe And Planer Tool Grinding T-1 T-1 Blount, Milford, NH Machine/Model Wheel Size Type Models B and BG ' Models J and G "Old Style" 12x3x8, Rim 2" Steel Plate (12 x '/sx 1) 12 x 2 x 17, 14 x 1'/, x 4 IP-425 T-1 T-1 Oliver Machinery, Grand Rapids, Mi Machine/Model Variety #384 Variety #585 Wheel Size 6 x 17, x 7, 8 x 7, x 74 8x2x7, 8 x 7, x 7, Sundstrand Machine, Dearborn, Ml Type R 1/S 4 x 1 T-1 R 1/S 67, x 17, T-1 Machine/Model Wheel Size Type SUNDSTRAND Tap Grinding 10 X 3 x 1.250 R 1/S 8 x 27, 10 x 27, x 77,, Rim 17," Plate Mounted (10 x V8 x 17,) or (10x7, x 2) T-6 IP-426 IP-427 Detroit Tap and Tool Co., Detroit, Ml Machine/Model Wheel Size Type DETROIT Tap Grinder 6 x 1 x 7, 6 x 7, x 7a Edward Blake Co., Newton Center, MA Machine/Model Wheel Size Type BLAKE No. 2 6 x 17, x 7, Tap Grinder 5x7, x V, Hybco Products, Inc., Cleveland, OH (formerly Henry P. Bobbis) R 1/S 5 x 7, T-1 Machine/Model Wheel Size Type HYBCO Tap Grinder * 4x1x7, 3 x '/e x 7S 3 x 7,s x 7. 3 X 7, X 7a 3 X 7, X 7a 3 x 7, x 7, T-1 T-1 T-1 T-1 T-1 T-1 Gisholt, Madison, Wl Machine/Model Wheel Size Type GISHOLT (10) x 57, x 4 11Y228 Norton Co., Worcester, MA Machine/Model Wheel Size Type "BURA-WAY" 7 x 17, x 3, Rim 2" Plate Mounted (7 X 7a x 1 '/<") 1P111 MIL 000221 12-19 Gallmeyer & Livingston Co., Grand Rapids, Ml Gleason Works, Rochester, NY (cont.) (Grand Rapids Tap Grinders) Machine/Model Wheel Size Type Machine/Model Size Capacity Wheel Size Type Tool Sharpener 'h" Rim 'IT Back Tap Grinder No. 6-1 '/a" Taps 8V2 X I'/jX 1 T-6 (7) x2x 17, Type 11Y147 No. 1 R 1/S S'h x 1 No. 12 Spiral Bevel 14x7, x 7 12 x 1'/2x 1 T-1 Cutter Sharpener Tap Grinder 7,-3" Taps 8V2 X 1'/;. X 1 T-6 (Old Style) No. 2 R 1/S S'/* x 1 No. 13 Spiral Hypoid 12x7, x 4 12Y382 9x1x1 T-1 Cutter Sharpener Comb. Drill & Tap No. 6-177'Taps Gdr. No. 10A & 10B Tap Grinder No. 6-3" Taps No. 12 Comb. Drill & Tap 7,-3" Taps IO'/jX Vhx 1 R 1/S 77; x 1 12 x 1 '/2 x 1 8'/z x 1 Vz x 1 R 1/S 5% x 1 872 x 1Y;X 1 T-6 T-1 T-6 T-6 Ingersoll (Oliver) Machine/Model INGERSOLL Cutter Grinder Wheel Size 10 x 7. x 1 10 X Vj x 1 10 X 7a X 1 Type T-1 654-Y T-1 Grdr. No. 20B R 1/S 5'/* x 1 K O Lee Co., Aberdeen, S.D. Comb. Drill& Tap Grdr. No. 20C 107; x V/2 x 1 R 1/S 6VZ x 1 T-6 Machine/Model B300 Wheel Size 4 X 1 'll X 7a Type 11Y-142 Oliver Instrument Co., Adrian, Ml or Machine/Model Wheel Size No. 384 Variety Tool Grdr. 6 X 17. X 37a Tool And Cutter Grinding Barber-Coleman Machine/Model Wheel Size Hob Grinder Reamer Grinder' 7 X Ye X Y* lOx 1 X 1' 10x1x1 4x 1'/,xV. Type Type 8582-Y 12Y201 12Y194 R 1/S 37; x 1'/s BA900 B2000 B6000 17, 6 X Yj X 7a or 17, 11Y-128 12Y-215 12Y-145 Oliver Machinery Machine/Model Wheel Size Type Face Mill Gdr. 5 x 2 x 7e #2 or #2A (3) x 17. X 7a Standard Universal 4 x 'h x 7e "ACE" 4 x V/iX 7a Oliver heavy duty "Ace" -- same except 17," hole R 1/S 4 X 17; 11Y127 12Y219 R 1/S 37. x 7, 'NOTE: This is a high speed machine; check RPM before ordering wheels. Contact Cincinnati Milacron Products Representative. Gleason Works, Rochester, NY Machine/Model Wheel Size Type No. 7 Spiral Bevel Cutter Sharpener No. 9 Automatic Disc No. 10 Hypoid Cutter Sharpener No. 12 Generator 8 x 17. x 17, 8 x 17. x 17. 12x7, x 4 7 x 2 x 17, T-12 T-12 12Y382 T-6 Cup Photo: Oliver 600 Drill Pointer 9x2x5 Plate Mount Typical Grade 29A601-K8-VA, WA703-K6-V4 Larger drills require coarser and softer wheel grades 12-20 MIL 000222 Trouble Shooting Problem 1. Wheel comer breakdown 2. Burning of workpiece 3. Poor surface finish or quality of grind 4. Wheel loading or glazing Possible Causes Poor wheel dressing. Wheel too coarse. Wheel too soft. Worn machine bearings. Poor coolant flow. Wheel acting hard. Work speed too slow. Infeed too fast. Wheel too soft. Wheel too coarse. Poor wheel dressing. Machine vibration. Dirty coolant. Wheel too hard. Wheel too fine. Dirty coolant. Poor wheel dressing. Suggested Correction Dress wheel finer. Use finer grit wheel. Use harder grade wheel. Check for run-out and correct. Increase or direct coolant to grinding contact. Dress wheel coarser or use softer wheel. Increase work speed. Reduce amount of stock removed per pass. Dress wheel finer or use harder grade wheel. Dress wheel finer or use finer grit wheel. Check diamond sharpness and redress. Check worn bearings and clamping. Clean coolant through filter. Use softer grade wheel. Use coarser grit wheel. Filter coolant or replace with new. Redress more frequently. Photo: Oliver 300HD Cutter and Tool Grinder Wheel Size: 4 x 2 x 1'A straight cup 4/3 x 2 x 17.i dare cup Wheel Grade: 32A46-I6-VFM 3MS8601-H6-VSA MIL 000223 12-21 13 Mounted Starting Grades Grinding Wheels Offer You These Features Economy CINCINNATI MILACRON mounted wheels specified for .your jobs combine accurate grading and tough bonds, to give you long life and high stock removal. Wide range Cincinnati Milacron offers 215 standard shapes and sizes, including center laps and reinforced resinoid points, in a variety of aluminum oxide and silicon carbide grains and vitrified or resin bonds. Free cutting Gradings recommended by Cincinnati Milacron will give you a smooth, fast-cutting grinding action. Self Dressing CINCINNATI MILACRON graded wheels virtually dress themselves, because as grits become dull and worn, they break away from the wheel and expose new sharp grits. Consult us Your Cincinnati Milacron Marketing Company distributor or sales representative will be glad to help you choose the right wheel. Call us today. MSB mounted wheels are available in most sizes in typi cal grades, i.e. 3MSB601-N-VBH. MOUNTED WHEELS Application Steel: Carbon Castings Stainless Tool-Steel Iron: Cast Iron Diamite Ductile Grey Iron Malleable Ni-Hard Recommendation A24-R4-BH A30-T5-B254 A36-T6-B254 A46-R5-BH R5A36-T5-B5 A30-Q4-BC R5A24-T4-B4 R5A36-T5-B5 A36-T5-B254 C30-Q4-BF 13-1 Starting Grades OPERATION Tool and Die Work (handbarbering)............................................ 9A60-N-V6 Precision Grinding Tungsten Carbide Tools................................................ 5C80-L-V8 Jig Grinding................................................. 9A60-M-V6 General Purpose Work on Soft Steel................................................ 9A60- N-V5 Blending......................................................... 2A80-I-BX Polishing.................................................... 2A80-G-BXP High Finish Polishing.............................. 2A220-P-R Grinding Non-Ferrous Materials................. 6C60-U-V7 Rough Grinding and Deburring...................................................... 2A60-P-V5 General Cast Iron Foundry Work.............................................. 2A30-W-V5 High Speed Foundry Finishing.................................................. 2A36-R-BB Weld Grinding............................................... 2A60-R-V5 If any of the following characteristics exist the wheel grade may be too hard, or too soft, and a shift in grade may help: GLAZE -- Wheel gets a slick shiny appearance and the cutting action is not free. This happens because the grinding pressures are not great enough to break the bond posts holding the worn grain. Generally under these conditions, the finish has a burnished look and some times shows burn marks. A softer grade should be tried. LOADING -- Soft metals (usually below 55 Rockwell C) sometimes leave deposits in the wheel face and inhibit the cutting action. The finish is usually poor because of the galled nature of the cut. Softer and coarser wheels are needed to alleviate this situation. BURN -- Burn marks on the piece are a result of grits becoming worn and dull. Under these conditions the wheel rubs rather than cuts the part and the increased friction raises the temperature high enough to oxidize the material. Fine grain wheels show a much greater tendency to burn than do coarse wheels (See "Glaze'-.) A softer grade should be tried. BREAKS DOWN TOO FAST -- If the point does not hold shape well and finish is poor, a harder wheel should be tried. Fine grain wheels usually hold shape better than coarse grain wheels. FINISH GETS PROGRESSIVELY WORSE -- This is a result of breakdown or load. Use a harder grade if breakdown occurs and a softer grade if the wheel loads. MIL 000224 MIL 000225 13-2 STANDARD SHAPES GROUP"W" STRAIGHT WHEELS . --L. 0 d 1- r 1 4 1 The standard mandrel for the W series is indi cated n the table by the prefix before the shape number Alternate mandrel sues can be soecified by adding a different prefix number as mdicated below. AUfRNAft MAMORUS Pieft * J 7 i 0<amt(er (d) 3/8 1/12 I1i/8t 1.4 1,4 cnffh (U \'l \1n,7 2 5/8 \;l Wheel Size 0l Shape No. 3,3? 5/J7 1/17 t/4 I/I I/I 1 t/l 1/4 l/l J't , 1/7 1 5/J7 5/3? 5,37 1/37 11/-4lk 3'I5 l/ll 3,16 1/1 1,16 t'4 i.ii 3 3.16 1 U 1 5*141 5W14J 5WI4J 5WI44 5*145 5*146 5WI47 SWJ4S 5*149 5*150 5*151 5*157 5*153 5*154 5*155 Wheel Size 0I Shape No. t.4 1 17 4 1 16 4 1,8 4 3 16 1.4 W t.4 5.16 4 3,1 4 17 1.4 J. 5,.6 1-16 5-li I'l 5/16 1(4 5/11 516 5 16 3'l 5 16 1/7 5*156 5W157 5*154 5*159 5*160 5l6l 5*167 5W16J 5*lt4 5*165 5*166 5*161 5*168 35W*i|6790 Wheel Size 01 Shape No. 5 16 ) 4 8 1,16 8 t8 38 | 4 88 38 17 3.8 1 1,4 1 3(8 1 1 1 7 1 37 1? 16 17 18 17 i4 1 7 18 1.7 i 7 5*1/1 5WJ/7 5*1 M 5*1/4 5*1/5 5*U6 5*(// 5*1/8 8*119 5*180 5*181 5*187 5*113 5*"J4 5*185 Wh eel Si ze 01 Shape No. 1 7 1 4 5*186 1,7 i 5*18/ l 7 i i 8*188 17 7 8*189 5 8 1 16 5*190 5 8 1 1 5*191 58 t4 58 11 5*197 5*193 58 51 17 i4 5*194 5*195 58 58 1 * 8*196 8*19/ 5 8 7 1. 8*198 1 4 :t( 5*199 3 < 1 8 5*700 Wheel Size 0f Shape No. Wheel Size 0( Shape No. 1.4 l < 3< 3 8 3.4 17 34 34 34 I 34 M4 3 * 117 14 7 3* 7 !.7 18 1 16 / 8 II /8 :4 MM 15.16 t 4 5*701 5*707 5*703 5*704 - 8*705 8*706 swto; 8*708 8*709 5*710 5*7 It 5*717 5*711 5*714 I 11 5*715 1 !,l 5*716 1 M 8*71/ 1.7 8*718 14 7 8*777 7 1 7 f*??3 1 3*774 1M 1 1 Wheel Shape Size No. 11*1 l l* t t * il * i i 7 I i,* 7 t 1,4 7 1,7 I 1/4 J I 1/M 4 I 1/7 1/7 I I'7 I I I 7 II 7 11'7 7 I 1:7 7 I 7 I 1,7 ) 71 8*779 r7JQ jw;ji i*;j7 1*?J) 3*?J4 IW.'JS 8*736 1*73/ 8*738 1*7)9 !*:<a ]W7<I JW747 Wheel Size 01 Shape No. 1 1/7 7 7 1/7 3 1/7 1 7 1/7 1 1/7 7 1/7 7 7 1/7 7 1/7 7 1/7 1 31 ] 1 1/7 37 3 7 1/7 3J JW/41 J*/44 3*745 3*74 3*750 1*751 3*757 J*75J 3*754 3*760 )w.*6l iw.'U 3*713 3*364 CENTER LAPS d - (. < The Standard mandrel for center laps is indi cated in the table by the prefix before the shape number Alternate mandrel sizes can be spec f-ed by adding a different pre<*x number as indi cated below AiifRhxsi MA*rR(;S Pefu 2 97 Qijmetei fd) i .rail'd) 12 : 1 ? 1147 | '8 13-3 Wheel Size 0t Shape No. 1/7 7 ictm 1 7 7 1/7 /C174/ 1.7 ) 9C174 5.1 7 icmi 51 ? 1/7 /ct:9* 51 3 JC1749 34 7 icix* 3-4 7 1/7 /C17Q9 3-4 3 9C1750 17 7C1777 1 ? 1/7 /C1771 3 8CL774 MIL 000226 Cincinnati Prefix Number Size GWI Suffix Designation 2 7. x 27, F4 3 7.x 17, 03 4 7,, x 17, Special 5 7* x 17j D1 Standard size tor Series B Mounted Wheels. 6 7. x 2V. Special 7 7. x 1 C2 8 7.x 17, 02 Standard size for Series A Mounted Wheels. 9 7i x 7* Special Note--See chart for Standard mandrels with Series W Mounted Wheels and center laps. ordering For quick handling, your order should specify the following: 1. Shape, number, and quantity desired. 2. Mandrel size -- standard man drels will be supplied unless other wise specified. 3. Grading desired -- or indicate the type and hardness of material to be ground, and results expected. bond types V5 This unusually tough vitrified bond for aluminum oxide abrasives gives you long wheel life and low costs. With the proper type of aluminum oxide grain you get a smooth, fast cutting action. V5 is specified primarily for grinding iron and steel castings, stainless steel welds, forgings, and forging dies. V6 A clear and colorless bond that provides a free cutting action for aluminum oxide grains. It has shown excellent results on internal grinding, and hard tool steel work. V7 A hard durable bond, used in hard grades with 6C black silicon carbide for general purpose portable grinding. V7 covers a wide range of silicon carbide applications. V8 Used in soft grade silicon carbide wheels for precision grinding, and for grinding cemented car bides, V8 bond provides exceptionally satisfactory results in the softer grades. BB The general purpose resin bond for all grain types. BX A reinforced resin bond consisting of alternate layers of abrasive and cotton fibers. Used exclu sively with either 2A or 6C grain. This extremely tough bond gives a very fine polishing action. BXP A reinforced resin bond similar to BX bond, but slightly more resilient. Produces a high polish ing action and is well suited for operations where two surfaces are to be blended. R A somewhat resilient rubber bond used exclusively with 2A or 9A abrasive. Well suited for general purpose work where a fine finish is required. VBH Special vitrified bond for use with MSB abrasive. treatments R TREATMENT -- The resin is impregnated in the wheel, which when cured, strengthens the vitri fied bond posts and reduces the tendency of the wheel to groove when grinding sharp fins or welds, or when deburring. It can also be used in center laps with V6 bond. This treatment adds consider able life to a wheel on such operations. S TREATMENT -- Keeps the wheel clean and free when grinding nonferrous materials. Soft ductile metals like aluminum, brass and bronze tend to load a grinding wheel -- S treatment reduced this tendency to a minimum. B TREATMENT -- This sulfur treatment is also available for those customers who find it helpful. mandrels Cincinnati mounted wheels can be secured on a complete range of mandrel sizes. Some of the vari ations are shown below. General Purpose No. a Mandrel 0 No. 6 Mandrel No. 5 Mandrel Flange Typec Center Lap Special Mandrel R0 Profile Grinder For Boyer Schultz Grinder Special Mandrel |1 11 Jig Grinder Special Mandrel AI Rigid safety standards have been established by the Grinding Wheel Institute for mandrel diameter and overhang at a given RPM. A booklet, "Mounted Wheels -- Safe Efficient Operation and Maximum Operating Speeds", published by the Grinding Wheel Institute, gives specific tables show ing these relative speeds. Copies can be secured by writing Products Division of Cincinnati Mllacron. The table at the left lists mandrel sizes and the corresponding Cincinnati number designation. These numbers should appear as prefixes to the shape number when specifying. For example, a B101 mounted wheel that is to have a mandreldiameter by IV," long would be written: 8B101. marking chart Grain Type 2A 9A 5C 6C 97A 32A MSB Grain Size Coarse Medium 16 36 20 46 24 60 30 80 Fine 100 120 150 180 220 Grade Bond Treatment Soft Med. Hard Vitrified EMQ FNR V5 GO S V6 S--Wax HPY V7 B--Sulfur f U V8 R--Resin J V VBH For MSB K W Resinoid L BB BX BXP Rubber R MIL 000227 13-4 BX Bond Mounted Points BX Bond, a hard and heat-resistant bond, is best adapted for snagging or burring, and is available in the following shapes, and in aluminum oxide grain only. Shape No. Coarsest Grain Size Shape No. Coarsest Grain Size Shape No. Coarsest Grain Size At 24 W162 36 W213 24 A2 24 W163 36 W214 24 A3 24 W167 54 W216 24 A4 24 W168 54 W217 24 A5 24 W169 54 W218 24 A6 24 W170 54 W219 24 AM 36 W174 36 W220 24 A12 36 W175 36 W221 24 A13 36 W176 36 W222 24 A14 36 W177 36 W223 24 A21 24 W178 36 W224 24 A22 24 W183 24 W225 24 A23 24 W184 24 W226 24 A2S 54 W185 24 W227 24 A26 54 W186 24 W220 24 A33 54 W187 24 W229 24 A34 54 W186 24 W230 24 A3S 54 W189 24 W231 24 A36 54 W192 24 W232 24 A37 54 W193 24 W233 24 A38 36 W194 24 W234 24 A39 36 W195 24 W235 24 841 54 W196 24 W236 24 842 54 W197 24 W237 24 851 54 W198 24 W238 24 852 54 W199 24 W239 24 861 S4 W202 24 W240 24 862 54 W203 24 W241 24 891 54 W204 24 W242 24 Bill 24 W205 24 W243 24 8112 24 W206 24 W244 24 0121 54 W207 24 W245 24 8122 54 W2Q8 24 W246 24 W160 54 W209 24 W161 36 W212 24 Check the following limits against those listed above before ordering Grade And Size Limits Aluminum Oxide Grain - 24, 36, 54, 80,120, 180, 320 Grades - H, 1 Min. size - V. inch 00 BXP Bond Mounted Points BXP bond, a softer and more resilient bond, is best suited for polishing, and is available in the following shapes, aluminum oxide grain only. Shape No Coarsest Gram Size Shape No Coarsest Gram Size A1 A2 A3 A4 A5 A6 All A12 A13 A14 A21 A22 A23 A25 A26 A33 A34 A35 A36 A37 A38 A39 841 842 851 052 861 862 B91 6iu 8112 8121 8122 W160 W161 36 36 36 36 36 36 36 36 36 36 36 36 36 54 54 54 54 54 54 54 36 36 54 54 54 54 54 54 54 36 36 54 54 54 36 W162 W163 VV167 W168 W169 W170 W174 W175 WJ76 W177 WI78 W183 W184 W185 W186 W187 W188 W189 W192 W193 W194 W195 W196 W197 W198 W199 W2Q2 W203 W204 W205 W206 W207 W208 W2Q9 V/212 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 .36 Check the following limits against those listed above before ordering. Shape No W213 W214 W216 W217 W2t8 W219 W220 W221 W222 W223 W224 W225 W226 W227 W228 W229 W230 W231 W232 W233 W234 W235 W236 W237 W238 W239 W240 W241 W242 W243 W244 W245 W246 Coarsest Gram Size 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 26 Grade And Size Limits Aluminum Oxide Grain - 36, 54, 80, 120. 180, 320 Grades - E. F, G, H, I Min. size - '/. inch OD MIL 000228 13-5 Description And Usage Definition Mounted wheels, or "mounted points" as they are frequently called, may be defined as a class of relatively small abra sive wheels, usually under two inches in diameter, and of various sizes and shapes, permanently secured to steel mandrels. The mounting on the mandrel is accomplished by molding a hole partially through the wheel before the wheel is fired or cured. A steel shaft, knurled on the end, which enters the hole, is cemented in place, usually with a phenolic resinbased cement. In the case of some resin-bonded mounted wheels, the mandrel is molded directly into the wheel and thus becomes firmly fixed when the wheel is oven-cured. This junction is subjected, while grinding, to large mechani cal and thermal stresses and must be of high quality. Mounting in this way allows the wheels to be used in a chuck in the same manner as a drill or other rotating tool. Uses The obvious advantage of mounted wheels is their portabili ty. Used in conjunction with modern high speed portable grinders they can be taken to the work where material can be removed from locations inaccessible to other tools. The small sizes of mounted points (A and B series) are widely used in high speed grinders by tool and die shops for mak ing molds and for grinding of special contours. Straight cylinder shapes (W series) may be used for precision inter nal grinding. Larger sizes are used chiefly in foundries, weld shops and in machine shops for rough grinding of surfaces which are too difficult to reach with other wheel shapes. Center Laps Center laps are special, shaped mounted points that are used to clean out, or straighten the center holes of hard ened or heat treated pieces. #7 or ft9 mandrel sizes are most commonly used in center laps. Typical designation and grading: 9CL222 2A180-R-V5S Safety Mounted wheels have an additional safety requirement not applicable to other wheels. This condition is too often ignored by users. It has to do with the amount of "overhang" when a wheel is mounted in the chuck of a grinder. Increasing the overhang beyond what is absolutely neces sary multiplies many times the probability that the mounted wheel will vibrate and whip. This can cause pounding and wheel breakage or bending and breaking of the mandrel. It should be kept in mind that under the best of conditions a shaft supported at only one end is not very stable. 13 Note: dimension "0" indicates overhang of mandrel. MIL 000229 13-6 Additional Mandrel Information Standard Threaded Mandrels -- Flange Type Thread Size 3-56 5-40 10-32 1/4-20 Thread Length 'A 7a % 'A Special Mandrels Dia. '/a y 'A 'A 7e '/2 % 7,-16 Length 4 or 5" 4" 6" 7" 3-3'A" or less 7.-1" 172-27." 16 Thread Flange type V2 long. Treatments R-Treatment -- The resin is impregnated in the wheel, which when cured, strengthens the vitrified bond post and reduces the tendency of the wheel to groove when grinding sharp fins or welds, or when deburring. S-Treatment -- Keeps the wheel clean and free when grinding nonferrous materials. Soft ductile metals like alu minum, brass and bronze tend to load a grinding wheel -- S Treatment reduces this tendency to a minimum. B-Treatment -- This sulphur treatment is also available for those customers who find it helpful. Suggestions for Ordering: Give the complete specification desired, including abra sive type, grit size, grade, bond, and include a descrip tion of the mandrel: mandrel diameter, mandrel length and whether the mandrel is straight, tapered, or thread ed. Use standard prefixes if applicable. EX: 5W indicates W shape with V8 diameter, 1long straight mandrel. Availability All users of mounted wheels should have a copy of the "American National Standard Safety Code for the Use, Care and Protection of Abrasive Wheels." These are available from wheel manufacturers or from the American National Standards Institute. There is also an excellent booklet on safe and efficient operation of mounted wheels published by the Grinding Wheel Institute. Tables giving maximum operating speeds of all the vari ous standard shapes and sizes of mounted wheels, tak ing into consideration the amount of overhang, are included in this section. These limits should never be exceeded. If the speed of the grinder is too high, any one or more of four different steps can be taken to bring the set-up within safety rules: 1. Reduce length of mandrel projection. 2. Increase diameter of mandrel. 3. Reduce diameter of wheel. 4. Reduce thickness of wheel. Grain Grain Size Grades Structure Bond Types 2A 97A 9A 12A 32A 6C 5C 2A, 97A. 9A MSB 46-220 46-220 46-220 46-220 46-220 46-220 46-220 46-220 46-220 l-U l-U l-U l-U l-U l-U l-U l-U l-U none none none none none none none none none V5 or V6 V5 or V6 V5 or V6 V5 or V6 V5 or V6 V7 V7 BB VBH Trouble Shooting Problem 1. Wheel glazing 2. Chatter marks on workpiece 3 Burning of workpiece Possible Causes Wheel too hard/line. Insufficient pressure. Wheel speed too high Mandrel overhang too large. Bent mandrel Wheel loo hard. Wheel too hard Insufficient pressure. Poor coolant flow (where used). (Also, see Internal Grinding) Suggested Correction Use softer and/or coarser grit wheel. Increase pressure on wheel. Reduce wheel speed Reduce overhang of mandrel Check wheel/mandrel for truth Use softer acting wheel Use solter grade/coarser gril wheel. Increase pressure/stock removal per pass Increase coolant flow MIL 000230 13-7 14 Abrasive Cut-Off Wheels Starting Grade Recommendations The Cutting-off Machine There are a number of different types of machines on the market for either dry or wet, hand-operated or auto matic, cutting. The types most commonly used are: The chop-stroke - the original, and still widely used cut ting off machine. With the workpiece held securely in a fixed position, the wheels cut down through the work. Workpiece capacity is dependent upon the wheel diame ter and horsepower of the wheel drive motor. The rotating-work machine is normally in the class of automatic type cutting-off machines. Its features are reduced area of contact and high unit pressures; also, it can handle larger workpieces than other type machines. This follows from the fact that the wheel cuts only to the center of the rotating bar stock or other workpiece. By using rotating chucks to hold the work, it is possible to cut large cross-sections of shapes other than rounds. The oscillating wheel head machine simulates a sawing action as it cuts, this machine had advantages over the plain chopper-type machine in that the area of contact between wheel and work is relatively small, resulting in higher cutting pressures per unit area - hence faster rate of cut. In addition to fast cut, this machine permits the use of more durable wheels, with a resulting savings in wheel costs. Again, work capacity is dependent upon wheel diameter and horsepower of the drive motor. In traverse machines either the cut-off wheel or the work is mounting on a sliding table, rails or ways. The advan tage to this work holding method is that long cuts can be made on large sheets, slabs or other flat stock. Material Method Grade Alnico Wet Dry Aluminum Tubing & Thin Section Wet Heavy Sections Dry Aluminum Bronze Bar Stock Dry Castings-Gates & Risers Dry Bits Coal Mining Dry Coal Mining Wet Blades - Turbine Wet Manual Op. Machines Wet Brake Lining Dry Reinforced Dry Brass & Bronze Bar Stock & Heavy Sections Wet Bar Stock & Heavy Sections Dry Tubing & Thin Sections Wet Tubing & Thin Sections Dry Gates, Risers, Castings Dry (Reinforced) Brick (Building) Dry Refractory Dry Cable - Steel Dry Less Burr Carbon Wet Soft Dry Hard Dry Cast Iron (Reinforced) Dry (Non-Reinforced) Dry Celotex Reinforced Dry Cemented Carbides Wet or Dry Ceramics Wet Refractories - Porcelain Etc. ' Dry Chilled Iron Chopper Type Dry Chopper Type Wet Swing Frame Dry Cinder Block & Concrete Block Portable Saw (Reinforced) Dry Copper Bars Wet Gates & Risers Dry Gates & Risers (Reinforced) Dry Drills (Cut Off) Drill Rod Dry Fibre Wet -- Board Dry General Purpose Wet Dry 2A46-M-RS 2A54-P9-B2S 2A46-0-RS 2A30-P9-B2S 2A30-P9-B2 2A24-P-BF9 2A36-R9-B90 2A36-P-R 2A46-N-R 2A54-P-R 6C24-R9-B2S 6C24-P-BF9 2A36-Q-RS 2A36-R9-B2 2A36-Q-RS 2A36-Q9-B2S 2A24-R-BF9 6C24-R-BF9 6C24-R-BF9 2A36-S7-B90 2A46-P9-B2S 6C36-R9-B90 6C36-P9-B90 2A24-R-BF9 2A36-R9-B90 6C24-R-BF9 MD120-R100-B V. CMD120-R100-B V, 5C36-P9-B90 2A36-N9-B90 2A46-M-RS 2A30-R-BF9 6C24-R-BF9 2A46-R-RS 2A36-R9-B2S 2A24-R-BF9 2A46-P9-B90 2A46-N-R 6C30-Q9-B90 2A46-Q-RS 2A36-Q9-B90 MIL 000231 14 14-1 Material Method Grade Glass Thin Wall Tubing Heavy Wall Tubing Gypsum (Reinforced) Inconel Bar Stock Bar Stock iridium (Pen Points) Cut Off & Slotting Iron Alloys Ductile Ductile (Reinforced) Knives (Machine) Malleable Castings Gates & Risers (Reinforced) Masonry Blocks, Masonite, Concrete Portable Saws Metallographic Specimens Monel Metal Bar Stock Bar Stock Tubing Tubing & Small Sections Nickel Bar Stock Non-Ferrous Castings Gates - Risers Gates - Risers Paper Compressed Tubes Pipe (Cast Iron) (Reinforced) Pipe - Steel General Purpose Heavy Wall Reinforced Pipe Ceramic Portable Saws (Reinforced) Plastics Railroad Cut Off & Rail Slotting (Reinforced) Reamers Salvage Cut Off (Reinforced) Rolls - Iron - Chilled - Cast - Alloy Cut Off - Necks - Rotary Rolls - Steel Cut Off - Neck - Rotary Rubber Soft Rubber Hard Sand Cores Portable Saws - (Reinforced) Steel Casting Cut Off (Reinforced Wheel) Steel - Hardened Steel - Soft Large Stock Medium Stock Small Stock Wet Wet Dry Dry Wet Wet Wet Dry Dry Wet Dry Dry Wet Dry Dry Wet Dry Wet Wet Dry Dry Wet Dry Dry Dry Wet Dry Dry Dry Dry Wet Dry Dry Dry Dry Wet Wet Dry Dry Dry Dry Wet Dry Wet Dry Dry 6C120-J6-RS 6C120-L6-RS 6C24-R-BF9 2A36-N9-B2S 2A60-M-RS 2A240-R-R 2A24-P-R 2A24-R-BF9 2A46-Q9-B90 2A80-P-R 2A24-R-BF9 6C24-R-BF9 2A80-N-RS 2A80-P9-B90 2A36-R9-B90 2A46-R-RS 2A60-S7-B90 2A80-T-RS 2A46-0-RS 2A30-R9-B2S 2A24-R-BF9 2A24-P-R 6C60-H6-RS 2A30-R9-B90 2A24-R-BF9 2A46-0-RS 2A30-S7-B90 2A24-P-BF9 6C24-R-BF9 6C36-P9-B90 6C46-N-R 2A36-R9-B90 2A24-T-BF9 2A36-R9-B90 2A24-R-BF9 2A36-0-RS 2A46-N-RS 6C3Q-Q9-B90 6C36-Q90-B90 6C24-R-BF9 2A24-R-BF9 2A60-N-RS 2A46-P9-B90 2A46-0-RS 2A36-R9-B90 2A36-S7-B90 Material Structural Channels - Angles, Etc. Channels - Angies, Etc. Channels - Angles (Reinforced) Steel - High Speed Tool and Reamer Salvage Tool and Reamer Salvage Steel - Stainless (Free Machining) Billets & Forging Bar Stock Bar Stock Bar Stock (Reinforced) Steel - Stainless (Types 302, 303, 329, 443) (Non-Free Machining) Billets & Forgings Bar Stock Bar Stock Stellite Stone Cut Off & Slotting Cut Off & Slotting (Reinforced) Taps Cut Off & Salvage Cut Off & Salvage Terra Cotta Reinforced Wheels Non-Reinforced Wheels Terrazzo Tile Portable Saws (Reinforced) (Non-Reinforced) Titanium Blades, Billets, Bars Tool Steel High Spe$d Steel (Hardened) High Speed Steel (Hardened) Salvage Salvage Transite Portable Saws Portable Saws Tubing Aluminum - Brass - Copper Aluminum - Brass - Copper Chrome Moly Chrome Moly _ Tubing (Continued) Steel - Heavy Wall Steel - Heavy Wall Steel - Thin Wall Steel - Thin Wall Stainless - Thin Wall Stainless - Thin Wall Galvanized Galvanized Tungsten Bars, Rods, Wire Valve Stems (Automobile) Vasco Jet Zirconium Method Grade Dry 2A30-R9-B90 Wet 2A30-P-RS Dry 2A24-R-BF9 Wet 2A46-N-RS Dry 2A54-P9-B90 Wet 2A30-P-RS Dry 2A36-N9-B90 Wet 2A46-0-RS Dry 2A24-P-BF9 Dry Dry Wet Dry Wet Dry Dry Dry Wet Dry Dry Dry Dry Dry Wet Wet Dry Wet Dry Wet Dry Dry Dry Wet Dry Wet Dry Wet Dry Wet Wet Dry Wet Dry Wet Dry Wet "Wet 2A30-S7-B90 2A30-N9-890 2A46-0-RS 2A60-P9-B90 2A54-Q-RS 6C36-O9-B90 6C24-R-BF9 2A54-P9-B90 2A54-N-RS 6C24-P-BF9 6C36-O9-B90 6C36-O9-B90 6C24-R-BF9 6C36-P9-B90 6C46-N-RS 6C46-R9-B90 2A60-P9-B90 2A46-N-RR 2A60-P9-B90 2A54-N-RR 6C24-R-BF9 6C24-P-BF9 2A30-P9-B90 6C80-R-R 2A30-Q9-890 2A30-Q9-B90 2A36-Q9-B90 2A54-0-RS 2A60-S7-B90 2A80-T-R 2A100-T-R 2A80-R9-B90 2A46-P-RS 2A54-O9-B90 2A80-R-R 2A36-T7-B90 2A80-M-RS 2A46-0-RS MIL 000232 14-2 Cut-Off Wheel Recommendations Horsepower Range: Cross Sec. of Cut (Sq. In.) APPLICATION Stainless Steel, Alloy Steel Mild Steel, Cast Steel Iron-Ductile, Gray Malleable Brass, Bronze Hot Cutting Ferrous Metals 10-15 HP Under 4 10-15 HP 4 & Over 20 HP & Over Under 8 20 HP & Over 8 & Over AZ24-XBZ-55 or AK24-X11-BZ-55 AK24-X11-BZ-55 AK24-X11-BZ-55 AK24-X11-BZ-55 AK24-X11-BZ-55 AZ24-XBL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AZ24-ZBZ-55 AK24-ZBZ-55 AK24-X11-BZ-55 AK24-ZBZ-55 AK24-X11-BZ-55 AK24-ZBZ-55 AZ24-X-BZ-55 AK24-X11-BZ-55 AK24-X11-BL3206-55 AK24-X11-BZ-55 AK24-X11-BL3206-55 AK24-X11-BZ-55 HOT PRESS CUT-OFF These reinforced hot pressed wheels are designed to be used in heavy duty cut-off operations where: 1. Cold press wheels do not meet the stiffness requirements. 2. Competitive hot press is being used. 3. Free-cutting, longer life wheels are needed. These are recommended starting specifications. The side pattern may change based on application. Optimizing - Cut-Off Wheels SPECIFICATION: AK24-T9-B9 Abrasive: 1. H5AK} 2. 10AK} Will reduce burn, cut faster but shorter life Will reduce burn, cut faster but shorter life Grit: 1. 20} 2. 247} Cooler cut and faster cut Will reduce burr, could increase burn Grade: 1. R9} 2. V9} Faster cut, shorter life, less burn Slower cut, longer life, possible burn Bond: 1. HP) Longer life but must have HP to cut Side Finish: 1. Rough Sides} Eliminate burr and burn 2. Smooth Sides} Better finish MIL 000233 14-3 Cut-Off Wheels Dimensional Limits Wheel OD B2S,B8S Minimum Thickness Limit (1) B2, B8 BF9S BF9 Maximum Thickness (2) B2, B8 & BF9 `Thickness Tolerance (1) - 0.000 + (as shown) 1 .049 0.020 N/A N/A vu .049 0.020 N/A N/A 2 .049 0.020 0.050 .035 2% .049 0.025 0.050 .035 3 .049 0.025 0.050 .035 3% .049 0.031 0.050 .035 4 .049 0.031 0.050 .035 4'/j .049 0.031 0.050 .050 5 .049 0.031 0.050 .035 6 .049 0.031 0.050 .035 7 .049 0.031 0.052 .035 8 .049 0.035 0.060 .040 9 .062 0.040 0.075 .050 10 .062 0.050 0.075 .060 12 .062 0.062 0.095 .075 14 .093 0.080 0.115 .093 16 .093 0.093 0.125 .095 18 .125 0.115 0.125 .125 20 .125 0.125 0.125 .125 3/16 3/16 3/16 3/16 3/16 3/16 3/16 3/16 3/16 3/16 1/4 1/4 1/4 1/4 1/4 3/8 3/8 3/8 3/8 +0.002 +0.002 +0.002 +0.002 +0.002 +0.002 +0.002 +0.002 +0.002 +0.002 +0.003 +0.003 +0.003 +0.003 +0.004 +0.004 +0.004 +0.005 +0.005 Notes (1) Thinner wheels and/or tighter tolerances can be provided in some cases -- contact Administrative Services. Wheel prices are increased substantially lor these special wheels. (2) A cut-off wheel cannot exceed this thickness. Thicker wheels are classified as Type 1 by the Grinding Wheel Safety Code. 'Applicable when Decimal Dimension is specified. See next page for Fractional Thickness Dimensions. Actual Versus Fractional Thickness Dimensions Actual Thickness Dimension Wheel Diameter 1 -12 12-20 Fractional Thickness 1/32 0.044 - 0.045 Not Available 1/16 0.077 - 0.079 Not Available 3/32 0.108-0.110 0.113-0.115 1/8 0.140-0.142 0.145-0.147 5/32 0171 -0.173 0.176-0.178 3/16 0.202 - 0.204 0.207 - 0.209 1/4 and Thicker "Nominal 0.001.5 "Nominal 0 0025 'Nominal means an exact conversion from fractional to decimal thickness, e.g., Y, = 0.250' 14-4 Soft Grade Hardness Limits Grit Size Soft tirade Hardness Limit by Band Type for Operating Speed of: Grain Types 12000 SFM 14200 SFM 16000 SFM B2 B8 BF9 B2 B8 BF9 B2 B8 8F9 24-36 K MM N Q M R R M 46-60 G MM N 0 M R R M 70 -120 G MM N Q M R R M 150-220 G MM N Q M R R M NOTE II) Above table also applies to rough side suffix "S" wheels (2) Softer grade B2 wheels may be available lor use at these high speeds depending on wheel dimensions. Contact Administrative Services with specific request. Limiting Wheel Dimensions Maximum Operating Speed Dimensional Factor 12000SFM 14200 SFM 16000 SFM Maximum 00 20 20 16 Minimum Thickness 62. B8 Note (1) 1/16 1/16 6F9.BF9S Note (1) Note (1) Note (1) Maximum 10 25% of 0D 25% of 00 25% of 00 Note (I) Thickness limited by availability as shown in Dimensional Limits Table. MIL 000234 Resin Wheel Recommendations Cut-Off Wheel Application Aluminum - Dry Aluminum Castings Brass Rod - Dry Brass Tubing - Dry Brick - Portable Saws Bronze, Hard Cast Iron Chilled Iron Concrete Blocks Copper - Gates & Risers Ductile Iron: Low HP High HP Malleable Iron, Annealed: Low HP High HP Specification AK36-R9-B9' AK24-T9-B9' AK24-T9-B9" AK36-P9-B9' CK24-R9-B9-2 AK24-R9-B9* AK24-R9-B9* AK30-P9-B9' CK24-R9-B9-2 AK24-P9-B9* AK24-P9-B9' AK24-Y-BZ' AK24-T9-B9" AK24-Y-BZ* Application Malleable Iron, Unannealed: Low HP High HP Manganese Steel: Low HP High HP Monel Metals Rails Steel Castings: Swing Frame High HP Steel, Soft: Low HP High HP Steel, Hardened: Low HP High HP Steel, Stainless: Low HP High HP Titanium Specification AK24-R9-B9* AK24-X7-BL3206-655 AK24-R9-B9* AK24-T9-B9* AK30-R9-B9* AK247-R9-B9-088 AK24-T9-B9-088 AK24-Y-BZ-55 AK24-T9-B9' AK24-X7-BL3206-655 AK30-R9-B9* AK30-X7-BL3206-655 AK24-R9-B9* AK24-X7-BL3206* CK80-P9-B9* "Special marking must be added for wheels requiring reinforcement and for cut-off wheels requiring special side construction. Hot Press Cut-Off Wheel Horsepower Range Cross-Section of Cut (sq. in.) Application Stainless Steel Alloy Steel Mild Steel, Cast Steel Iron Ductile, Gray Malleable Brass, Bronze Hot Cutting Ferrous Metals 10-15 HP Under 4" AZ24-X-BZ-55 AK24-X11 -BZ-55 AK24-X11-BZ-55 AK24-X11 -BZ-55 AK24-X11 -BZ-55 AK24-X11-BZ-55 10-15 HP 4" & Over AZ24-X7-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 AK24-X11-BL3206-55 20 HP & Over Under 8" AZ24-Z-BZ-55 AZ24-Z-BZ-55 AK24-X11-BZ-55 AK24-Z-BZ-55 AK24-X11-BZ-55 AZ24-Z-BZ-55 20 HP & Over Over 8" AZ24-Z-BZ-55 AK24-X11-BZ-55 AK24-X11-BL3206-55 AK24-X11 -BZ-55 AK24-X11-BL3206-55 AK24-X11-BZ-55 HOT PRESS CUT-OFF: These reinforced hot pressed wheels are designed to be used in heavy duty cut-off operations where: 1) Cold press wheels do not meet the stiffness requirements. 2) Competitive hot press wheels are being used. 3) Free-cutting, longer life wheels are needed. These are recommended starting specifications. The side pattern may change based on application. Cold Press Cut-Off Wheel HP Range 10 HP or Less 10 HP or Less 11-19 HP Cross-Section Under 4" Over 4" Over 4" of Cut (sq. in.) Application Alloy Steel AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-B9-188 Aluminum AK24-R9-B9-188 AK24-P9-89-188 AK24-T9-B9-188 Brass/Bronze AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-B9-188 Carbon Steel AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-B9-188 Cast Steel AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-B9-188 Ductile Iron AK24-R9-89-188 AK24-P9-B9-188 AK24-T9-B9-188 Gray Iron AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-B9-188 Malleable Iron AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-89-188 Mile Steel AK24-T9-B9-188 AK24-R9-89-188 AK24-V9-B9-188 Stainless Steel AK24-R9-B9-188 AK24-P9-B9-188 AK24-T9-B9-188 "Reinforcement code may change based on application. These are recommended starting specifications. 11-19 HP Over 4" AK24-R9-B9-188 AK24-R9-B9-188 AK24-R9-B9-188 AK24-R9-B9-188 AK24-R9-B9-188 AK24-R9-B9-188 AK24-R9-B9-188 AK24-R9-B9-188 AK24-T9-B9-188 AK24-R9-B9-188 20 HP & Over Under 8" 20 HP & Over Over 8" AK24-V9-B9-188 AK24-V9-B9-188 AK24-V9-B9-188 AK24-V9-B9-188 AK24-V9-B9-188 AK24-V9-B9-188 AK24-V9-B9-188 AK24-V9-B9-188 AK24-X11-8328-188 AK24-V9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-T9-B9-188 AK24-V9-B9-188 AK24-T9-B9-188 MIL 000235 14-5 Rubber Bond Wheels Grain Type 2A 6C-5C 2A-6C-5C A 2A-C4A 6C-5C Grit Size 24-220 24-220 24-220 60-220 24-220 24-100 Grit Size Combination Grades Available Cut-Off Wheels Nominal or 3 L-N-O-P-Q-R-S-T-U-W Nominal or 3 H-l-J-L-N-O-P-R-T General Purpose - Tool Room None N-P-R Centerless Regulating Wheels None R-S-T Centerless - Cylindrical - Surface Grinding None L-N-P-Q-R-T-U None L-N-P-Q-R-T-U Structure None None None 2 None None NOTE: Subject to limitations of minimum thickness chart. *R = Smooth Sides `'RS = Rough Sides Bond R-RS* R-RS* R R R R Rubber Wheels Minimum Thickness Chart Coarsest Grit -- Softest Grade Dia. .005 .010 .015 .020 1/32 3/64 1/16 3/32 V, 7.T- 5/32 3/16 7/32 7. 7. 54-220 54-220 24-220 24-220 24-220 '/ 240-320 180-280 100-28- 80-280 L-W L-W L-W L-W L-U to L-U L-U L-U L-U 4 240-280 240-280 240-280 240-280 46-80 L-U L-U L-U L-U W 5 "" 6 * ** - 7 * u 24 24 24 24 N-RR N-RR N-RR N-RR "" *" 80-220 L-W 8 " " -- 240-280 L-U 9 10 54-220 L-W 12 240-280 L-U - 14 24-80 24-80 L-U L-U 16 * " " 18 * " " - 20 14 24 46-80 46-80 46-80 - 46-80 L-U L-U L-U L-U 26 " 28- - - 30 32 - 34 H Rough side wheels minimum thickness 1/32. Diameter intermediate to those shown, same as next greater diameter Thicknesses intermediate to those shown, same as next smaller thickness 'Toternces for `"/,V is . J55-170 available in 14 to 26 diameter, inclusive. SiC Cut-011 Grades Softer Than "L" Dia. 1/32 3/64 1/16 12 60-H6 60-H6 60-H6 14 120-H6 60-H6 16 60-H6 18 20 3/32 60-J6 60-J6 60-J6 60-J6 60-J6 1/8 60-J6 60-J6 60-J6 60-J6 60-J6 i 14-6 MIL 000236 9 Bond Types** BA B320 BC BF BH B254 65 General Purpose Cutoff Snagging Fluting Roll Grinding Portable* Centerless NID/Type 2 Segments X XXX X X XXX X XX X XXXX X XXX X XXXXX X XX 'With exceptions of Type 27, 27A, 28, 28A "With exception of AZ product NOTE: Specifications subject to approval by Carlisle Engineering X BL B9 7227 B90 B291 E X X X XX XX X BZ BL 8L BZ (HP) 3206 6823 1830 B283 B303 (HP) (HP) (HP) X XX XX X X XXX X Available Abrasives Description Aluminum Oxide Regular Semi-Friable Norton's 32A White, Friable Pink, Friable Alumina/Zirconia Alumina/Zirconia Premium Grit Size Available 12-30 36-220 24-220 16-220 24-220 14-46 14-36 Carlisle *A '2A 11A *10A 82A 20A AZ Silicon Carbide Regular, Black Green 12-220 24-220 *C GC Mixture Mixtures 50/50 10A/A 50/50 C/A 50/50 C/10A 35/65 20A/A 35/65 20A/C 50/50 20A/A 50/50 20A/C 60/40 20A/A 60/40 20A/C 50/50 82A/A 24-220 16-220 16-220 16-220 14-46 14-46 14-46 14-46 14-46 14-46 24-220 FC *H5A *R5A *E5A 18A 18C W5A W5C 15A 15C 27A 'Available in limited grit sizes with silane coating designated with "K" i.e. A silane coated = AK Cincinnati A 2A 32A 9A 12A -- -- 6C 5C 7C 97A CA, C2A -- -- -- -- -- -- -- MIL 000237 14-7 High Performance Resin Bonds BOND BA BC BF BH B254 B5 USAGE RANGE F-N L-Q P-R Q-S P-W R-V B320 F-0 B9 BL6823 BL3206 BZ BZ1830 E N-V X X X-Z z H-P PURPOSE General purpose. Range from A Bond (soft) to H Bond (hard). High strength bonds used for both precision and snagging operations. Coolant resistant bond. Used for roll grinding and soft grade cut-off. Basic cold-pressed cut-off bond. Softest hot-pressed bond to hardest. Shellac Bond Wheel Reinforcement Code Suffix Marketing Fiberglass Placement - 0 Cut Off Only -1 -2 -3 -4 - 6 Cut Off Only -8 -10 Cut Off Only 1 Full Diameter Inside 2 Short Diameter Outside 1 Full Diameter Inside 2 Full Diameter Outside 2 Full Diameter Outside 1 Full Diameter Inside 2 Full Diameter Inside 2 Full Diameter Inside 2 Short Diameter Outside 3 Full Diameter Inside 2 Short Diameter Outside Cut-Off Wheel Side Roughness Cut-Off wheel side roughness is shown in the suffix. If the wheels are reinforced, the following code markings are added to the reinforcement codes: -66 smooth sides -88 rough sides -99 tefglas sides For hot-pressed cut-off, the following indicates both 3 reinforcement and grooved sides unless another rein forcement pattern is specified: -55 fine grooves -77 coarse grooves 14-8 Carlisle Cut-Off Wheels -- Cold Press Grade Bond SOFT K-P B320 MEDIUM P-V B9 HARD V-X B283 Carlisle Cut-Off Wheels -- Hot Press SOFTEST BL6823 BL3206 *BZ243 HARDEST BL1830 'Normal trial would be in BZ243 bond. MIL 000238 General Information 1. We specialize in Type 1 : A. Cut-off wheels non-reinforced .020" thru 1/4" to 20" diameter. B. Cut-off wheels reinforced 1/32" thru 3/8" to 20" diameter. 2. Wheels will be formulated to your specifications. 3. Reinforcement is available and recommended on severe job applications We reinforce wheels as thin as 1/32" thick at regular prices. 4. Maximum thickness limit on all wheels is 5/8" nonreinforced and 3/8 reinforced. 5. Cut-off wheels are normally stenciled (2-1/2" and larger) with blotters furnished loose. 6. Operating speeds higher than those shown in ANSI Safety Code B7.1 1978 will require a special speed certificate. 7. Manufacturing conditions under which special price must be charged: A. All wheels less than .020 thickness regardless of diameter. B. Any wheel made below our manufacturing limits charge. 8. All popular hole sizes available as well as: 20MM, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12. Special holes for drive pin mounting available on request at no extra charge. 9. Metal centers available on wheels .093 or thicker. (Note: If universal center is required, wheel must be .109 or thicker.) 10. Precision balance wheels do not require an extra charge. 11. Rough sides (screen sides) are available. We do not offer "phonograph" sides. Saw gummer sides must be specified. 12. Thin wheels (.049 or thinner) cannot be rough sided at published prices. 13. Close thickness tolerance cannot be held on rough sided wheels. NOTE: Phonograph sides are available only on Hot Press Wheels. Grade Use as hard a grade as possible to get maximum wheel life. Start with a softer grade (M-O) on hard materials (e.g. steel) and harder grades (P-Q) on softer materials (e.g. brass). Reinforced Wheel - Rough Side The fiber glass reinforcement is placed on both sides of BF9 cut-off wheels. In some specifications, it is possible to put a single sheet of fiber glass inside the wheel and provide rough sides. Contact Application Services to determine if this can be done for each specific applica tion. Such wheels will also be designated by the suffix S. Example: 2A46-P7-BF9S or R5A46-P7-B320-88 Structure Structure changes permit fine tuning of a grade for an application. A high structure number wheel (e.g. 9) con tains less abrasive grain than a low structure number wheel (e.g. 5). The less dense, high structure number wheel will act slightly softer than a lower structure num ber wheel of the same hardness grade. A 7-structure wheel should be selected for all starting specifications. The hardness grade should be increased until the wheel acts too hard. A 9-structure wheel in the "too hard" grade, or a 5-structure wheel in the next softer grade provide between grade hardness changes. Example: If a 2A60-P7-BB8 is too hard, and a 2A60-O7B8 was too soft, try either: 2A60-P9-B8 or 2A60-O5-B8. Bond Type B2 -- a softer acting bond available in a broad range of grades -- especially useful on heat sensitive materials. Available in K and harder grades, 7 and 9-structure. B8 -- a durable bond for high production operations. Available in M-W hardness grades, 5, 7 and 9-structure. BF9 -- a fiber glass reinforced product similar in perfor mance to B8. It is used where high strength is required. Available in M-W hardness grades, 5, 7 and 9-structure. B8 and BF9 should be substituted grade for grade for B2 or competitive wheels. MIL 000239 14-9 General Information (cont.) Rough Sides Rough sides are available on B90-B320 and B8 cut-off wheels, the rough sides help to reduce drag and friction from side rubbing. Rough sides are designated by the suffix S. Example: 2A46-P7-B8S. Rough sides are limited by wheel size and thickness. Rough Side Dimensional Limits Wheel OD Minimum Thickness For Rough Side 1 - 12" 1/32" (1) 14-20" 1/16" (1) Note (1) Thickness also limited by availability as shown in Dimensional Limits Table. Rough Side Cut-Off Wheels* BF-9 -- The fiber glass reinforcement is placed on both sides of BF9 cut-off wheels. In some specifications, it is possible to put a single sheet of fiber glass inside the wheel and provide rough sides. Such wheels will also be designated by the suffix S. Example: 2A46-P7-BF9S. B90-B320 -- Rough sides are available on B90-B320 and B8 cut-off wheels. The rough sides help to reduce drag and friction from side rubbing. Rough sides are designated by the suffix S or 88. Example: 2A46-P7B8S. Safety -- Wheel Orders Cut-off wheels are used on special, well-guarded machines. In recognition of this, cut-off wheels are per mitted by the ANSI B7.1 to run at special higher operat ing speeds. A wheel of a size similar to a cut-off wheel may be used in another type of grinding operation, e.g. flute grinding. Such a wheel is classed as a Type 1 wheel and must be proof speed tested at a higher level than a cut-off wheel. It is imperative that wheel orders show the correct type of wheel: "cut-off" for cut-off wheels and Type 1 for thin wheels used on other grinders. 'See dimensional limits table for minimal thickness. Dimensional and Operating Speed Limits The following tables designate the standard available dimensional limits and the limits of operating speed by dimensions and cut-off wheel specification. Exceptions to these limits can sometimes be made as shown in the table footnotes. In addition, one other exception should be noted: Wheel Thickness and ID Size The tables show that the thickness and ID sizes of cut off wheels are limited relative to the OD size. These limi tations are specified by the ANSI B7.1. Wheels exceed ing these limits are classified as Type 1 wheels. Type 1 wheels are not normally operated at cut-off wheel speeds. However, Application Services may be able to authorize the use of specific Type 1 wheel specifications at cut-off wheel speeds. These wheels will be identified with the suffix E indicating that they have been approved for use at a special speed. 14-10 MIL 000240 Machine & Wheel Data Campbell Machine Div., (cont'd) All cut-off wheels are Type 1. They are furnished for both wet or dry operations in the various organic bond systems (rubber, resinoid or shellac). Most production type jobs use rubber wheels on wet applications and resinoid wheels on dry applications, although some rubber wheels are also used dry. Shellac wheels are generally supplied in relative ly small sizes, for either wet or dry applications, predomi nantly of the tool-room type category where extreme ver satility and quality of cut are of major consideration. See Bond Types. Typical Machine Manufacturers Approved Devices Campbell Carborundum Continental Curtis-Toledo Delta deSanno (Radiac) Emerson Everett Max Savage Stone Ty-Sa-Man Waber Wallace Approved Devices Co. Machine/Model Cut-Off Machine--Dry or Wet Wheel Size* (6, 7 or 8) x yl6 x 7* Spindle Speed/RPM 4000 Campbell Machine Div., American Chain & Cable Co., Inc. Bridgeport, CT (W.J. Savage, Knoxville, TN) Machine/Model Wheel Size* Abrasive Cutting Machines No. 15--Dry-Bar Type 15--Wet-Bar Type 20--Dry-Bar Type 28--Dry-Bar Type 202, 203, 212, 213 Wet-Bar Type' 223, 265--Wet-Bar Type 302--Wet-Horizontal 342--Wet-Horizontal 3240--Wet-Horizontal 401--Wet-Cutamatic 406--Wet-Cutamatic 425--Wet Cutamatic 460--Wet-Semi Automatic 470--Wet-Automatic 476--Automatic- CUTAMATIC 480--Wet-Semi Automatic 1--Wet-HUDORKUT 2--Wet-HUDORKUT 12 x 7 x 1 14xVbx 1 16 x 7.x 1 18x7. x 1 16 x (7,6 x to 7.) x 1 (16 or 18) x (7,6 thru 7.) x 1 (16 or 18) x (7,6 thru 7.) x 1 20 x 7. x 1 20 x 7. x 1 20 x 7, x 1 20 x 7. x 1 18 x 7. x 1 20 x 7. x 1 20 x 7, x 1 20 x 7. x 1 26 x 7= x 1 14 x (7m thru 7M) x 1 16 x (7m thru 7e) x 1 Spindle Speed/RPM 5200 2600 4200 2450 2450 2150 1200 & 1800 1200 1200 1400 1400 1800 1400 1400 1400 1200 1800 1400 Machine/Model 509--Wet-Rotary 514--Wet-Rotary CUTAMATIC No. 64 Wet 102A--Wet 270--Wet-Bar Type 290--Dry-Wire Rope 364--Wet-Horizontal 481--Wet-Semi Automatic 612--Wet-Semi Automatic 930--Wet-Rotary SEVER-AII Machines 1A--Dry-Bar Type 2B--Dry-Bar Type 3A--Dry-Bar Type 22A--Dry-Angle 52A--Dry-Rotary Wheel Size* 20 x V, x 1 20 x 7, x 1 (16 or 18) x V, x 1 20 x'/,x1 (16 or 18) x (V,6 thru 7.) x 1 16 x (7. thru 7,) x 1 26 xVaXl 26 x 5/m x 1 34 x 7m x 1 30 x 7m x 1 12 x 3/ x 1 20 x 7. x 1 26 x 7m x 1 20 x 7. x 1 20 x 7. x 1 Spindle Speed/RPM 1400 1400 2150 1450 2150 2150 1000 1000 840 1400 3450 2150 1700 2150 2150 The Carborundum Co., Niagara Falls, N.Y. Machine/Model Machine/Model Vibratory Cut-Off VB600 -- 50HP VERTIARC V10-75HP VERTIARC V14-150HP Orbital Cut-Off RCS-24" -- 100HP RCS-30" -- 150HP RCS-34" -- 150HP Horizontal Plate Saws 144 Series -- 20HP 111-211 Series --50HP 122-222 Series -- 75HP 133-233 Series --150HP Wheel Size* Wheel Size* 26 x 7,. x 1 36 x 7m x 6 38 x 7a x 6 34 x 7m x 6 48 x 7. x 6 20 x 7. x 17. 34 x 7m x 1 '7,6 36 x 7m x 27, 48 X 3/a x 37. Spindle Speed/RPM MOS/RPM 1760 1400 750 900 750 1900 1400 1400 750 Continental Machine Tool Co., Irvine, CA Machine/Model - Wheel Size* CONTINENTAL ULTICUT 34W75-75HP - - 34" Wet 34 x .240 x 1 26W50-50HP -- 26" Wet 26 x .180 x 1 22W20-20HP -- 22" Wet 22 x .165 x 1 semi-automatic (also made complete automatic) DS2420-20HP -- 24" dry 24 x .170 x 1 manual feed control, miter/straight WS2420-20HP -- 24" wet 24 x .170 x 1 manual power feed, totally automatic Spindle Speed/RPM 1000 1350 1550 2000 1450 `Wheel Shape -- Type 1 MIL 000241 14 14-11 Curtis-Toledo, A Wyle Company (Formerly Toledo-Beaver) St. Louis, MO Machine/Model No. 151 No. 100, 110, 120 Speed Cut--Dry No. 14 S.C.--Wet or Dry No. 14 S.C.--Dry No. 16 S.C.--Wet or Dry No. 16 S.C.--Dry No. 16 S.C.--Dry No. 20 S.C.--Wet or Dry NO. 20 S.C.--Dry No. 20 S.C.--Dry No. 20 S.C.--'Wet Wheel Size* 12 x 7a x 1 14 x 3/k x 1 14 x 7a x 1 16 X 3/m x 1 16 x V. x 1 18 x 7. x 1 20 x x 1 11 x 7.5 x 1 14 X 3/k x 1 14 x 7 x 1 16 x7x 1 16 X 3/k x 1 16 x 7, x 1 18 x 7. x 1 18 x 7b x 1 20 x 7, x 1 20 x 7, x 1 Spindle Soeed/RPM 4000 2800 2800 2300 1530 4060 2875 2875 2875 2875 2875 2300 2300 2300 1470 A.P. deSanno & Son, Inc. Phoenixville, PA Machine/Model Wheel Size* Type C--Dry Type F--Dry Type G--Wet Types J & JH--Wet Type JOAH--Wet Type K & KH--Wet Dry Types L & M--Dry Type N--Wet 12 x7ax 1 14 x 7k x 1 10 x 7k x 7s 10 x (7,5, 7 or 7e) x 7b 18 x (7.6, 7k or 7a) X1 20 x (`/is, V32 or Ve) x1 20 x (7k or 7a) x 1 16 x (7.6, 7k or 7a) x1 14 x (7k or 7a) x 1 12 x (7.5, 7 or 7b) X 7a TS 0 X x 7s Type N16--Wet 16 x (V16, V32 or '/a) X 7a Type N 16-FA--Wet 16 X 7k X 7a Type P--Dry 18 x Vo x 1 RADIAC Machines GR-200 (Manual)--Wet 10 x 7,6 x 1 12 x 7k x 7< GR-201 (Semi-Automatic)-- 12 x7k x 17, Dry GR-203 14 x 7k x 1 (Fully-Automatic)--Wet Spindle Soeed/RPM 5200 4300 5200 2050 2050 2050 1600 2050 4100 5200 2050 2050 2050 2500 2050 2050 4300 2700 A.P. deSanno & Son, Inc. (cont'd.) Machine/Model Wheel Size* Spindle Speed/RPM GR-75 (Fully-Automatic) travelling head)--Dry 14 X 7k X 17a 4300 GR-601 (Fully-Automatic) 16 x 3/k x 1 3600 work rotating machine)--Dry JR-400 (Manual)--Wet or Dry 18 X 7a x 1 2050 JR-401 (Semi-Automatic)- -20 x 7. x 1 Wet or Dry 2050 JR-403 (Fully-Automatic)- 22 x 7. x 1 Wet or Dry 2050 CTR-501 (Semi-Automatic)-- 24 x 7k x 1 Wet 1500 CTR-503 (Fully-Automatic)-- 26 x 7,6 x 1 Wet Single speed motor 1500 Variable speed motor variable BR375 FA (Fully-Automatic) 1 4 X 3/k X 7a 2700 travelling head--Wet BR276SA (Semi-Automatic) 18 X 7e x 1 3600 bearing cap--Dry TW-100 2HP, 1 or 3 phase 7 x .020 x (7j thru 7a) 3450 capacity 1" solids or 2" tubing--Wet 10 x .030 x (Va thru 7.) deSCal Machines DM--Dry 12 X 7a x 1 3400 DJ-DJA--Dry 16 X 7a x 1 2950 DS-DSA-DTG--Dry 20 X 7a X 1 2200 NOTE: All models K, KH, JOAH, J and JH made prior to 1964 are equipped with diameter spindles. Emerson Electric Co., Special Products Division, St. Louis, MO Machine/Modei Abrasive Cut-Off Machines--Dry Wheel Size* 16 x (7k thru 7,b) x1 10 X (3/k X 7e) X 7a 8 X (3/k thru 7a) X 7S Spindle Speed/RPM 3100 4750 4750 Everett Industries, Inc., Warren, OH Machine/Model Cut-off Machines-Dry30HP Wheel Size* 26 x 7k x 1 Spindle Speed/RPM Type 1 MIL 000242 14-12 Arbor Holes E-23 |-*--1 1/8 1 J --1 1/16-*- e i FOR TRI-LINE. CLIPPER MACHINES E-26 UNIVERSAL ARBOR HOLE .817 USEOONSKILSAWIE-1U THOR (M U MAU (E-24>. WAPPAT (E 24) ANO OTHER MACHINES HAVING r ROUND ARBORS WHEN USEO WITH EXTRA BUSHINGS CAN AISO BE USEO ON MAU (S-lOl ANO ON OTHER MACHINES SUCH AS THE SPEEDMATIC HAVING l/T Oft 5/8' ROUNO ARBORS (E*2?, E-28. E-29) E-27 (BUSHING E-18 HOLE) -.000 *1.000 +.005*- , 1/32 R M- hB-502^15 H\J t .502 i00050 CAN BE USEO ON MALL MACHINES ' E-30(SAME AS 6-31) 'Or- r. i i/2" ,i h1 5c//a8 HR BORE 3 H0LES 5/8 DIA _ 120 SPACING -31 (SAME AS E-30) J 5/8 R 1". 1 1/2" B0RE 3 HOLES 5/8 OIA 120 SPACING 14 1 3/8 R >1 1/2 R _____FORCAMPBELL MACHINES 1 3/8 R FOR CAMPBELL MACHINES MIL 000243 14-13 E-11 FOR SKILSAW, THOR MACHINES E-13 ' E-12 f\ yi r 1 REPLACES SHAPE SHOWN 8YOOTTE0 LINES FOR BLACK & DECKER MACHINES E-14 REPLACES SHAPE SHOWN BY DOTTED LINES FOR BLACK & DECKER MACHINES E-15 E-16 E-17 -*-- 3/4--_ . 1_ r 11 1I1 t J 1/16 R 1 FOR POWER KING. U.S. ELECTRIC MACHINES E-18 ------- 502 + 005 | -000 | 502 + -.000 /1/32 R' 1 FOR THOR. MALL MACHINES 14-14 MIL 000244 Principles Of Abrasive Cut-Off Wheels Abrasive Cut-Off Machines can be operated dry or wet, low or high speed, and either manual operated or auto matic. Machines are manufactured with an oscillating or reciprocating wheel head or special work holding fixture that rotates the work while cutting, all the way down to the more common general purpose, chopper type machine. Each type has its advantages and field of application. The majority of materials used in the construction trades and manufacturing can be satisfactorily cut off with abra sive wheels, more wheels are used to cut metals than other materials. However, natural stone, ceramics, tile, brick, plastics, insulating materials, glass, concrete blocks and reinforced concrete, etc., are also cut with abrasive cut-off wheels. The maximum wheel speeds shown in Table 20 of the American National Standards Institute Safety Code (A.N.S.I.) B7.1 for organic cut-off wheels larger than 16" diameter are 9500 SFPM to 14,200 SFPM, including reinforced organic wheels. For wheels 16" diameter and smaller, the maximum wheel speeds for organic cut-off wheels, including reinforced organic, are 9500 SFPM to 16,000 SFPM. For wet cutting off operations, the wheel is generally operated much slower, approximately 10,000 SFPM, to cool the work more effectively. The wheel operating at high speeds throws an air blast that blows the cutting fluid away from the point of contact. When the work requires submerged cutting, the wheels operate at speeds between 6000 and 10,000 SFPM. Machines with an oscillating spindle are usually operated wet. The oscillating movement of the wheel greatly increases the size of work that a machine can handle, making it possible to cut bars and tubes up to 6" diameter. Machines equipped for rotation of work can cut larger diameter work with smaller diameter wheels than most other types of cut-off machines and can wear a wheel to a smaller diameter stub, the reduced arc of contact decreases wheel life. Wheels for cut-off machines are available in two bond types -- resin and rubber. Rubber bond cut-off wheels are generally used wet. When used dry, the bond softens under the heat of the cut and breaks down rapidly, and at the same time, gives off the obnoxious odor of burning rubber. The odor is greatly reduced and wheel life increased when used wet. Most dry cutting off operations are done with a resin bond wheel. However, resin bond can be used either wet or dry. If coolant is used, it must be applied to the point of contact between the wheel and the work, and equally on both sides of the wheel to obtain a straight cut. Note sketch showing wear pattern of cut-off wheel faces and the effect of coolant application. 1, 2, and 3 show a normal wear pattern of wheel faces that have an equal amount of coolant on each side and point of contact, and will make a straight cut. Sketch number 4 and 5 shows a wheel face caused by an unequal amount of coolant having been applied to the sides of the wheel (greater wear on the bevel side, which is the side with least coolant). This wheel cannot cut straight and is subject to more frequent breakage than wheels that wear like shapes 1, 2, and 3. The con cave face on Sketch #1 is the result of an insufficient volume of cutting fluid, or grade of wheel is too had. A small concave face is satisfactory and will not cause breakage, and will make a straight cut. However, if con cave becomes excessive, it will be necessary to use a softer grade of wheel to eliminate it. 14 MIL 000245 14-15 Two types of abrasive grains are used to cut the majority of materials, silicon carbide and aluminum oxide. Silicon carbide is generally recommended for non-ferrous met als, glass, ceramics, plastics, refractories, etc., and alu minum oxide for ferrous metals. To select a grade of wheel to cut various materials, refer to the General Starting Recommendation chart. Soft wheels give the highest quality cuts. They cut faster, but don't last as long as harder wheels. For machines with less than 5 horsepower, use soft or medium grade wheels. For oscillating spindle machines and rotary machines where the work can be rotated as it is being cut, use medium to hard grade wheels. Use a coarse grit wheel to cut solids. Use finer grit wheels to cut tubing or solids to produce less burr. Always use wheels that wear to a square or concave face, not to a face that is pointed or convex. Smooth sided wheels are used in most general cut-off work where the material does not have a tendency to load the wheel, or where there are machining operations following the cut-off operation. Rough sided wheels are recommended when the cut-off operation requires a minimum burr, or no burn, or on heavy sections, and deep cuts, and the material has a tendency to load or bind the wheel. Rough sided wheels are also used for brass and copper, soft bronze, steel cable, aluminum, carbon and soft steel, and similar materials. Some rubber wheels are made with a series of holes thru the wheel to help carry cutting fluid into the cut, cooling the part more than a non-perforated wheel would. These holes are arranged in a spiral from the flange diameter to the periphery and are located so that 2 holes are breaking thru the periphery of the wheel at one time. This gives an intermittent cut which helps the wheel to break down and prevent load, increasing the wheel's ability to cut cooler and freer when cutting heavy sections and large diameter bars, etc. ROTATING WORK OSCILLATING WHEELHEAD 14-16 MIL 000246 Trouble Shooting Common Cut-Off Wheel Problems 1. Angular Cuts and Wheel Breakage A. Improper mounting of wheel. Corrective Action 1. A. Check flanges, they should be flat and the same diameter, and recessed to provide equal and opposite bearing areas. Excessive tightening of the spindle nut may have bent the flanges causing wheel breakage. B. Work improperly clamped Inadequate clamping of work will allow movement of the work while wheel is in the cut. C. Wheel vibration from worn spindle bearings. D. Excessive wheel feed into work. E. Belt slippage or not enough power. Wheel slows or stalls in cut. 2. Burning of work -- wheel chipping on edge. 3. Excessive burr. 4. Wheel wears on 1 side -- will not cut straight. 5. Excessive wheel wear A. Grade of wheel too hard, causing burning out of bond. B. Grade of wheel too soft, causing excessive breakdown. C. Inadequate coolant supply. B. The work should be clamped on both sides of the cut to prevent movement of the work while cutting. C. This vibration will break wheels -- replace spindle bearings. D. This happens more on machines with power feed than manual feed. Reduce feed rate to within metal removal capability of wheel. E. Check belts and tighten, if needed. Increase HP. or take lighter cuts. 2. Wheel too hard -- use softer grade. 3. Use finer grain and softer wheel. 4. Unequal distribution of coolant on sides of wheel. 5. A. Use softer grade of wheel. B. Use harder grade of wheel. C. Increase volume of coolant. MIL 000247 14-17 15 Flute Grinding Recommended Starting Grades For Flute Grinding Wheel Dia. (mm) >100<200 >200 MM >300<500 <300 >300 >300<500 >300<500 Thickness Variable Variable Variable Variable Variable Variable Variable Variable Variable <2 >2<3.5 >3.5<4.75 >4.75 >2<4.75 >4.75 >2<4.75 >4.75 <4.75 >4.75 <4.75 >4.75 >4.75 <6mm >6mm Variable Variable Variable <25mm <16mm End Use Straight Fluting Taps<8mm >8mm<13mm >13mm Straight Fluting Reamers Straight Fluting Extra Long Reamers & Taps Fluting Centre Drills Fluting Short End Mills Fluting Router Bits (Small) Fluting Router Bits (Large) Spiral Fluting of Drills & Taps Spiral Fluting of Soft End Mills Spiral Fluting of Tough Steel End Mills Spiral Fluting of Drills & Taps Spiral Fluting of End Mills End Mills - Soft Steels Gun Pointing Spiral Taps Gun Pointing Straight Taps Slotting Long Drills 25mm Slotting Small Taps - Reamers Drill Step Gashing End Mills General Specifications AK120-V11-B5 AK120-V11-B5 AK100-V11-B5 AK120-V11-B5 AK100-V11-B5 AK100-S8-BH AK100-S8-BH AK100-V11-B5 AK100-Q8-BH AK150-R8-BH AK120-Q8-BH AK120-Q8-BH AK120-Q8-BH AK120-P8-BF AK120-P8-BF AK100-R8-BH AK100-S8-BH AK120-P8-BF AK120-Q8-BH AK120-P8-BF AK120-S8-BH AK60-S8-8H AK150-Q8-BH AK100-Q8-BH AK120-V11-B5 AK100-S8-BH AK120-V11-B5 AK80-P8-BF AK100-S8-BH HERTLINE AK100-V11-BL7331 AK100-V11-BL7331 AK100-V11-B5 AK100-V11-BL7331 AK100-V11-BL7331 AK100-X11-BZ AK100-X11-BZ AK100-V11-BL7331 AK100-R8-BH AK180-S8-BH AK120-R8-BH AK120-R8-BH AK120-Q8-BH AK120-S8-BF AK120-S8-BH AK100-X11-BZ AK100-X11-BZ AK120-Q8-BH AK120-R8-8H AK120-R8-BH AK100-X11-BH AK54-S8-BH AK120-S8-BH AK80-S8-BH AK100-V 11-BL7331 AK100-S8-BH AK 100-V 11-BL7331 AK100-Q8-BF AK100-X11-BZ DA Recommendation DA100-V11-B5 DA100-V11-B5 DA100-V11-B5 DA100-V11-B5 DA100-V11-B5 DA100-X11-8L3206 DA100-X11-BL3206 DA100-V11-B5 DA100-S8-BH DA150-S8-BH DA120-S8-BH DA120-S8-BH DA120-R8-BH DA120-S8-BH DA120-S8-BH DAI 00-X11-BL3206 DA100-X11-BL3206 DA120-Q8-BH DA120-R8-BH DA120-S8-BH DAI 00-X11-BL3206 DA54-S8-BH DA120-S8-BH DA120-S8-BH DAI 00-V 11-BL7331 DA100-T8-B5 DA100-V11-B5 DA100-R8-BH DA 100-X11-BL3206 BH Products BH products are available within the following limits: Maximum diameter 20" Maximum thickness 1/2" Minimum thickness same on cut-off wheels Abrasive types 2A, 97A, 9A, 12A, 6C, C2A, 29A Purpose Thread & others Drill points or spiral flutes Straight tap flutes or spiral flutes All spiral flutes 15-1 Bond System BH BHJ BHR BHQ Grit Size 24-240 36-180 46-240 36-180 Available Grades P-X N-T P-X M-X Structure Preferred Alternate 7 5, 9 79 7 (none) 7 (none) MIL 000248 Machine And Wheel Data Machine/Model/ Application Tap Shank Squaring Maching SQ-100 SQ-150 Tap Chamfer Grinder TC-100, TC-200 Tang Grinder TG-150, TG-170 Subland Drill Grinder SL-100 Clearance Grinder (Drill Margins) CG-8 CG-10 CG-12 CG-80 Drill & Countersink Relief Grinder OCD-50 OCD-15Q Center Drill Grinder CD-312E CD-318E, CD-418 Drill Point Grinder DPG-8 PG-80 Step & Radial Relief Grinder SD-100 Router Bit Grinder RBR-100 Wheel Size Clearance 30 x 1 x 12 (Soft Steel) Clearance 30 x (Various) x 12 Clearance 14 x (Various) x 5 Clearance 30 x (3/4 &1) x 12 Fluting 15 x .350 x 8 Clearance 8 x 1/4 x 1-3/4 (1/4 tapered to 1/8) Clearance 8 x (1/8, 5/32, 3/16) x 1-1/4 Clearance 10 x (3/16, 1/4, 3/8, 1/2) x 1-1/4 Clearance 12 x (3/8, 1/2, 5/8, 3/4) x 3 Fluting 8 x (Various) x 1 -3/4 Clearance 20 x 3/8 x 5 20 x 7/8 x 5 (Recess 1/Side) Fluting 12 x (Various) x 8 Fluting 18 x (Various) x 8 8 x 3/4 x 1-1/4 8 x 2-1/4 x 5-1/8 Cup Wheel for soft steel 8 x 2-1/4 x 5-1/8 Cup Wheel Clearance 16 x 1 x 5 16 x 1-1/2 x 5 R 1/S 7-1/4 X 1/2 16X2X5 R 2/S 7-1/4 X 1/2 Clearance 14 x 1 x 5 Wheel Grade 82A80-Q8-BH 82A54-T8-B5 82A54-T8-B5 2A80-T8-B5 82A54-R8-BH 82A100-R8-BH 9A80-K6-VRW 2A100-K6-VRW 2A100-R-R 2A100-R-R 2A100-T8-B5 2A80-P-R 2A80-R-R 82A100-R8-BH 82A100-R8-BH 12A80-J6-VRW 12A54-I6-VRW 2A220-O5-BC H5A80-P8-BF H5A80-P8-BF H5A54-P8-BF 2A80-P-R MIL 000249 Machine/Model/ Application RBR-125 Saw Grinder SS-100 Slot Grinder SG-100 Gun Tap Grinder GP-100 GP-125 Tap Shank Squaring Machine SQ-150 End Mill Grinder EM-110 EM-120 EM-100 Diamond Roll Grinder PLG-100 Relief Grinder RG-110 RG-110 RG-120 Crankshaft Point Grinder CSG-12 Wheel Size Clearance 14x2x5 usually (R 1/S 8-1/8 X 1) Fluting 12 x (Various) x 3 Fluting 12 x (Various) x 5 Fluting 18 x.250x8 Fluting 1 x (Various) x 3 Clearance 30 x (Various) x 12 Fluting 20 x .625 x 12 Fluting 20 x (.375. .500, .625) x 12 Clearance 30 x (Various) x 12 Fluting 18 x (Various) x 8 14 X 3 X 10, 2" rim (Plate mounted) 14 x 1/4 x 11/4 four 9/16" plain holes on a 4-3/4" bolt circle 12x3/8x3 Wheel Grade 2A80-P-R 82A80-Q8-BH 97A1001-W7-BHQ 2A120-T-R 2A100-T-R 12A54-S7-B90 82A100-R8-BH 82A100-R8-BH 82A54-R8-BH 82A100-R8-BH 12A60-J9-B90 12A80-J9-VFM Applications (Fluting) The wheels covered by this application guide are used primarily for fluting, slotting, clearing, gashing, and gun pointing on cutting tools such as taps, reamers, drills, end mills, router bits, etc. Whereas in thread grinding, stock removal amounts are relatively small, in flute grinding (and related areas) the plunge operation removes larger amounts of material in a single pass. The most common machines encountered are HERTLEIN and NORMAC machines. You must pay particular attention to wheel speeds as some of the newer NORMAC machines operate at 16,000 SFPM (6" & 8" diameter wheels) w hile the HERTLEIN machines generally operate around 12,000 SFPM. The high speeds tend to increase the wheel effi ciency but may also require a specification change if burn starts to develop. The most commonly encountered wheel diameters are: 3'', 6", 8", 10", 12", 15'', 16", 18" and 20". Thicknesses will vary from .070 up to .625. The most commonly used abrasives for flute grinding are: 15-3 2A, 9A, 12A, 97A and the most commonly used bond systems are BHJ and BHQ, see 15-4. Because tap flutes are usually short and fairly shallow, harder grades and rougher grains can be used. Production rates are high and dressing cycles can vary widely. When grinding spiral drill flutes the problems encountered are different. Here you have a long uninter rupted deep plunge cut. Wheel shape must be held while burning is kept to a minimum to avoid metallurgical damage. Special tough, yet friable abrasives are required to do this job matched up with the proper bond type. If required, coolant slots (side grooves) are avail able to aid in reducing a burning condition. The following information is to be used as a starting guide and may not necessarily be fhe only specifications for the job. When ordering be sure to specify the speed at which the machine is operating. 000W0 Fluting Wheel Dia. (mm) >100<200 >200MM >300<500 <300 >300 >300<500 >300<500 Thickness Variable Variable Variable Variable Variable Variable Variable Variable Variable <2 >2<3.5 >3.5<4.75 >4.75 >2<4.75 >4.75 >2<4.75 >4.75 <4.75 >4.75 <4.75 >4.75 >4.75 <6mm >6mm Variable Variable Variable <25mm <16mm End Use General Specifications Straight Fluting Taps 8mm >8mm<13mm >l3mm Straight Fluting Reamers AK120-V11-85 AK120-V11-85 AK100-V11-85 AK120-V11-B5 Straight Fluting Extra Long Reamers & Taps AK100-V11-B5 Fluting Centre Drills Fluting Short End Mills Fluting Router Bits (Small) Fluting Router Bits (Large) AK100-S8-BH AK100-S8-BH AK100-V11-B5 AK100-Q8-BH Spiral Fluting of Drills & Taps AK150-R8-BH AK120-Q8-BH AK120-Q8-BH AK120-Q8-BH Spiral Fluting of Soft End Mills Spiral Fluting of Tough Steel End Mills AK120-P8-BF AK120-P8-BF AK100-R8-8H AK100-S8-BH Spiral Fluting of Drills & Taps Spiral Fluting of End Mills End Mills - Soft Steels AK120-P8-BF AK120-Q8-BH AK120-P8-BF AK100-S8-BH AK60-S8-BH Gun Pointing Spiral Taps Gun Pointing Straight Taps Slotting Long Drills 25mm Slotting Small Taps - Reamers Drill Step Gashing End Mills AK150-Q8-BH AK100-Q8-BH AK120-V11-B5 AK100-S8-BH AKI20-V11-B5 AK80-P8-BF AK100-S8-BH HERTLINE AK100-V11-BL7331 AK100-V11-8L7331 AK100-V11-85 AK100-V11-8L7331 AK100-V11-BL7331 AK100-X11-BZ AK100-X11-BZ AK100-V11-BL7331 AK100-R8-BH AK180-S8-BH AK120-R8-BH AK120-R8-SH AK120-Q8-BH AK120-S8-BF AK120-S8-BH AK100-X11-BZ AK100-X11-BZ AK120-Q6-BH AK120-R8-BH AK120-R8-BH AK100-X11-BZ AK54-S8-BH AK120-S8-BH AK80-S8-BH AK100-V11-BL7331 AK100-S8-BH AK100-V11-BL7331 AK100-Q8-BF AK100-X11-BZ DA Recommendation DA100-V11-B5 DA100-V11-B5 DA100-V11-B5 DA1Q0-V11-B5 DA100-V11-B5 DAI 00-X11-BL3206 DA 100-X11-BL3206 DA100-V11-B5 DA100-S8-BH DA150-S8-BH DA120-S8-BH DA120-S8-BH DA120-R8-BH DA120-S8-BH DA120-S8-BH DA100-X11-BL3206 DAI 00-X 11-BL3206 DAI 20-Q8-BH DA120-R8-BH DA120-S8-BH DAI 00-X11-BL3206 DA54-S8-BH DA120-S8-BH DA120-S8-BH DA 100-V11-BL7331 DA100-T8-B5 DA100-V11-B5 DA100-R8-BH DA 100-X 11-BL3206 Trouble Shooting Problem A. Burning or discoloration of work B. Maintaining proper root width C. Poor Thread form (other than root) D. Lead error E. Poor finish and chatter Possible Cause Not enough coolant Too heavy on infeed Too slow work speed Direction of cutting cycle Wheel too coarse Wheel too slow Proper coolant flow on work piece Poor diamond dressing Dressing diamond worn or loose Dressing cut too heavy Wheel deflection Diamond scratch lines evenly placed Surface roughness Scratches Out of balance wheel Work speed too high Possible Correction Redirect coolant at cutting point Reduce amount of stock removed per pass Increase work speed and reduce infeed proportionally Change cycle to finish or "upcur Change to finer grit size Increase wheel speed on narrow roots Ensure coolant is directed at the cutting point Dress from point of wheel toward edges Replace or tighten nib Take lighter cuts Change to thicker wheel or use larger flanges Change dressing procedure Use lighter cut or slower work speed on finish pass Clean oil Retrue and rebalance Use slower work speed MIL 000251 15-4 16 Snagging Wheels 16-1 MIL 000252 Snagging Wheels Large diameter snagging wheels are ideal for applications which require the fast removal of large amounts of metal. They are engineered for most swing frame or floor stand grinders. for a variety of metal removal jobs, such as removing excess weld beads, cleaning prior to painting, smoothing rough surfaces, and grinding of parting lines, fines and risers. Highly efficient super speed wheels also are avail able, which are capable of running up to 17,000 SFPM. Resin Bonded Cups Straight (T-6) and flaring (T-11), (T-11A) cups are utilized in horizontal grinding applications for rough, heavy stock removal. Cups also are available with or without steel backs. Snagging wheels are available in a full range of abrasive grains, including Zirconia, and in a complete range of non-reinforced and reinforced wheels in diameters up to 42 inches. Resin Bonded Portable Wheels Straight wheels, depressed center wheels, and cones and plugs are available as a complete line for hand-held portable grinding applications. These wheels are suited mil oo0253 16-2 Resin Wheel Recommendation High Speed Type 11A Cups* Wheel Size 4/3x2 x 5/8-18 Max. SFPM 12,500 5/3-3/4 X 2 X 3/4-16 11,800 6/4-3/4 x 2 X 7/8-14 12,500 *11A - The "A" designates steel back. Cast, Gray Ductile Iron R5A167-N-12 27A167-N-12 R5A167-N-11 27A167-N-12 R5A167-N-12 27A167-N-12 Malleable (Annealed) 27A167-N-12 R5A167-N-12 27A467-N-12 R5A167-N-11 27A167-N-12 R5A167-N-12 Steel 27A467-N-12 27A487-N-12 27A467-N-12 Stainless Steel 27A467-N-12 R5A167-N-12 27A467-N-12 R5A167-N-11 27A167-N-1 R5A167-N-12 Snagging Wheel Application 9500 SFPM Light Pressure 9500 SFPM Heavy Pressure 12500 SFPM Light Pressure Aluminum Castings R5A16-04-BCW R5A16-P4-BCW R5A16-04-BCW Brass, Bronze R5A16-P4-BF R5A16-Q4-BF R5A16-Q4-BF Cast Iron W5C14-Q4-BF W5C14-R4-BH W5C14-Q4-BF Chiilled Iron R5A16-PR-BF R5A16-P4-BF R5A16-P4-BF Ductile Iron W5A14-P4-BF W5A14-Q4-BF W5A14-P4-BF Malleable Iron Annealed Unannealed W5A14-Q4-BF W5A14-P4-BF W5A14-R4-BH W5A14-Q4-BF W5A14-R4-BH W5A14-Q4-BH Steel Castings W5A14-Q4-BH W5A14-Q4-B254 W5A14-R4-8H Stainless Steel W5A16-P4-BF W5A16-Q4-BF W5A16-P4-BF Titanium R5A16-P4-BF R5A16-Q4-BF R5A16-P4-BF These are starting recommendations for snagging wheels. The reinforcement codes need to be added. Based on competitive specification, these may be altered. 12500 SFPM Heavy Pressure R5A16-P4-BCW R5A16-R4-BH W5C14-R4-BH R5A16-Q4-BF W1A14-R4-8H W5A14-R4-B254 W5A14-R4-BH W5A14-R4-B254 W5A16-Q4-BF R5A16-Q4-BF Portable Snagging Wheel Application Aluminum Castings Brass, Bronze Castings Billets (Cleaning): High Carbon. Low Alloy Steels Stainless Steels High Alloy & Tool steels General Purpose: Ferrous Non-ferrous Non-Metallic Gray Iron Castings Buried In Sand Malleable Iron & Steel Castings (annealed) Malleable Iron Castings (unannealed) Titanium Track Welds Welds: Carbon Steel Stainless Steel TYPE 1 Straight Wheel A24-05-BC2W A24-N5-BCW AZ16-R-BX or W5A16-R4-BH AZ16-R-BX or W5A16-R4-BH AZ16-R-BX or W5A16-R4-BH A16-Q4-BH R5A16-P4-BF C24-05-BC AZ16-Q-BX or AZ14-Q-BX AZC14-Q-BX AZ16-R-BX or W5A16-Q4-BH AZC14-Q-BX or 15C14-Q4-BF C20-Q5-BF . AZ24-R-BX or W5A24-R4-BH AZ16-Q-BX or W5A16-R5-B254 AZ16-R-BX or W5A16-SS-B254 TYPE 6, 11 Cup A24-05-BCW A24-05-BCW AZ16-R-BZ or W5A16-R4-BH AZ16-R-BX or W5A16-R4-BH AZ16-R-BX or W5A16-R4-8H A16-P5-BF R5A16-05-8C C24-OS-BC AZ16-Q-BX or W5A14-Q4-BF AZC14-Q-BX or W5C14-Q4-BF AZ16-R-BX or W5A16-R4-BH AZC14-Q-BX or 15C14-Q4-BF C20-Q5-BF AZ16-R-BX or W5A16-R4-BH AZ16-Q-BX or W5A16-R4-B254 AZ16-R-BX or W5A16-R4-B254 All Resin wheels run 9500 SFPM except reinforced Type 1 - 12500 SFPM maximum. T16,17,18,19 CONES & PLUGS A24-05-BCW A24-05-BCW AZ24-R-BX or A24-R4-BH AZ24-R-BX or A24-R5-BH AZ24-R-BX or A24-R5-BH A24-R5-BH C20-O5-BC C24-Q5-BF AZC24-R-BX or R5A24-R5-BH AZC24-R-BX or 15C24-R-BX AZ24-R-BX or A24-R4-BH AZC24-R-JBX or C24-S4-B254 C20-05-BF AZ24-R-BX or A24-R4-BH AZ24-R-BX or A24-R4-B254 AZ24-R-BX or A24-S4-B254 16-3 MIL 000254 17 Type 27 & 28 Super Speed SUPER LANCER APEX 2000 and SUPER LANCER Depressed Center Grinding Wheels for Your Portable Application APEX 2000 and SUPER LANCER Grinding Wheels were specifically developed for improved performance and productivity in your portable applications. APEX 2000 with zirconia alumina abrasive, and SUPER LANCER aluminum oxide wheels will consistently out perform your standard depressed center grinding wheels. Cincinnati Milacron understands the unique requirements of your portable operations. Years of research and bond development have resulted in real breakthroughs in our grinding wheels. APEX 2000 and SUPER LANCER Grinding Wheels are excellent for difficult applications and hard to grind mate rials, such as high nickel and high carbon steel alloys, and other exotic alloys. They are also the wheels of choice for weld grinding applications. Our grinding wheels are designed to give you the win ning edge. They last four times longer than standard alu minum oxide wheels, which means less downtime for wheel changes. They stay sharper longer and require less pressure to grind, thereby increasing your operators' productivity. 17 MIL 000255 17-1 Resin Wheel Recommendation PORTABLE SUPER SPEED WHEEL Type 1 6x1x1 8x1x1 Max SFPM 17,000 17,000 Material Steel Castings Hardened Steel Low Carbon Manganese Monel & Hi-Nickel Alloys Cast & Gray Iron Ductile & Nodular Recommended Spec. A24-P-17 A24-P-17 A24-R-17 A24-P-17 A24-P-17 R4A24-Q-17 R5A24-P-17 R5A24-Q-17 A24-Q-17 Material Stainless 300 Series 400 Series Welds Malleable (Annealed) Meehanite Ni-Hard Recommended Spec. A24-Q-17 R5A25-Q-17 A24-R-17 A24-P-17 A24-Q-17 R5A24-Q-17 C24-Q-17 DEPRESSED CENTER GRADES Size 3x1/8x3/8 3x3/16x3/8 3x1/4x3/8 4x1/8x3/8 4X1/8X5/8 4X. 125X3/8 4X3/16X3/8 4X3/16X5/8 4X1/4X3 4X1/4X5/8 4-1/2X1/8X7/8 4-1/2X1/8X5/8-11 4-1/2X. 125X7/8 4-1/2X3/16X7/8 4-1/2X3/16X5/8-11 4-1/2X1/4X7/8 Type 27 27 27 27 27 27 27 27 27 27 27 27A 27 27 27A 27 SUPER LANCER Metals A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T Alum A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P Masonry C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P APEX 20QQ Metals AX24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V Size 4-1/2x1/4x5/8-11 5x1/8x7/8 5X1/4X7/8 6X1/4X7/8 7X1/8X7/8 ' 7X1/8X5/8-11 7X1/4X7/8 7X1/4X5/8-11 9X1/8X7/8 9X1/8X5/8-11 9X1/4X7/8 9X1/4X5/8-11 7X1/4X7/8 7X1/4X5/8-11 9X1/4X7/8 9X1/4X5/8-11 Type 27A 27 27 27 27 27A 27 27A 27 27A 27 27A 28 28A 28 28A SUPER LANCER Metals A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T A24-R&T Alum A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P A24-P Masonry C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P C24-P APEX 2000 Metals AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T8V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V AZ24-T&V MIL 000256 17-2 18 Thread Grinding Starting Grade Recommendations Type of Thread Fine pitch screws Amer. Natl. Form Thread Screws, Studs And Bolts (Ameican National Form Threads) Taps (High Speed Steel) N.C. and N.F. Threads Pipe Thread Taps (American Standard Pipe Threads Threads per inch 32 to 40 8 to 12 14 to 20 24 to 28 32 to 36 40 to 44 4 to 12 14 to 20 24 to 36 8 to 18 20 to 26 27 Precut Thread 97A2201-M4-VRW 97A601-L4-VRW 97A801-M4-VRW 97A1501-M4-VRW 12A80-J6-VRW 12A120-L4-VRW 12A220-L4-VRW 97A1001-L4-VRW 97A1501-M4-VRW From Solid 12A220-S6-B90 97A1001-R9-B90 97A1201-R9-B90 97A1501-S7-B90 97A1801-S7-B90 12A220-S7-B90 97A1001-Q9-B90 97A1201-R9-B90 97A1801-S7-B90 97A1001-S7-B90 97A1501-T7-B90 97A1801-T7-B90 Specification & Selection B-H Resin Bonded Wheels Chart II External Thread Grinding Taps M-2 High Speed Steel 63-65 Rockwell Hardness Type Thread Acme American National Fine Threads American Standard Pipe Threads Threads Per Inch 8-18 (From Solid) 20-26 (From Solid) 27-32 (From Solid) 4-12 (From Solid) 14-20 (From Solid) - 24-32 (From Solid) 8-18 (From Solid) 20-26 (From Solid) 27-32 (From Solid) Specifications Commercial Quality 2A100-S7-BH 12A100-S7-BH 2A150-T7-BH 12A150-T7-BH 12A180-T7-BH 12A180-V7-B5 2A100-S7-BH 12A100-S7-BH 2A120-S7-BH 12A120-S7-BH 12A180-T7-B5 12A180-V7-B5 2A220-WY-BH 2A100-S7-BH 12A100-S7-BH 2A150-T7-BH 12A150-T7-BH 12A150-T7-BH 12A150-V7-B5 12A180-V7-B5 Notes to Selection Guide: 1. 2A is the standard abrasive. 12A is our premium grain to be used on special metals and alloys. 2. All trial specifications should be in "7" structure to start. The 5" and 9" structures are used only to fine tune a specification. 3. Pay particular attention to wheel speeds and work speeds. They are important in determining the proper hardness. 4. "W" and "X" grades available if required. Try softer grades first. 18 MIL 000257 18-1 Surface Feet Per Minute Wheel Diameter Revolutions Per Minute SFPM 9,000 10,000 12,000 12 2864 14 2455 16 2149 16 2387 2865 18 2122 2546 20 1910 2292 24 1591 1910 Standard Wheel Sizes: External Thread Grinders Machine DAIZEN #1 DAIZEN #2 EXCELLO JONES and LAMSON LANDIS Wheel Size 16 X 1/4X7 12 X 1/4 X 7 18X3/8X9 20x3/8 x 10 20 x 3/8 x 10 Thread Grinding Wheels Resin Bond Operating Speed 12,000 SFPM All Grain Types Bond Types - B90 & BH Grain Size 54-60-70 80 and finer Grade "P" and harder "N" and harder Maximum Operating Speed RPM O.D. 16 2865 18 2546 20 2292 24 1910 Wheels must be for use on conventional thread grinding machines and orders must be labeled "Thread Grinding". American Standard Thread Threads/in. 40 36 32 28 24 20 18 16 14 13 12 11 10 9 8 7 6 5 4'* 4 Root Width .0031 .0035 .0039 .0044 .0052 .0062 .0069 .0078 .0089 .0096 .0104 .0113 .0125 .0139 .0156 .0178 .0208 .0250 .0278 .0312 Coarsest Grit Size Resin Bond 220 180 180 150 150 120 100 100 100 90 90 90 80 80 80 80 70 70 60 60 Coarsest Grit Size Vitrified 220 220 180 180 150 120 120 120 100 100 90 90 90 80 80 80 80 80 70 70 The grit sizes in this chart are subject to the limits of the grain charts in the Engineering Data Book. Following are some general recommendations of starting grades for average thread grinding operations. The vitrified grades shown can be used for either diamond dressing or crush forming. Acme or worm threads 4 to 6 8 to 12 12 to 16 12A80-J6-VRW 12A100-J6-VRW 12A120-J6-VRW 2A80-P8-B90 2A100-R9-B90 97A1201-09-B90 18-2 MIL 000258 Diameter/Thread Pitch Comparison Size #0 #1 #2 #3 m #5 #6 #8 #10 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1" Inch Series Dia. (In.) .060 .073 .086 .099 .112 .125 .138 .164 .190 .250 .212 .375 .437 .500 .625 .750 .875 1.000 TPI 80 64 56 48 40 40 32 32 24 20 18 16 14 13 11 10 9 8 Size Ml.6 M2 M2.5 M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M27 Metric Series Dia. (In.) Pitch (mm) TPI (Approx.) .063 .35 .079 .4 .098 .45 74 64 56 .118 .5 51 .157 .7 36 .196 .8 .236 1.0 32 25 .315 1.25 20 .393 1.5 17 .472 1.75 14.5 .551 2 12.5 .630 2 12.5 .787 2.5 10 .945 3 8.5 1.063 3 8.5 Vitrified Bond Thread & Flute Grinding Wheels Type 1 Only Standard maximum operating speed for thread grinding is 12,000 SFPM for high strength vitrified bonds. Wheels used for thread grinding within the range described below do not require an "E" or an over-speed label. Maximum Operating Speeds j VFM2A, 4A, 9A, 97A, 12A j VRW Grain in Structures 4 and 6 ID 7 9, 10 & 12 54-220: H and Harder 54-70: H and Harder 80-220: 80-220: J and Harder SFPM 00 12 14 16 18 20 24 9,000 RPM 2864 2455 2149 H and 1 10,000 RPM 2387 2122 1910 1591 12,000RPM 2865 2546 2292 1910 18 MIL 000259 18-3 Basic Principles Thread Grinding Thread grinding can be generally classified into two cat egories, namely single-rib and multi-rib methods of thread grinding. The multi-rib method can be further described as multi-rib plunge cut, multi-rib traverse and centerless methods. The centerless method can be fur ther divided into the traverse method for headless parts and the plunge cut method for cap screws, bolts, etc. The majority of thread grinding is done by the single-rib method or single-edged wheel. The periphery of the wheel is trued to the exact form of the thread to be ground and the wheel swiveled to match the helix angle of the thread. Wheels for this type of thread grinding are usually dressed with single-point diamond dressing tools designed to fit the special dressing attachments of the machines. The grinding wheels may be vitrified or resin bond, depending on the accuracy of the thread required or the operation involved. Vitrified wheels are used when grinding pre-cut threads that have been distorted by hardening or to correct lead error in the thread and when grinding thread gages where very accurate threads are required. Resin bond wheels are generally used when grinding from the solid rod. Thread grinders are equipped with a variable speed spindle for the grinding wheel, making it possible to increase spindle speed to maintain a constant SFPM as the wheel wears down. Wheel speed on thread grinding varies from 6500 SFPM to 12,000 SFPM, and while most grades of thread grinding wheels are safe at these speeds, there are exceptions when material is hardened or the design of the part requires a coarse and softer wheel. The speed marked on the wheel by the wheel manufacturer must not be exceeded. The work speed is usually determined by trial; one work speed for all class es of work would not be practical. A work speed of 2'h SFPM would be a good starting point on medium pitch threads ground from the solid. Grinding oil has proven to be the best coolant to use for both vitrified and resin bonded wheels. It helps the wheel to hold form, produces a better finish, and keeps the wheel clean and free-cutting. The application of coolant is as important as volume. Keep the nozzles adjusted to direct coolant on the part and wheel at point of contact. When selecting a grade of wheel to grind threads, the bond is considered first, the bond type used depending on type of operation. If grinding pre-cut threads or thread gages, use vitrified bond. Resin bond is used on high production jobs where threads are ground from solid in as few passes as possible and as many pieces as can be ground within tolerance between dresses for a greater number of pieces per dress and give a brighter finish than vitrified bond. The grain type is not as critical as in other types of pre cision grinding. The majority of jobs, both soft and hard ened, can be ground satisfactorily with regular and semi-friable grain. Internal thread grinding, due to the longer arc of contact, needs the cooler cut of the full fri able grain. The grit size is controlled by the root width of the thread to be'ground. The root width varies inversely with the number of threads per inch; the greater the number of threads per inch the narrower the root width. It is imprac tical to grind a thread with a root width smaller than the cross section of the grain. The dressing diamonds would have to machine the grain on the edge of the wheel to a smaller size. The grain usually breaks out from the pres sure of the diamond, making a ragged edge on the periphery of wheel that may develop chatter in the root of the thread. See the chart on page 16-2 for coarsest grit size recom mended to grind American Standard Thread Form, Multi-Rib Thread Grinding The term multi-rib describes the wheel face, meaning the wheel has 2 or more ribs dressed on the periphery corresponding to the number of threads per inch the wheel will grind. Each rib is dressed to the form of the thread by either crush dressing or diamond dressing. The grinding wheel usually is as wide as the thread is long or wider, and is plunged into the full thread depth in the first half-revolution of the part. The full length and depth of the thread is completed in one and one-half revolutions of the workpiece. 18-4 The Skip Rib method of multi-rib thread grinding uses a wheel that is as wide or wider than the length of the thread, having the ribs spaced to grind every other thread during the first revolution of the work, and com pleting the thread with the second revolution of work. This method requires 2'k revolutions of the work to com plete the thread and works especially well where resinoid wheels must be used on fine pitch threads. This wheel form lends itself readily to very accurate diamond dress ing and permits better distribution of coolant, usually giv ing more parts per dress than the multi-rib or single-rib method. MIL 000260 Multi-Rib Thread Grinding (cont.) The centerless method of thread grinding can be used on work that can be fed through the grinder (similar to thrufeed) such as headless set screws, headless bolts, tubing or pipe, etc. The grinding wheel generally is from 2" to 5" wide and the thread form is crush-trued on the wheel; the regulating wheel then feeds the work across the grinding wheel as does a thrufeed grind. The machines have to be especially equipped for crush-truing and this type of work. It is impractical to crush-form a thread when the root width is less than .005" or when the thread is finer than 20 threads per inch. Crush-dressing is not recommend ed for better than a class 3 fit, however, it is possible to obtain a class 4 fit by the centerless method on a pro duction basis. Grit Size and Type Usually start with standard A abrasive. To reduce burning, go H5A to 10A. Grit size depends on size of flute and thread. Coarse Thread -- 8-20 threads/inch -- 80 grit Medium Thread -- 20-26 threads/inch -- 120 grit Fine Thread -- 27-32 threads/inch -- 180 grit Normal Grades -- Cold Press - R-V; Hot Press - X11 Rule of Thumb When grinding threads from the solid, resinoid wheels work best, i.e. H5A80-T9-B5. When grinding precut threads, use vitrified grinding wheel, i.e. 9A80-P4-VFME. Carlisle FDT Wheels -- Cold Press Grade Q-S S-T T-U-V Bond BH B254 B5 Carlisle FDT Wheels - Hot Press Softest Hardest BL6823 BL3206 *BZ243 BL1830 *Normal trial would be BZ243 Trouble Shooting Burning of Work: Make sure there is a sufficient volume of coolant direct ed where it will flood the contact area between the wheel and the work. Burning can be caused by too heavy feed or too fast work speed -- take lighter cuts at reduced work speeds. On hardened high-speed steel, a change to a smaller grit size will often reduce burning. Direction of work rotation is often critical in thread grind ing. Some work will burn when rotated in climb-cut direc tion and not burn when rotated in the opposite direction to wheel rotation, or the up-cut direction. Finish cuts should always be made with work rotating in the up-cut direction. Thread Form: Poor thread form is usually caused by dressing or truing the wheel; check diamonds for cracks or loose diamonds. Also, if diamond is dull, the side pressure developed on the wheel by the diamond may cause the wheel to deflect enough to affect the thread form. Lead Error: Lead error is a common problem when using a resin bond wheel to grind a pre-cut thread. It is advisable to use vitri fied bonded wheels on pre-cut threads. The vitrified wheel is not as flexible as the resin wheel and will correct the lead error instead of deflecting and following the pre-cut thread. If conditions dictate the use of resin bond, then thicker wheels or larger diameter flanges will help resist deflection of the wheel. Chatter: Chatter in thread grinding can be the result of the same conditions which cause other grinding problems: wheel out of balance, glazed wheel from dull diamond, too high work speed, etc. Truing a sharp edge on a coarse grit wheel (such as is generally used on coarse pitch threads) causes a ragged edge on the periphery of the wheel, which will sometimes cause chatter in the root of the thread. If a small flat is dressed on the periphery of the wheel, it will stop chatter from this source. 18 MIL 000261 18-5 19 Diamond and CBN Superabrasives Proven Application Expertise Cincinnati Milacron has built a solid reputation for world class grinding wheels and grinding process knowledge by developing advanced technology products like Superabrasive Grinding Wheels. As a result of its long standing reputation as a leading manufacturer of machine tools, conventional and superabrasives, and high performance metalworking fluids, Milacron has the unique distinction within the grinding industry of a total systems approach. Nobody knows more about advanced technology grind ing than Cincinnati Milacron ... from automotive cam shafts to aircraft engine parts ... from carbide tipped tooling to the most advanced alloys. Wherever there is a need for state of the art grinding wheels and process knowledge, a Cincinnati Milacron Representative will be there to help determine precisely the right wheel and metalworking fluid. Superabrasives: Your Competitive Edge The grinding wheels of tomorrow are here today -- Cincinnati Milacron Products Division's Superabrasives. The term superabrasive refers to the extraordinary hard ness of diamond and CBN abrasives. Diamond is the hardest material known to man, and is three times harder than its conventional abrasive counter part, silicon carbide. CBN (cubic boron nitride) is second in hardness only to diamond, and is twice as hard as its conventional counterpart, aluminum oxide. Super hard with exceptional wearability, Diamond and CBN wheels reduce grinding time and help eliminate common problems like burn, part-to-part variations, and excessive downtime due to wheel dressing. Best of all, with the continuous improvement the Superabrasives 19-1 offer in quality and productivity, these wheels are also masters of cost efficiency. Diamond Cincinnati Milacron's Bonded Diamond wheels are cus tom engineered for the grinding of extremely hard, nonferrous materials such as carbide, glass, ceramics, and titanium. They perform exceptionally well when used to grind and sharpen carbide tooling, grind dies, bevel glass, engineered ceramics and grind carbide tipped saws. Only the finest synthetic virgin diamonds are used, and the diamonds for each type of wheel are engineered especially for specific applications. CBN -- Cubic Boron Nitride CBN, cubic boron nitride, is second only to diamond in hardness. Cincinnati Milacron carefully engineers the bonds in these wheels for ferrous grinding such as the automotive compressor bearing and aerospace indus tries, where super hard materials like hardened tool and die steel, alloys and superalloys, stainless steel, and cast iron are being used. They are ideal for grinding and re sharpening tooling, surface grinding, superfinishing, and groove grinding. Cincinnati Milacron's MarathonTM Vitrified Bonded CBN wheels are designed for high production and high preci sion grinding of such ferrous materials as bearing steels (52100, M50, and 8620), alloys, superalloys -- especially aircraft materials, cast iron, and powdered metal. They are ideal for use in production grinding of bearing bores (D grinding), cylindrical grinding, and in applications involving difficult to grind aircraft and automotive parts and rotary compressors. Applications include internal, cylindrical camshaft and crankshaft surface and creepfeed grinding. MIL 000262 1 Superabrasive Grinding Wheels Are Available In a Variety of Shapes (All types are not listed. These are examples of the most common shapes used in the industry.) Cl 1A8 MIL 000263 19-2 MARATHONTM Grinding Wheels Availability and Markings Vitrified Cubic Boron Nitride (CBN) for High Production Grinding Selecting The Wheel Specifications The MARATHONTM wheel is a unique product for high-production grinding of hardened ferrous metals. Applications Bore Grinding Bearing Notch Grinding Bearings Room Air Conditioner Components Fuel Injection Components Automotive Parts (i.e. camshafts, crankshafts) Machine Capabilities Needed Reproducible Diamond Dress Compensation 0.0001" desirable Skip Dress Capability Automatic Preferred Grinding Fluid Necessary and Critical Rotary Diamond Trueing Device Materials Ferrous materials over 50 Rc Hardened Tool & Die Steels Hardened Steels and Cast Irons Stellite and Super Alloys Grit Size The surface finish and metal removal rate require ments determine grit size. 15 Microinch RMS and Less Use 180 Grit and Finer Over 15 microinch RMS Use 150 Grit of Coarser Wheel Shapes Types 1A8 (Solid) and 1A1 (Rimmed). Mounted Wheels -- 1A8-W, 1A1-W. Some wheel sizes are available as mounted wheels with straight or tapered shanks, or flanged threaded mandrels. Wheel Sizes Minimum Diameter-- 1/4" Maximum Diameter -- 24" Minimum Thickness -- 1/4" Maximum Thickness -- 7/8" (one piece) ID sizes vary with equipment availability. When converting from conventional wheels that grind on the periphery, do not reduce the CBN wheel OD. This reduces SFPM and with it, grinding efficiency. Reducing the size of wheel can be done if the SFPM can be maintained with a higher RPM. Wheel Speeds 6500-20.000 SFPM. Rigidity of set-up is important, especially at higher speeds. Speeds as low as 2500 SFPM have been successful for very small diameter MARATHONTM grinding wheels. Vitrified CBN wheels show increased grinding efficiency at higher wheel speeds. Mounting, Trueing & Dressing For an in-depth explanation, see the section enti tled Mounting, Trueing and Dressing. For assistance on a specific application, contact your local Cincinnati Milacron Grinding System Engineer (GSE). Grinding Fluid Maximum performance can be achieved by using a fluid providing high lubricity. Cincinnati Milacron offers a wide range of CIMCOOL Metalworking Fluids to meet your individual grinding requirements. 2BN 150-R100-VHA 1/16 Grit Type Grit Sizes' Grades Concentrations'* Bonds Depth of CBN 2BN 60 Thru 320 P-R-T-U 100-125-150 VHA (Vitrified) ... 2BN 60 Thru 320 P-R 100-125-150 VHC (Vitrified) 60. 80. 100. 120. 150. 180, 220, 240. 280. 320 ** Other Concentrations Available See Your Local Grinding System Engineer (GSE) For Assistance ** When Wheels With a Rim are Used CBN Type & Application CBN Type 2BN (Uncoated) Grinding Condition Wet Only Bond Types Bond VHA VHC Use Wet Only Replaces Aluminum Oxide Wheels Wet Only Replaces Silicon Carbide Wheels MARATHON 2 Vitrified Bond Open Structure CBN Wheels Grit Type Grit Sizes 2BN Uncoated 60 Thru 320 2BN Uncoated 60 Thru 240 2BN Uncoated 60 thru 320 2BN Uncoated 60 thru 240 2BN Uncoated 60 thru 240 2BN Uncoated 60 thru 240 *'* When Wheels Wiih Rims Are Used Grades M-N-0-P M-N-0 . M-N-0-P M-N-0 M-N M-N-0 Concentrations 80-150 100-150 -164100-150 100-150 164 Bonds VEA VEC VEB VMA VMC VMB Depth of CBN ... MIL 000264 19-3 Resin Bonded Cubic Boron Nitride (CBN) Wheels Availability and Markings Selecting The Wheel Specifications Materials Hardened Tool & Die Steels Hardened Steels and Cast Irons Stellite and Super Alloys Wheel Grade Use the hardest grade you can use without caus ing heat damage to the wheel or work. Most applications fall within the following grade ranges: Q-S-U for B4 Bond T-W for B7 Bond T-W for BBL Bend Concentration Most applications fall within the following ranges: 80-100 Concentration for B4 and B4Y Bond 66-88 Concentration for B7 Bond 66-88 Concentration for BBL Bond Wheel Sizes When converting from conventional wheels that grind on the periphery, do not reduce the CBN wheel OD. This reduces SFPM and with it, grind ing efficiency only if SFM can be maintained with higher RPM. Wheel Speeds Dry Grinding: 3500-5000 SFPM -- at higher speeds, there is danger of workpiece burning. Wet Grinding: 4000-9000 SFPM -- for best wheel life, 6500-8500 is good. At higher speeds, wheel balance and machine rigidity are a large factor in performance. Feed Rates Excessive feed rates cut down on wheel life and should ordinarily be avoided. Contact your local GSE for cycle optimization. Mounting, Trueing & Dressing The techniques for mounting, trueing and dress ing resin bond CBN wheels are the same as dia mond with the following exceptions: A diamond impregnated tool (metal bonded par ticle diamond) about 80-150 mesh can be used to true CBN wheels. Use vitrified bonded aluminum oxide trueing wheels to true CBN wheels. For an in-depth explanation, see the section enti tled Mounting, Trueing and Dressing. For assistance on a specific application, contact your local Cincinnati Mllacron Grinding System Engineer (GSE). Grinding Fluid Recommended for grinding, trueing and dressing whenever possible. However, economical results can be achieved on wet or dry applications. We recommend Cincinnati Milacron's CIMCOOL'9 Metalworking Fluids for best results. MIL 000265 1BN 150-U100-B4 1/8 Grit Type IBM Grit Sizes' 46 thru 320 Grades Soft-M-0-Q-S-U-Hard Concentrations" Low-80-100-High Bonds B4. B4Y (Resin) Depth of CBN 18N 46 thru 320 0 -- Light Outy T -- General Purpose W -- Heavy Duty Fixed 0=44 T=66 W=88 B7 (Resin) ... Q -- Ught Outy BN 100.150. 220 T -- General Purpose W -- Heavy Duty Fixed Q = 44 T = 66 W = 88 BBL * 46, 60. 80. 100. 120. ISO. 180. 220. 240. 280. 320 (Finer available upon request) '* Concentrations are Fixed in the 87 and 681 Bond System. Concentration and Grade are Dependent Upon Application of Product, i e Ught Outy. General Purpose or Heavy Outy (See Grades) *' When Wheels With a Rim are Used *'** These Wheels are Part of the Toolmaster Program CBN Type & Application CBN Type I8N (Nickel Coated) BN (Nickel Coated) Grinding Condition Wet or Dry Wet or Dry Grit Size and Selection Guide Operation Roughing and Heavy Stock Removal Medium Stock Removal, Average Finish Ught Stock Removal, Good Finish Fine Finishing Super Finishing Grit Size 80 -100 120-180 220 - 320 400 - 500 600 & Finer Recommended Starting Grades For Popular CBN Wheel Shapes Type ot Grinding Surface Grinding horizontal spindle reciprocating table (including broach grinders) rotary table vertical spindle large (usually rotary table) 0.0. Grinding centertype centerless Popular Wheel Shapes 1A1 6A9. 11V9 6A2-12A2 IA1 2A2T, 6A2 1A1 1A1 Slotting (no cutott) 1A1, 1 AT R Saw Sharpening rake clearance 12A2,15A2 11V9. 12V9,15V9 Small Drill Pointing 2A2, 6A2 Hob Sharpening (wet only) IVt, 12V9 Rotary Burs or Files (machine and ofthand grinding) 1VI 1V1 End Mill Flute Grinding (wet only) 1At. 1V1 Other Multi-Tooth Cutters and Tools (relieving, backing off and clearing end mills, face mills, reamers, etc) 6A9.11V9, 12V9.15V9 Internal Grinding general purpose (wet only) 1A1. IAS Specifications HEAVY DUTY GEN.PURPOSE 1BN60-T-B7 1/8 1BN80-T-87 1/8 1BN80-Q80-B4Y 1BN60-T-87 1/8 1BN80-W-B7 1/8 1BN60-W-B7 1/8 1BN100-W-87 1/4 1BN80-T-B7 1/8 BN100-T-B8L 1/8 1BN46-T-B7 1/8 18N80-T-B7 1/8 1BN120-T-B7 1/8 (Finish) 1BN150-W-B7 1/4 1BN80-W-B7 1/8 1BN80-W-B7 1/8 1BN80-W-B7 1/16 1BN80-W-B7 1/8 1BN100-W-B7 1/8 (Finish) . 1BN100-W-B7 1/8 1BN100-Q100-B4Y 1BN100-W-B7 1/8 18N150-T-B7 1/8 1BN150-W-B7 1/8 18N150-W-B7 1/8 1BN220-W-B7 1/8 18N180-T-B7 1/8 1BN180-Q80-B4Y 1BN150-Q100-B4Y 1BN80-T-B7 1/8 BN150-W-BB11/8 1BN120-Q100-B4Y 19 19-4 Resin Bonded Diamond Wheels Availability and Markings Selecting The Wheel Specifications Wheel Grade Use the hardest letter grade that can be used without causing heat damage to the wheel or work. Most diamond applications will be in the N-P-R range. Concentration Most diamond applications will be 75-100 concen tration. internal grinding wheels should be 100 concentration and medium-to-hard grades. Wheel Size When converting from conventional wheels that grind on the periphery, do not reduce the dia mond wheel OD. This reduces SFPM and with it, grinding efficiency. Wheel Speeds The best average wheel speed for wet grinding is 5000 to 6000 SFPM for most applications. In dry surface and cutter grinding, wheel speeds of 4000 to 5000 SFPM give best grinding efficien cy. Speeds of 2500 to 3000 SFPM provide the best results in internal grinding. Using incorrect wheel speeds may reduce wheel life. Feed Rates Excessive feed rates cut down on wheel life and should ordinarily be avoided. Mounting, Trueing & Dressing For an in-depth explanation, see the section enti tled Mounting, Trueing and Dressing. For assistance on a specific application, contact your local Cincinnati Mllacron Grinding System Engineer (GSE). Grinding Fluid Diamond wheel grinding should be done with a grinding fluid whenever possible. Synthetic fluids should be used with diamond abrasives. We recommend Cincinnati Milacron's CIMCOOL' Metalworking Fluids for best results. MIL 000266 19-5 CMP 150-R100-B 1/16 Grit Type Grit Sizes* Grades MD 46 thru 600" Soft-J-L-N-P-R-Hard CMD 46 thru 320 J-L-N-P-R AMD 46 thru 320 J-L-N-P-R DM0 60 thru 320 J-L-N-P-R EMD 60 thru 320 J-L-N-P-R NCD 100, 150,220 P-R Concentrations" Low-50-75-1Q0-High 50-75-100 50-75-100 50-75-100 50-75-100 75-100 46.60. 80, tOO. 120, 150,180. 220. 240. 280. 320. 400. 500. 600 * Finer Gnt Sizes Available When Wheels With a Rim are Used These Wheels are Part of Ihe Toolmaster Program Diamond Type & Application Diamond Type M0 (Uncoated) CMD (Nickel Coated) AMO (Copper Coated) DMD (Nickel Coated) EMD (Nickel Coated) NCD (Nickel Coated) Material To Be Ground Carbide With Very Little Amount of Metal Carbide With Limited Amount of Mefal Carbide Only Carbide With Relatively Large Amount of Metal Carbide Only Carbide with Limited Amount ol Metal Bonds B, BY B. BY B5, B5Y B6, B6Y B, BY BDL Depth or CBN ... Grinding Condition Wei or Dry Wet or Dry Dry Wet or Dry Wet Wet or Oty Grit Size and Selection Guide Operation Roughing and Heavy Stock Removal Medium Stock Removal, Average Finish Light Stock Removal, Good Finish Fine Finishing Super Finishing Grit Size 80 -100 120-180 220 - 320 400 - 500 600 & Finer General Resin Bond Diamond Wheel Recommendations Suggested Specifications For Grinding Cemented Carbides Grinding Operations Chip Breakers Cutting-Off and Slotting Internal (wet) Lapping Multiple Point Tools (Milling Cutter, Reamers. Broaches. Hobs. Saws) Roughing (wet) Roughing (dry) Finishing (wet) * Finishing (dry) Single Point Tools Roughing (wet) Roughing (dry) Finishing (wet) Finishing (dry! Surface Roughing (wet) Roughing (dry) Finishing (wet) Finishing (dry) Inserts Wet Roughing Finishing Recommended Specifications (Diamond depth omitted * Usually 1/8") MD150-N100-BY (less than 1/4" thick) MD150-R100-BY (1/4" thick or thicker) CMD150-R100-BY CMD150-N100-BY M0400-L50-BY CMD100-N100-BY or NCDIOO-PIOO-BDL AMD1O0-RIOO-B5Y CMD220-N100-8Y or NCD220-P100-80L AMD220-R100-B5Y CMD100-N100-BY or NCDIOO-PIOO-BDL AMD100-N100-85Y CM0220-P75-6Y or NCD220-P75-8DL AMD220-P75-B5Y CM0120-N100-BY or NCD100-P100-BDL AMD120-N100-B5Y CMD240-P100-BY or NC0220-P100-BDL AMD240-P100-B5Y CMD220-P100-BY `CERAMIC INSERTS CMD400-P100-8Y USE "L" HARDNESS Quality Control -- In-House Testing Cincinnati Milacron's sophisticated SPC Controls pro gram monitors quality constantly to ensure extremely high product consistency. The Products Testing Laboratory tests new and improved grinding wheels in actual use on machines. Specialists with grinding machine tool industry experi ence use the latest scientific equipment to evaluate per formance and help determine if the grinding wheel is being used to its optimum level. Finally, before a wheel is released to the field, it is used in demanding production environments in many of Cincinnati Milacron's plants. You never get a Cincinnati Milacron grinding wheel until it is proven in actual use. Physical Properties Both Diamond and CBN wheels are ultra hard. Milacron's diamond wheels reach over 7000 on the KNOOP Hardness Scale. By comparison, aluminum oxide and carbide wheels only reach approximately 2100-2400 KNOOP hardness. (Figure 1) Superabrasives will provide grinding ratios from 100-1000 times higher than conventional abrasives. (Figure 2) In addition, superabrasives conduct heat better than all other grinding wheel materials. (Figure 3) As they work, they pull heat away from the grind and the workpiece. Conventional abrasives are insulators, forcing heat back into the workpiece. By increasing quality, overall productivity and reducing wheel wear to a fraction, Diamond and CBN grinding wheels will provide a significant return on investment. There is less scrap, because burn is virtually eliminated. Part quality is consistently higher. And downtime due to wheel changes is drastically reduced. (Figure 4) When you want greater cost efficiency and need applica tion expertise to help find solutions, count on Cincinnati Milacron Products Division. HARDNESS COMPARISON A1203 SIC | 2.00 | 2480 CBN Diamond 14TM | 7000 -------1------r--i-------1------- 1------ 1-------1------- 1000 2000 3000 4000 5000 6000 7000 KNOOP HARDNESS (Kg/mm*) Figure 1 THERMAL CONDUCTIVITY GRINDING RATIO EXAMPLES WORKPIECE M-2 M-4 M-50 T-15 0-1 A-2 D-2 GRAY IRON NODULAR IRON '10 W OK -5 IN. OIK HARDNESS 60 Re 60 Rc 60 Rc 65 Rc 62 Rc 62 Rc 62 Rc 32 R* 57 R* AlOx* 4*5 2.0 50 20 3.0 -- -- CBN" 1030 180 250 750 390 650 2700 870 Figure 2 ECONOMIC EVALUATION Documented Savings Range from 10 to 70% with CBN GAWOWQW006 Q WHEEL COST O LABOfVOVERHEAD COST O SAVINGS THERMAL CONDUCTIVITY (gr.-cal.) Figure 3 l--------------1-------I------ 1------ 1I____ L...1 -I. t .1 Total OrtrxSftfl Cott (%} Figure 4 MIL 000267 19-6 Grade Selection Mounting, Trueing and Dressing Resin Bonded Diamond & CBN Wheels NOTE: The techniques for mounting, trueing and dress ing resin bond diamond and CBN wheels are the same with the exceptions noted. Mounting The Wheel 1. The Importance of Care The care taken in mounting a new wheel the first time always pays off in longer wheel life. The grinding wheel must be in contact with the work across the full width of the wheel face in order to grind at full efficiency. The dia mond or CBN rim must be trued and dressed. Thus, every careful attention to attaining perfection in the origi nal wheel mounting operation will minimize abrasive loss due to trueing. 2. Standards Wheels where the OD is used for grinding should never runout more than 0.0005". Even less runout than this may be required on finish grinding to obtain very fine finishes. Cup and other "face" grinding wheels should not runout more than 0.001" on the wheel face. 3. How to Mount Do not use blotters on wheels with aluminoid cores. Always use a dial indicator reading to 0.0001" to check runout and out-of-roundness of the wheel. The arbor holes of CINCINNATI MILACRON diamond and CBN wheels are manufactured with a controlled amount of oversize. This enables the mounted wheel to be adjusted to meet the runout standards. Here is the technique: a. OD Grinding Wheels Mount the vyheel and tighten the flange nuts only enough to allow for stable repositioning as follows: Check the wheel runout with the indicator. If the runout is too high, the wheel position should be adjusted. Place a wooden or plastic block against the wheel at the point of greatest runout. Gently tape the block with a hammer (see Figure 1). Repeat this process until the runout is minimized and then securely tighten the flanges. (NOTE: Use flanges with the largest diameter possible when mounting diamond cutoff wheels.) b. Face Grinding Wheel Mount the wheel and tighten the flanges securely. Check the face runout with the dial indicator (see Figure 2). If the face runout is too great, loosen the flange and rotate the wheel. Again tighten the flanges securely and again indicate the wheel runout. If repetition of this process does not eliminate the runout, the wheel must be condi tioned as described in the next section. MIL 000268 19-7 Grade Selection (cont.) Trueing and Dressing Vitrified Wheels Vitrified-bonded CBN wheels do not require a two-step procedure of trueing and dressing provided they are cor rectly trued with a rotary diamond trueing device. Several types are available, some better than others. Parallel-axis and cross-axis types are available. The key to success is to reduce the amount of contact area between the wheel and the diamond roll without sacrificing excessive dia mond wear. Trueing and dressing tools are metal bond or plated diamond wheels which provide the necessary cut ting action to remove CBN wheel stock with little or no additional wheel conditioning. It may be necessary to slightly condition or dress the wheel face by grinding at reduced rates for a short time. Whether or not this is necessary depends upon the type and grade of diamond trueing wheel used. Grinding at a reduced rate would only be required after the initial dressing of a new wheel; subsequent in-process trueing will not require this extra step. Stationary tools which traverse across the face of a vitri fied CBN wheel will true it. However, this trueing tech nique will excessively load and glaze the wheel. A wheel trued in this manner will not grind effectively and needs further conditioning. In production grinding, extra time for conditioning after every in-process trueing operation is not acceptable. Single-point and impregnated-diamond tools will not effi ciently true and dress vitrified CBN wheels for production grinding. These wheels are so hard that when 0.001 inch is dressed from the wheel a like amount can be worn from the dressing tool. Therefore, wheel geometry can not be accurately assured. Rotary dressers do not wear significantly compared to single-point tools. Reducing grinding wheel speed prior to trueing will enhance CBN wheel material removal, but this isn't always practical. In order to see the differences between the trueing and dressing procedures of resin-bonded and vitrified-bonded CBN wheels, let's examine the start-up procedure for a vitrified-bond CBN wheel on an internal grinder. When a new wheel is placed on the machine it should be lightly covered with a marking medium such as a china marker or crayon. This helps the operator see when the diamond dresser touches the wheel. The initial dress-off should be made in increments of 0.0002 inch on diameter per pass of the rotary dresser. The trueing should stop as soon as the diamond dresser completely touches all across the wheel. Traverse the diamond dresser at the rate of 0.001 to 0.002 inch lead per revo lution of the grinding wheel. Trueing should not be con tinued to remove traces of the marking medium that may be in the pores of the wheel. To insure that the wheel is trued, it is best to check by grinding a few parts. After the truing procedure is completed, the wheel will have a silky, smooth appearance. The wheel is now very dull but is ready for grinding. Initially, it will not cut effi ciently because of excessive contact with the diamond roll. Start grinding at about half the normal rate to allow the wheel to open up and thus eliminate the possibility of overloading the wheel. This process is called the "condi tioning cycle". As the wheel becomes conditioned, the grinding rate can be increased until the optimum cycle time is reached. This conditioning process can be reduced or completely eliminated with the use of an open structure vitrified bonded CBN such as MARATHON 2. After the wheel is sharp and open, and the grinding cycle has become stabilized, the skip dress counter for in-process dressing may be raised or lowered depending on the wheel performance. For example, it may be set for dressing after every 50 parts are ground. In any event, the dressing tool in-feed compensation should be kept at 0.0001 inch or less. This small increment of dress will not affect the cutting efficiency of the wheel between dress cycles. The grinding cycles need not be reduced. Every time a new wheel is put on the grinding machine, the same start-up procedure should be followed. The extra five to ten minutes consumed by this procedure will be offset by the extremely long-life of vitrified CBN wheels. Except for this initial wheel trueing/dressing pro cedure, the production and dressing cycles can be made fully automatic. MIL 000269 19 19-8 Grade Selection (cont.) Wheel Conditioning The condition of the working face of a diamond or CBN grinding wheel will greatly affect its grinding perfor mance. The wheel surface condition, along with wheel speed and feed rates, can determine the success of fail ure of any correctly graded and correctly mounted wheel. The grinder operator will control the condition of the grinding surface by trueing, dressing and (when needed) core relieving. NOTE: Never attempt to true or dress a diamond or CBN wheel with a single point diamond. Serious damage will result to both. Also whenever possible, use a grinding fluid when trueing a wheel. Always true a wheel to make it concentric with the spin dle and to give the desired wheel geometry. For diamond OD grinding wheels, use the following methods: (1) is preferred, then (2) or (3). For CBN OD grinding wheels, use methods (1), (2), or (3), or use a diamond impregnated tool (metal bonded particle diamond), about 80-150 mesh. 1. Trueing a. OD Grinding Wheels (1) Mount a brake type dresser on the grinder. Brake true wheel grades are as follows: For Diamond Wheels - 6C120-M6-VSC For CBN Wheels - 9A120-M6-VFM (2) Remove the diamond or CBN wheel and mount from the grinder. Place the wheel mount on a special mandrel having a taper that fits the taper of the wheel mount. Place this assembly on a cylindrical grinder or on a lathe that has a mounted tool post grinder. If the special tapered mandrel is not available, the diamond or CBN wheel may be remount ed on a standard flange and nut type mandrel for trueing. This technique, however, will require very careful remounting of the trued wheel to avoid runout. True the diamond or CBN wheel with a silicon carbide or aluminum oxide wheel as recommended in (1).The true ing wheel and diamond or CBN wheel must rotate in opposite directions. The rotational speed of the diamond or CBN wheel should be reduced (if possible) to no more than 'A of its normal operating speed. (3) Mount a standard dressing stick or a piece of mild steel on the grinder (see Figure 4). Grind a small amount off this workpiece using 0.001" maximum feed per pass. Although time consum ing, this technique will ultimately true the wheel. MIL 000270 19-9 Grade Selection (cont.) 2. Dressing Correctly graded resin bond diamond wheels operated in the correct manner will require very little dressing. Wheel dressing removes bond material to expose the sharp cutting edges of the abrasive crystals. The wheel surface is lightly scrubbed with a soft, fine abrasive dressing stick to remove glaze and load (see figure 5). Some of the resin bond is removed during dressing. This leaves the diamond abrasive grits protruding from the remaining bond to provide a sharp, cool cutting wheel. Diamond wheels should be dressed only when needed. Excessive dressing may prematurely remove partially worn dia mond grains. Dressing is needed after trueing because trueing glazes diamond wheels. Diamond Stick Recommendation -- 9A220-G4-V9468 The core relieving operation on all core materials must be performed with a lathe type carbide or HSS cutting tool (see Figure 6). A dressing stick should never be used for core relieving, as it may cause serious damage to the wheel. The damage results from the intense fric tional heat and high contact pressure necessary with a dressing stick -- this can cause the core to become per manently distorted. 3. Core Relieving Core relieving is required on some diamond wheel shapes. Whenever the core material makes contact with the workpiece, it must be relieved. For example, the core area adjacent to the rim on a cup wheel will start to rub on the workpiece as the diamond rim wears down. This core material must be removed to restore the diamond cutting area to top efficiency. This core removal or reliev ing must be done on all diamond wheels of this type, regardless of what the core material is. If the core is not relieved, the wheel grinding face will load. A loaded wheel face has a reduced cutting and finishing efficiency and will cause smearing of the ground surface. Further, the rubbing of an unrelieved core creates frictional heat which will quickly result in wheel failure and damage to the part being ground. MIL 000271 19 19-10 MARATHONTM 2 Vitrified CBN Applications Leading the Way Production I.D. grinding Creepfeed grinding Cam lobe and crankshaft grinding Cylindrical grinding of fuel injection components Centerless grinding Needle bearings Engine valves Camshaft main bearings MARATHONTM 2 Case History 1 Industry: Part: Material: Operation: Wheel grade: Automotive Engine Valve Steel Stem and seat grind Seat -- 2BN120-0164-VMB Stem -- 2BN 150-MI 64-VMB Wheel Size: Machine: Metalworking Fluid: Dressing System: Stem -- 18 x 4,500 x 12 Seat -- 17.250 x .280 x 12 Cincinnati 2-250 Centerless 2AXJ-3 @ 5% Diamond Roll Advantages: * Seat roundness 1.5 um Stem roundness .30 um Straightness .3 um 800 parts per dress on seat grind Cycle time reduced to 6 seconds (stem only 2.55) 1000 part per dress on stem and higher wheel speed could push to 4,000 MARATHONTM 2 Case History II Industry: Automotive Part: Material: Operation: CVJ Component 8620 55RC Track grind Wheel grade: 2BN80-K100-VMC Wheel Size: .722 x .832 x .354 Machine: Metalworking Fluid: Excello Oil Dressing System: Diamond Cup Advantages: Increase skip dress from 6 to 12 Reduced compensation from 5 microns to 3 microns Increased feed rate to 350 degrees per minute @ 120% 19-11 MARATHONTM 2 Case History III Industry: Part: Material: Operation: Wheel grade: Wheel Size: Machine: Metalworking Fluid: Dressing System: Automotive Camshaft Steel 58RC Lobe grind 28N100-N164-VMB 17.700 x .748 x 12.050 Landis Semi-synthetic Diamond Roll Advantages: Increased camshafts per dress from 50 to 130 Eliminated any trace of burn * Produced more consistent finish and overall quality MARATHONTM 2 Case History IV Industry: Part: Material: Operation: Wheel grade: Wheel Size: Machine: Metalworking Fluid: Dressing System: Automotive Drive shaft component 5150 56-60RC Slot grind 2BN120-N164-VMB 16 x 1 x 8 ABA Creep Feed Grinder Cimperial 1011 Diamond Roll Advantages: Removed material in a single pass .400 wide x .468 deep Q' = 22 in'/min/in Grinding time less than 5 seconds MARATHONTM 2 Case History V Industry: Part: Material: Operation: Wheel grade: Wheel Size: Machine: Metalworking Fluid: Dressing System: Bearing Cone 52100 58-62RC I.D. grind 2BN120-Q164-VMB 1.250x.812x.500 Heald ICF Soluble Oil Diamond Cup Advantages: Increased wheel life from 200 ppw to 27,000 Improved CR on ID side and taper Reduced wheel changes from 1250 to 9 Reduced machine idle time from 155 hours to 4 hours 1 operator for 8 machines MIL 000272 VIDA Abrasives VIDA Abrasive product which combines the superior properties of diamond and Milacron's patented vitrified bonding technology. i I. Current Markets Carbide Tools, Drills, End Mills Polycrystalline Diamond and CBN (PCD, PCBN) Cermets | Composites II. Developing Markets Engineered Ceramics Types of Ceramic Alumina ; Zirconia i Silicon Nitride i Silicon Carbide | III. Ceramic Components Bearings - Ball Bearing j Tools - Inserts I Engine Components - Valves, Cam followers, Spring | Guide j Heat Exchangers Biomedical Electronic - Magnetic Heads, Substrates, Semiconductors Advantages of Vitrified Diamond VIDA contains porosity or chip clearance unlike resin or metallic bonds Cooler grinding Lower HP consumption (See chart I) Higher grinding ratio (See chart I) Reduced conditioning required. Some grades eliminate conditioning alt together Product Definition Grading System -- RD100-0100-VDA Grain Type: RD (Uncoated) Grain Size: 60-320 (Finer requires lab #) Hardness: M, N, O Concentration: 50, 75, 100, 125 Bonded Designation: VDA GRIT TYPE RD Vitrified Diamond Abrasive Typical Marking RD280-N75-VDA 1/8 GRIT SIZE 60-320 >320 w/code number GRADES M, N, O. P, Q CONCENTRATION 50, 75, 100 125 BOND VDA t Diamond Depth MIL 000273 19 19-12 Selection of Wheel Specification Grade Selection A. Grain-RD -- uncoated grain B. Mesh Size Roughing and Heavy Stock Removal (.015-.020) 120-150 Medium Stock/Average Finish -- 16RA -- 180-220 Light Stock/Good Finish -- 10-12RA -- 240 Fine Finishing 6-1 ORA -- 400-600 Super Edge Quality, Fine Micro 600-1200 (PCD Tools) C. Wheel Grade Available Range = soft M, N, O, P Hard The trend is O and P hardness for most tool grinding. Considerations Large Contact Areas (O.D.) grinding Wet or Dry Grind; Wet, Harder -- Dry, Softer Wheel Speeds D. Concentration Availability: 50, 75, 100, 125 - PCD Tools -- 100, 125 - Internal -- 50-75 - Surface -- 75 - Cylindrical -- 75-100 Light Stock -- 50 cone. Medium -- 75 cone. Heavy Stock -- 100, 125 cone. E. Bond Designation VDA -- Used on all applications Mesh size finer than 320 requires an NPI form be submitted (New Product Inquiry) F. Depth of Diamond Internal -- 1/8 Cylindrical --1/8 Surface -- 1/8 PCD Tools -- 3/8 Application Considerations Application -- Surface Grind - internal -- Cylindrical -- Side/Face Grinding Key Elements Surface Contact area, wheel speed (4500-6000 SFPM), stock removal, depth of cut (.0002-.0005) surface finish. Internal Wheel conformity, wheel speed, stock removal, surface finish. 19-13 Cylindrical Part diameter, part length, wheel speed, pickfeed amount (.0002-.0005) traverse speed. Side & Face Grind (Type 2 & 6) Area of part to grind, desired tool geometry normally finer mesh 240-600, PCD Tools 600-1200. Types Availability VIDA products are available in the following shapes and sizes: 1A1 1A1 specials 1A8 6A2 6A2C-6A2H, and other similar facing wheels (i.e. 4A2, 12A2, etc.) Sizes Diameter .250 -- 24" Thickness .250 -- 1, >1 available in multiple 1 sections. Core Materials Ceramic Aluminum Steel Diamond Depths 1/16, 1/8, 1/4, 3/8 Grading System Grain Type -- RD Mesh Size -- 60-1500 finer than 320 requires a code number Hardness -- M, N, O, P soft -------- hard Structure -- Standard structure is 9 Concentration -- 50, 75, 100, 125 Bond Designation -- VDA Material/Industry A. Non-Ferrous Materials - Carbides - Ceramics -- 4 types: industrial, technical, electrical, advanced - Silicon Nitride - Silicon Carbide - Alumina - Zirconia - Composites - PCD -- Polycrystalline Diamond Tools - Plasma Sprays - Aluminum MIL 000274 Modified Resilient Resin -- BY Bond I BY Bond A. Definition BY Bond is an epoxy modified resin which is more forgiving and can withstand higher grind tempera tures. B. Advantages Can be used with diamond or CBN Extends wheel life of our resin bonded products by 30% (minimum) More consistent resin in terms of wheel to wheel and start to stub In some cases BY Bonds have been more cost effec tive than polyimide resins BY Bond is priced as a standard resin Availability Diamond (All bond systems) CBN (B4 system only) How to Specify Use the letter "Y" to designate Example: Standard Grade CMD120-R100-B 1/8 IBN150-Q80-B4 1/8 Modified Resilient Resin CMD120-R100-BY 1/8 IBN150-Q80-B4Y 1/8 i BY System (Epoxy Modified Resin) I | Advantages | Better life [ Higher heat resistance i More resilient ! * Extended wheel life I Less grinding pressure Better form holding Applications of Resin Bonds A. Diamond -- Grinding of non-ferrous materials Carbide tipped saw grinding Carbide insert grinding Carbide tools; drills, end mills, reamers i Plasma spray coatings Ceramic - roughing Glass grinding ! B. CBN -- Grinding of ferrous materials HSS tools; end mills, drills, reamers Huffman, Walter, Star CNC Grinders Surface grinders MIL 000275 19 19-14 CIMFORM GRINDING WHEELS SUPERABRASIVE MARKING CHARTS RESIN BOND DIAMOND WHEELS GRIT TYPE MD CMD AMD DMD EMD NCD Uncoated Nickel Coated Copper Coated Nickel Coated Nickel Coated Nickel Coated GRIT SIZES 46 thru 600 46 Thru 320 46 thru 320 60 thru 320 60 thru 320 100,150, 220 GRADES Soft-J-L-N-P-R-Hard J-L-N-P-R J-L-N-P-R J-L-N-P-R J-L-N-P-R P-R CONCENTRATIONS Low-50-75-100-High 50-75-100 50-75-100 50-75-100 60-75-100 75-100 BOND B, BY B, BY B5, B5Y B6, B6Y B. BY BDL DEPTH OF DIAMOND RESIN BOND CBN WHEELS GRIT TYPE 1 BN 1 BN Nickel Coated Nickel Coated GRIT SIZES 46 thru 320 46 thru 320 BN Nickel Coated 100,150, 220 GRADES Soft-M-O-Q-S-U-Har Q - Light Duty T - General Purpose W - Heavy Duty Q - Light Duty T - General Purpose W - Heavy Duty CONCENTRATIONS Low-80-100-High Q=44 T=66 W=88 Q=44 T=66 W=88 BOND B4, B4Y B7 BBL DEPTH OF DIAMOND **** VITRIFIED BOND DIAMOND WHEELS GRIT TYPE RD GRIT SIZES 60-320 GRADES M-N-0 VITRIFIED BOND CBN WHEELS GRIT TYPE 2BN 2BN Uncoated Un coated GRIT SIZES 60 thru 320 60 thru 320 GRADES P-R-T-U P-R VITRIFIED BOND OPEN STRUCTURE CBN WHEELS GRIT TYPE 2BN 2BN 2BN 2BN 2BN 2BN Uncoated Uncoated Uncoated Uncoated Uncoated Uncoated GRIT SIZES 60 thru 320 60 thru 240 60 thru 320 60 thru 240 60 thru 240 60 thru 240 GRADES M-N-O-P M-N-0 M-N-O-P M-N-0 M-N M-N-0 19-15 CONCENTRATIONS 50-75-100 BOND VDA DEPTH OF DIAMOND .... CONCENTRATIONS 100-125-150 100-125-150 BOND VHA VHC DEPTH OF DIAMOND .... CONCENTRATIONS 80-100-125-150 100-125-150 164 100-125-150 100-125-150 164 BOND VEA VEC VEB VMA VMC VMB DEPTH OF DIAMOND .... MIL 000276 20 Grinding Wheel Recommendations Throughout this general wheel rcommendation section we have predominantly recommended our VFM bond where precision vitrified bonded wheels were applicable in alumimum oxide grain. Where conditions prevail that will allow you to fine tune your setup to get the most out of your grinders, such as parts per dress, faster grinding cycles, better form hold ing, etc., we recommend that you investigate the use of our premium VRW SUPER CIMFORM bonded wheels to increase your productivity. Also available (not premium priced) is our VQC bonded wheel. This wheel is available in most popular sizes, grain types, and grades. It has shown improvement in part quality without fine tuning any setups and the most popular sizes are readily available from stock. Consult your Cincinnati Milacron Marketing Company Products Division Representative to apply our finest product to your most complex grinding job. Cincinnati has a group of Abrasive Application Engineers and Account Service Specialists who specialize in abra sive applications. Whether it is a new job or material, or you want to improve the wheel grade currently used, if you can supply the following information we can help solve your problems. CUSTOMER name, location OPERATION - centerless, centertype, internal, etc. MACHINE - manufacturer and horsepower WHEEL TYPE AND SIZE WHEEL SPEED - SFPM WHEEL GRADE - full grade of present wheel PART DESCRIPTION - brief PART MATERIAL - metal type PART SURFACE - to be ground; give diameter, length, etc. PART HARDNESS STOCK REMOVAL on outside diameter FINISH REQUIRED GRINDING TIME - cycle time or feed rate DRESSER TYPE, e.g. single point diamond, cluster, etc. REASON FOR DRESSING - e.g. maintain size, finish, etc. PIECES PER DRESS with present wheel CUTTING FLUID used, oil or water based NOQ - customer Normal Order Quantity Call Cincinnati, Ohio - (513) 841-8721 or 841-8250 Alnico Cylindrical Surfacing Cutting-off (wet) Cutting-Off (dry) Disc-Wet Centerless Internal Aluminum Cylindrical Centerless Surfacing General Reinforced Cut-Off Less than 16" 16" and over Surfacing (Discs) Internal Bars Cutting-off (dry) Cutting-off (wet) Aluminum Castings Disc Small - light work Large - heavy work Surfacing Cylindes, cups, segments Aluminum Plate Surfacing Cylinders, cups, segments Armatures (Laminations) Cylindrical - roughing - finishing Internal Asbestos - Cement Products Cutting-off - Asbestos Clutch Facings Disc Balls for Bearings (Large) Semi-finishing (Small) Semi-Finishing Final Finishing Ball Bearing Races Disc Surfacing outer and inner races - soft Disc Surfacing outer and inner races - hard Grind O.D. cups - roughing and finishing internal Grind outer race (form) Grind outer race (oscillating) Wheel diameter 1/4 - 7/8" Wheel diameter 1 - 3" Wheel diameter 3" - up 97A541-L4-VFM 9A60-H6-VFM 2A80-L-R 97A601-L9-B90 97A601-H9-B90 97A601-K6-VFM 9A60-J6-VFM 9A46-I6-VFM 9A46-L6-VFM 6C36-J6-VSC 2A24-P7-BF9 2A24-R7-BF9 6C24-J9-B90 6C46-K6-VSC 2A24-Q9-B2S 2A46-P-R C2A361-J9-B90 C2A241-L9-B90 12A30-G10-VA 6C24-F10-VSC 9A60-I6-VFM 9A120-I6-VFM 97A461-J6-VFM 6C24-O9-B90S 6C24-T7-BF9 6C24-J9-B90 97A801-J6-VFM 97A1201-L4-VFM 97A1501-L4-VFM 97A461-J9-B90 97A801-F9-B90 97A601-L6-VFM 97A1201-L6-VFM 97A1001-L4-VFM 97A1001-K6-VFM 97A1001-J6-VFM MIL 000277 21 20-1 Grind inner race (form) Grind inner race (oscillating) Internal grind bore Bars (Centerless) Hard or soft steel 3/4" and smaller 3/4" to 2-1/2" over 2-1/2" Aluminum, some tool and stainless steels Steels tubing To achieve a commercial or better finish Bearings (Centerless) Pins (straight) up to 1/8" O.D. Roughing Finishing Pins (straight) over 1/8" O.D. Roughing Finishing Races O.D. (roughing and finishing) 3" dia. and less over 3" dia. Rollers (straight) Roughing Finishing Rollers (tapered) Boron Carbide (Norbide) Cylindrical Roughing Semi-finishing Finishing Cutting-off (1A1R) Internal Grinding Roughing (1A1, 1A8) Finishing (1A1, 1A8) O.D. Grinding Roughing (1A1) Semi-finishing (1A1) Finishing (1A1) Surface Grinding Roughing (1A1, 2A2, 6A2) Finishing (1A1, 2A2, 6A2) Bolts (Screws and Studs) Cylindrical Centerless Brake Lining (Molded) Surfacing (Discs) roughing Surfacing (Discs) finishing Surfacing (Drum Type) Cutting-off (dry) Brake Lining (woven) Surface (discs) Brake Drums (automotive) Regrinding Brake Shoes (railroad) chilled iron 97A1001-K4-VFM 97A541-S9-B90 97AS41-R6-B90 97A541-Q9-B90 C2A541-Q9-B90 97A601-Q9-B90 97A801-Q9-B90 12A80-S7-B90 C12A1001-T6-890 12A60-Q9-B90 2A100-R6-B90 12A60-M6-VFM 12A60-K6-VFM 12A60-L6-VFM 97A1001-M4-VFM 97A1001-M4-VFM CMD100-L100-B CMD220-L100-B MD320-L100-B MD400-L100-B CMD100-N100-B CMD100-N100-B CMD320-N100-B CMD100-L100-B CMD200-L100-B MD320-L100-B CMD100-N100-B MD320-L100-B 12A60-K4-VFM 12A60-M6-VFM 6C24-M9-B90 6C36-L9-B90 6C46-L9-B90 6C30-Q9-B90 6C24-L9-B90 97A461-K4-VFM 7C241-P9-B90 Brass Centerless Cylindrical Internal Surfacing Type 1 Wheel Cylinders, cups, segments Surfacing (discs) Cutting-off rod (dry) 9000-16000 SFPM Cutting-off rod (wet) 7500-12000 SFPM Cutting-off tubing (wet) 9000-16000 SFPM Cutting-off tubing (dry) 7500-12000 SFPM Brass Rod Cutting-off (dry) Cutting-off (wet) Brass Tubing Cutting-off (dry) Cutting-off (wet) Brick (Vitrified) Cutting-off (dry) Cutting-off (wet) Surface (cups and cylinders) Surfacing (discs) hard Surfacing (discs) refractory Broaches Sharpening Bronze (soft) Use same wheels as for brass Bronze (hard) Centerless Cylindrical Internal Surfacing (cylinders, cups, segments) Surfacing - (type 1) Surfacing (discs) Bushings (Hardened Steel) Centerless Cylindrical Internal Bushings (Centerless) Bronze Bushings (Cast Iron) Cylindrical Internal Toolroom Surface (dry) Surface (wet) InternaL (wet) 6C36-L6-VSC 6C36-K6-VSC 6C60-L6-VSC 6C36-J6-VSC 6C24-H6-VSC 6C24-J9-B90 2A24-T7-B90S 2A46-N-R 2A120-P-R 2A80-P-R 2A24-T7-B90S 2A46-N-R 2A80-P-R 2A120-P-R 6C24-O9-B90S 6C24-P7-BF9 6C24-N6-VSC 6C24-L9-B90 6C24-K9-B90 9A60-K4-VFM 9A46-M4-VFM 97A461-M4-VFM 97A601-L4-VFM 9A36-G10-VA - 97A361-J6-VA C2A241-K9-B90 12A60-L6-VFM 9A60-L4-VFM 9A60-K4-VFM 6C46-Q4-VSC 6C46-K6-VSC 6C46-J6-VSC 9A60-K4-VFM 9A60-H6-VFM 5C60-I6-VSC . 12A46-H6-VA 12A60-I6-VA 12A60-K6- VA MIL 000278 20-2 CPM 10-V Toolroom Surface (dry) Surface (wet) Internal Cable (Steel) Cutting-off (dry) Camshafts (See Cam Grinding in Centertype Product Application and Selection Section) Carboloy See Diamond and CBN Section Carbon Surfacing Surfacing (discs) Surfacing Fine Finish Carbon (Metallic) Cutting-off (dry) Carbon (Soft) Surfacing Cutting-off (dry) Cutting-off (wet) Carbon (Hard) Centerless Cutting-off (dry) Cutting-off (wet) Cartridge Dies (Internal) Tungsten Steel Roughing Finishing Cast Iron Centerless General Reinforced Cut-Off Internal Surfacing (cylinders, cups, segments) Ductile Gray Chilled Ni Hard Surfacing (disc) Cemented Carbides Single-point tools, offhand Cup or plate mounted wheels Roughing (wet or dry) Semi-finishing General Purpose Roughing (wet or dry) Semi-finishing (wet or dry) Single-point tools Roughing and finishing (wet) 9A60-H6-VRW 5C60-J6-VSC 9A46-H6-VFM 1BN100-T-B7 1BN100-Q100-B4 2A24-V7-B90S 6C24-I6-VSC 6C24-I9-B90 6C100-I9-B90 6C24-O9-B90 6C46-I6-VSC 6C60-N9-B90S 6C36-K9-890S 6C46-L6-VSC 6C60-N9-B90S 6C46-K9-B90S 5C80-J6-VSC 5C120-16-VSC 6C46-L6-VSC 12A54-K6-VFM 2A24-R7-BF9 2A24-V7-BF9 9A60-J6-VFM 97A301 -FI 0-VFM 97A301-F10-VFM 6C30-H6-VSC 9A36-F10-VFM C2A24-I9-B90 CMD100-R75-B 5C100-H6-VSC MD120-P75-B 5C60-I6-VSC 5C80-16-VSC 5C80-J6-VSC Chip Breaker Grinding Less than 1/4" thick 1/4" and thicker Milling Cutters, Reamers, etc. Backing-off, Cup Wheel Roughing (type 11V9) Finishing (type 11V9) Combination General Purpose (type 11V9) (type 12A2) Surface Grinding Straight Wheels Roughing (wet) Finishing (wet) General Purpose (wet) Cylindrical Grinding Roughing (wet) Finishing (wet) Internal Roughing Finishing Centerless Lapping Cup Wheel (wet) Cutting-off Chasers (Thread) Surfacing (cup wheels) Surfacing (straight wheels) Grinding Throats Chain Saw Blades Disc Chilled Iron Surfacing Chisels (Woodworking) Sharpening Chrome Plating Internal Small Parts Large Parts Surfacing (Type l Wheel) Cylindrical Commercial Finish Good Commercial Finish High Finish Clutch Plates Discs Colomony Internal Cylindrical Centerless Colomony Surface Straight wheel Vertical spindle Columbium Cylindrical Surfacing MD150-R100-BY MD150-N100-BY CMD100-R75-BY CMD180-R75-BY CMD150-R75-BY CMD120-R75-BY CMD120-N75-BY CMD100-P100-BY CMD220-P100-BY CMD120-N100-BY CMD100-R75-BY CMD220-N75-BY CMD120-N100-BY CMD220-N100-BY CMD120-R50-BY MD400-L50-BY CMD100-R100-BY 9A46-K6-VFM 9A60-J6-VFM 9A80-K6-VFM 97A461-K9-B90 6C36-I6-VSC 9A60-K4-VFM 9A100-K4-VFM 9A80-I6-VFM 9A80-I6-VFM 9A60-J6-VFM 12A150-K4-VFM 7C220-J9-B90 2A36-J9-B90 6C80-I6-VSC 5C60-K6-VSC 6C54-M6-VSC 5C46-J6-VSC ' 5C46-I6-VSC 9A60-K6-VFM 97A461-J6-VFM MIL 000279 Commutators (Copper) Roughing and Finishing (wheel) Concrete Cutting-off Discs Connecting Rods (automotive) Internal Surfacing (discs) Discs Copper Cylinder Surfacing (cups and cylinders) Surfacing (discs) Cutting-off Rod (dry) Rod (wet) Tubing (dry) Tubing (wet) Gates and Risers (dry, tabor) Reinforced resinoid Mach. 16000 SFPM Core Files (Silicon Carbide) 1" x 8" 1" x 10" 1'A" x 12" Cores (sand) Cutting-Off Cork Crankshafts (See Crankshaft Grinding in Product Application and Selection Section) Cutlery Knives - Butcher Hemming and Klotz Machines Carbon Steel & Stainless Steel Surface Surfacing Sides Sharpening (Production) Knives - Kitchen Hemming Machine Carbon Steel & Stainless Steel Hollow Grinding Knives - Pocket Hemming Machine Carbon Steel & Stainless Steel Knives - Table Hemming Machine Stainless Steel Cutters (also see Tool Room Grinding in Product Application and Selection Section) Sharpening (Machine) Cutters (Molding) Sharpening (offhand) 6C60-J9-B90 6C24-T7-BF9 6C24-J9-B90 97A801-J4-VFM 97A461-I9-B90 97A361-I9-B90 6C60-K6-VSC 6C24-J6-VSC 6C24-I9-B90 2A46-P-R 2A60-N-R 2A80-Q-R 2A120-P-R 2A24-V7-BF9 6C24-J6-VSC 6C24-09-B90 9A24-H6-VFM 9A24-F10-VFM 97A801-E10-VA 9A100-I6-VA 9A100-I6-VA 9A100-G6-VA 9A100-G6-VA 97A120-H6-VA 97A120-H6-VA 9A46-K6-VFM 2A60-N4-VFM Cylinders, Automotive (cast iron) internal Regrinding (wheels) Commercial Finish Mirror Finish Cylinders (Aircraft) Internal Molybdenum Steel Roughing Finishing Regrinding Nitrided Before nitriding After nitriding Regrinding Dies (Blanking & Drawing) internal Carbon Steel High Carbon, High Chrome Dies (Forging) (See Mounted wheel Section) Dies (Drawing) Surfacing (hardened) Fast Traverse (wet) Cup Wheels (wet) Discs Segments Surfacing. (Annealed) Straight Wheels (dry) Cup Wheels (wet) Discs Segments Drills (Manufacturing) Cutting-off Soft (wet) Cutting-off Soft (dry) Cutting-off Hard (wet) Cutting-off Hard (dry) Cylindrical Centerless (soft) Centerless (hard) Precision Sharpening Fluting Pointing 1/2" and smaller Larger than 1/2" Grinding Relief 1/2" and smaller Larger than 1/2" Drills (Salvaging) Cutting-off (small) Cutting-off (large) Drills (Resharpening) 1/4" and smaller - machine 1/4" and smaller - offhand 1/2" to" - machine 1/2" to 1" - offhand 1" and larger - machine 6C36-H6-VSC 6C46-G10-VSC 6C120-L6-VSC 7C220-J6-VSC 97A461-J4-VFM 9A60-I4-VFM 97A541-I4-VFM 6C60-I4-VFM 97A541-J4-VFM 6C60-J4-VFM 97A601-K4-VFM 9A80-K6-VFM 9A60-F10-VFM 9A46-H6-VFM 9A60-I6-VFM 9A46-G6-VFM 97A461-I6-VFM 97A461-I9-B90 97A461-G6-VFM 9A46-I6-VFM 9A24-H6-VFM 97A301-I9-B90 97A241-H6-VFM 2A46-R-R 2A34-V6-B90S 2A60-N-R 97A461-P9-B90S 97A601-M4-VFM 2A60-M6-VFM 12A60-M6-VFM 97A461-L4-VFM 12A100-S7-BHQ 97A801-P9-B90 2A80-09-B90 97A541-M4-VFM 97A361-L4-VFM 2A60-M9-B90 97A601-O9-B90S '9A100-I6-VFM 2A80-L4-VFM 97A461-L4-VFM 97A601-L4-VFM 9A46-H10-VFM 20-4 MIL 000280 Ductile Iron General Reinforced Cut-Off Less than 16 16 and over Duralumin (Tubing) Cutting-off (dry) Cutting-off (wet) Ebonite Cutting-off (dry) Fasteners (steel centerless) Fasteners (Steel) Centerless Regulating Wheels (See Centerless Grinding Section) Ferrotic Cylindrical Surface Internal Hardened State Fiber Board Cutting-off Fiberglass Cutting-off Fiberglass Insulating Board Cutting to size Fiberglass Rods Cylindrical (dry) Fiber Tubing Cutting-off Fiber Surfacing (discs) Cutting-off (board) Flute Grinding (See Flute Grinding Section) Forgings Centerless Cylindrical Gages (Thread) Grinding Threads 12 pitch and coarser Grinding Threads 13-20 pitch Grinding Threads 24 pitch and finer Gages (rings) Internal Roughing Finishing Fine Finishing Gears (Casehardened - Precut) 18-20DP 5-18DP 2-5DP Gears (Casehardened - from a solid) Finetooth 2A24-T7-BF9 2A24-V6-BF9 2A60-W-R 2A80-W-R 6C30-M9-B90 97A801-M6-VFM 97A801-M6-VFM 97A601-K4-VFM 9A60-I6-VFM 9A80-J6-VFM CMD100-R100-B 6C36-J9-B90 6C36-J9-B90 6C36-J9-B90 6C46-I10-VSC 6C46-K9-B90 6C24-J9-B90 6C24-K9-B90 97A601-K6-VFM 97A601-J6-VFM 9A100-K6-VFM 9A120-L6-VFM 9A1B0-N6-VFM 9A60-L6-VFM 9A100-I6-VFM 9A220-I4-VFM 9A120-I6-VA 9A80-J6-VA 9A60-I6-VA 9A120-16-VA Gears (Cast Iron) Teeth Gears (Hardened Steel) Internal Surfacing (cups and cylinders) Surfacing (segments) Surfacing (discs) (remove burrs) Surfacing Glass (circular mirrors) Rough Beveling (automatic) Rough and Final Beveling (automatic) 6C54-I6-VSC 97A601-K4-VFM 9A36-I6-VFM 97A361-J6-VFM 97A461-J9-B90 9A46-J6-VFM 5C80-K6-VSC 5C120-J6-VSC Glass (cut glass) Concaving bottoms of tumblers Edging Glass (flat) Beveling Cutting-off 9A90-L6-VFM 6C180-N4-VSC 5C100-K6-VSC C2A601-R9-BF9 Glass (Globes) Grinding Edges 5C80-I6-VSC Glass (Lenses) Edging - Machine 5C220-I6-VSC Glass Tubing Centerless Cylindrical Internal Thin Wall (1A1R) 5C180-J6-VSC 6C46-I6-VSC 6C90-H6-VSC CMD220-R50-B Glass (Tumblers) Edging - Lead Glass Edging - Lime Glass 6C120-P4-VSC 5C150-J4-VSC Granite Surfacing (Planer Wheels) Molding 7000-9500 SFPM Roughing Finishing 6C24-K9-B90 6C24-O9-B90 6C60-M9-B90 Gun Barrels Spotting and O.D. Cylindrical Centerless Internal Grind Contours of Cartridge Chamber 97A601-M4-VFM 97A601-L6-VFM 9A60-L6-VFM Hastalloy Surface Vertical Spindle Internal Cylindrical Centerless 9A46-H6-VFM 9A46-F10-VFM 97A541-L6-VFM 9A54-K4-VFM 97A541-K6-VFM Inconel or Inconel X (with heavy duty soluble or straight oil) Surface Type 1 Wheel Vertical spindle Form Grinding .- 9A60-H6-VFM 9A46-F10-VA 97A601-I6-VFM 97A601-J6-VFM MIL 000281 2 20-5 Cylindrical Centerless Thread Knives (Machine) Cutting-off (dry) Cutting-off (wet) Chipper and Barker, Sharpening Hog, Sharpening Leather Fleshing, Sharpening (Bricks) Leather Shaving, Sharpening Cylindrical Molding, Offhand Sharpening Machine, Sharpening Paper, Sharpening Section, Beveling Surfacing Backs Veneer, Sharpening Veneer, Surfacing Limestone Surface (Drum Rubber) Lawn Mowers Resharpening Leather Misc. Grinding Suede Finishing Lucite (centerless) Cutting-off (dry) Cutting-off (wet) Marble Surfacing (wheel) Roughing Finishing Molding - 5000-6500 SFPM Roughing Semi-Finishing Masonite Cutting-off Meehanite (see Cast Iron) Metallized Materials (Sprayed Metal) Minerals - Lapidary Soft Roughing Finishing Hard Roughing Finishing Molybdenum Cylindrical Surfacing 9A60-J4-VFM 6C60-K6-VSC 9A180-N6-VFM C2A461-M9-B90 C2A461-M9-B90 97A361-I6-VFM 97A361-J4-VFM 97A361-P4-VFM 97A461-P7-B90 97A461-I6-VFM 97A461-I6-VFM 97A701-I6-VFM 97A461-M4-VFM 97A461-I6-VFM 97A601-I6-VFM 9A46-I6-VFM 6C36-L9-B90 97A601-M6-VFM 6C30-J6-VSC 6C60-M6-VSC 6C60-M6-VSC 6C60-L9-B90 6C60-L9-B90 6C24-M6-VSC 6C60-K6-VSC 6C24-M6-VSC 6C54-K4-VSC 6C24-09-B90 6C54-I6-VSC 6C100-N6-VSC 6C220-L6-VSC 6C100-M6-VSC 6C220-K6-VSC 97A601-J6-VFM 97A461-I6-VFM Monel Metal General Reinforced Cut-off Less than 16" 16" and over Internal Cutting-off (dry) Cutting-off (wet) Cylindrical Needles Pointing Nickel Rods and Bars Cutting-off (dry) Cutting-off (wet) Ni Hard Centerless Cylindrical Internal Surfacing Wheels Segments Nitralloy (cylindrical) Before nitriding After nitriding Commercial Finish High Finish Reflective Finish Noroc Centerless Cylindrical . Internal Surface Nylon Centerless Surfacing Pen Parts (centerless) Rubber Plastics Pen Points (iridium) Cutting-off Pipe (Cast Iron) Cleaning Pipe (Steel) Finish Unimportant Cutting-off (dry) Cutting-off (wet) Pipe Balls Centerless Regrind Pistons (Aluminum) Cylindrical Centerless Regrinding Pistons (Cast Iron) Cylindrical Centerless Regrinding 97A301-R7-BF9 97A301-R7-BF9 6C60-J6-VSC 97A301-R7-B2S 2A24-P-R 6C60-K6-VSC 97A1201-M4-VFM 97A461-P9-B90 97A461-P9-B90 97A601-K6-VFM 97A801-K4-VFM 9A80-K6-VFM 9A46-I6-VFM 9A36-F10-VFM 9A60-H6-VFM 9A60-I6-VFM 6C100-I6-VSC 7C2201-I9-B90 6C100-H6-VSC 6C100-H6-VSC 6C100-H6-VSC YC80-H6-VSC 6C36-L6-VSC 97A361-L6-VFM 6C30-J6-VSC 9A80-N6-VFM 2A220-R9-B90 97A361-K9-B90 2A24-R9-B90 2A24-R9-B90 97A361-P4-VFM 97A361-P4-VFM 97A461-J4-VFM 6C46-J6-VSC 97A461-I6-VFM 5C46-J6-VSC OR 6C36-K6-VSC 6C46-K6-VSC 97A461-I6-VFM MIL 000282 20-6 Piston Pins Centerless Machine Roughing Semi-Finishing Finishing Surfacing Ends (discs) Piston Rings (Cast Iron) Surfacing Rough (cylinders) Surfacing (discs) Roughing Semi-finishing Finishing Surfacing Internal Piston Rings Plasma Spray - Carbides, Chrome) Centerless Roughing and Finishing Finishing Piston Rods (Locomotive) Cylindrical Plastics Cutting-off and Surfacing Cutting-off (dry) Cutting-off (wet) Cylindrical Plexiglass Cut-off Surfacing Plumbing Fixtures (Vitreous) Disc Polystyrene Centerless Cut-off Porcelain Cutting-off Cylindrical Centerless Propeller Hubs Internal Rough and Finish Fine Finish Pulleys (Cast Iron) Cylindrical Roughing with Pulley Grinder (Cyl. Wheel) Finishing with Pulley Grinder (Cyl. Wheel) Race Grinding (See Microcentric and Chucking Grinder Section) Reamers Backing-off Cylindrical 2A60-M6-VFM 97A541-P7-B90 97A601-N7-B90 97A801-M6-VFM 97A2201-N9-B90 C2A54-I9-B90 9A30-H6-VFM 6C24-K9-B90 5C46-I9-B90 5C80-G9-B90 9A80-K6-VFM 6C46-M6-VSC 5C80-H6-VSC 6C60-L6-VSC 2A46-M4-VFM 2A36-K9-B90 2A36-K9-B90 2A36-K9-B90 6C46-I6-VSC 2A36-K9-B90 2A36-K9-B90 6C36-K9-B90 6C46-J6-VSC 6C60-P9-B90 6C36-N9-B90 5C80-K6-VSC 5C80-I6-VSC 9A60-J6-VFM 97A120M4-VFM 6C36-J6-VSC 6C24-J6-VSC 6C60-J4-VSC 9A54-J6-VFM 97A601-K6-VFM I Regulating Wheel (See Centerless Grinding Section) Rene Surface (Form Grinding) Rexalloy (See Stellite) Rocker Arm Internal Rods (Centerless) Miscellaneous Steel 300 Series Stainless Nitralloy (before nitriding) Silichrome Steel Brass and Bronze Hard Rubber Carbon Plastic Rokide (Plasma Spray) All Operations Roughing (1A1,2A2) Finishing (1A1,2A2) Roller Bearing Cups Centerless O.D. Internal Rollers for Bearings Centerless - Roughing - Finishing Surfacing Ends (discs) Rolls See Roll Grinding in Centertype Section Roll Scouring Bricks Hot Mill Rolls Cold Mill Rolls Rotors (Laminated) (Cylindrical) Roughing Finishing Rubber (Soft) Cylindrical (dry) Rubber (Hard) Cutting-off Cylindrical Rubber Hose Cutting-off (dry) Cutting-off (dry, steel mesh) Sand Cores Cutting-off (dry) Saws See Toolroom Section Scissors and Shears (Cast Iron) Surfacing Sides or Blades 97A601-J6-VFM 29A801-J6-VA 97A60-M4-VFM 97A60-M6-VFM 6C54-N6-VSC 2A601-L6-VFM 97A601-K6-VFM C2A54-R7-B90 6C60-K6-VSC 6C30-K6-VSC 6C36-N6-VSC 9A80-N6-VFM CMD150-N75-BY CMD400-N75-BY 97A601-L6-VFM 97A801-L4-VFM 97A801-L6-VFM 97A1201-P9-B90 C2A101-I9-B90 6C80-L6-VSC 6C120-L6-VSC 97A1001-I6-VFM C2A2201-J9-B90 97A241-L9-B90 6C46-K9-B90 6C46-K9-B90 6C24-L9-B90 6C46-O9-B90 6C24-N9-B90 97A801-I6-VA MIL 000283 20 20-7 Scissors and Shears (Steel) Surfacing Sides of Blades Grinding Flash from Bows Pointing and Shaping Grinding Neck or Corner Strike Cutting Edges Resharpening (small wheels) (large wheels) Shafts (centerless) Pinion Spline Shear Blades (Power Metal Shears) Sharpening (Segments) Sharpening (Cylinders) Shells (Ordnance) Centerless Silicon Nitride Surface and Cylindrical Roughing (1A1, 2A2) Finishing (1A1, 2A2) Silver Cylindrical Skate Blades Resharpening Slate Cutting-off Coping Molding Spline Shafts Centerless Cylindrical Grinding Splines Sprayed Materials, (wet grinding) General Nickel, Chrome, Cobalt and Stainless Materials: Surface Cylindrical Centerless Internal Carbide, Zirconia, Tungsten, Alumnia, Airconte, High Cobalt and Titania Materials: Surface Cylindrical Centerless Internal Sprayed Metal Internal 97A461-Q4-VFM 97A801-P4-VFM 2A120-09-B90 97A1201-O4-VFM 9A100-M6-VFM 9A100-K6-VFM 97A901-M4-VFM 97A601-M4-VFM 97A601-Q9-B90 97A601-O4-VFM 9A46-I6-VA 9A46-I6-VA 2A60-M6-VFM MD100-N75-BY MD320-N75-BY 9A100-K6-VFM 97A801-K6-VA 6C36-P9-B90 6C46-M9-B90 6C54-K6-VSC 97A601-M6-VFM 97A601-N4-VFM 97A601-L4-VFM 5C46-H6-VSC 9A46-H6-VFM 5C60-J6-VSC 9A60-J6-VFM 5C60-J6-VSC 9A60-J6-VFM 5C80-L4-VSC 9A80-L4-VFM 7C541-I6-VSC 7C541-J6-VSC 7C601-J6-VSC 7C801-I60VSC 6C46-J6-VSC Springs (Coil) Squaring Ends (discs) Small Gage Wire Medium Gage Wire Large Gage Wire C2A361-J9-B90 C2A361-J9-B9 C2A241-I9-B90 Stainless (17-4HP) with heavy duty soluble or straight oil Surface Internal Cylindrical Centerless 9A60-I6-VFM 6C60-J6-VSC 9A46-J4-VFM 6C46-K6-VSC 9A60-K4-VFM 6C54-K6-VSC 29A601-K6-VFM Steatite (Ceramic) Centerless Cut-off Surfacing 6C60-J6-VSC 6C80-M9-B90 6C46-J6-VSC Steel Castings (Low Carbon) Internal External 9A54-L6-VFM 97A601-J6-VFM Steel Castings (Manganese) Surfacing Internal (rough grinding) General Reinforced Cut-off 12A24-H10-VA 97A361-L6-VFM 2A24-R7-BF9 Steel Forgings (discs) Small - light work Large - heavy work 97A461-I9-B90 97A361-G9-B90 'Steel (Tool 55 Rc and harder) Cutter Sharpening Type 1A1 Cup Wheel roughing finishing Disc Wheel Surfacing Type 1 Wheel Internal Mounted Points or Type 1 Wheel 1BN120-T-B7 1BN80-W-B7 1BN180-Q100-B4 1BN120-W-B7 97A601-J9-B90 1BN120-T-B7 1BN120-Q100-B4 2BN120-R125-VHA 1BN120-Q100-B4 'For conventional recommendations refer to Tool Room Section. Also see Diamond and CBN Section. Steel 'Hard) (Rc55 and harder) Centerless (fine finish) Centerless (commercial finish) Centerless (regulating wheel) Cylindrical (smaller wheels) Cylindrical (larger wheels) Internal Internal bearing Surfacing 97A1201-M4-VFM 2A60-K6-VFM A80-R-BR 97A601-L4-VFM 97A541-L4-VFM 9A60-L6-VFM 97A801-K4-VFM 9A80-K6-VFM 9A60-H10-VA MIL 000284 20-8 Steel (Hard) (Rc55 and harder) cont. Surfacing (cylinders, cups, segments) Broad Contact Narrow Contact Surfacing (discs - rough) Surfacing (discs - finish) Cutting-off Steel (Soft) (Up to Rc55) Cut-off Reinforced Cut-off Cylindrical Less than'l diameter Over 1 diameter Disc Roughing Finishing Internal Surfacing Type 1 Wheel Cylinders, Cups, Segments Steel (Stainless - 300 Series) Centerless Centerless (Regulating Wheel) Cylindrical Internal Surfacing (Type 1 Wheel) . Surfacing (cups and cylinders) Surfacing (segments) Surfacing (form grinding) Cutting-off Steel (Stainless) General Reinforced Steel (High Speed) Centerless (commercial finish) Centerless (fine finish) Centerless (regulating wheei) Cylindrical (14 and smaller) Cylindrical (16 and larger) Internal Surfacing (type 1 wheels) Surfacing (cups & Cylinders) Surfacing (segments) Cutting-off Cutting-off (tubing) Steel (Stainless - 400 Series Hardened) Centerless (commercial finish) Centerless (fine finish) Centerless (regulating wheel) Cylindrical (14 and smaller) Cylindrical (16 and larger) Internal Surfacing (type 1 wheels) Surfacing (cups & cylinders) 9A36-E10-VFM 9A46-H6-VFM 97A361-I9-B90 97A461-G9-B90 97A541-O9-B90 2A46-R9-B90 2A24-R7-BF9 97A601-M4-VFM 97A541-L4-VFM 97A241-J9-B90 97A461-I9-B90 97A461-M4-VFM 9A36-K6-VFM 9A24-G10-VA 97A541-K6-VFM A80-R-BR 9A46-J6-VFM 9A46-I6-VFM 9A46-J6-VFM 9A30-H6-VFM 9A46-F10-VA 97A601-I6-VFM 97A601-J6-VFM 6C46-Q9-B90 97A301-R7-BF9 97A301-T7-BF9 97A601-K6-VFM 97A801-I6-VFM A80-R-BR 97A601-L4-VFM 9A60-K4-VFM 9A80-K6-VFM 9A46-H6-VFM 9A60-F10-VFM 9A46-G6-VFM 9A46-H6-VA 97A461-O9-B90 97A541-Q9-B90 97A601-K6-VFM C2A801-N9-B90 A80-R-BR 97A601-L4-VFM 97A541-K4-VFM 97A601-K6-VFM 9A46-I10-VA 9A36-G50VFM Steel (Stainless - 400 Series Hardened) cont. Surfacing (segments) 9A24-G10-VA Surfacing (form grinding) 97A601-I6-VFM 97A601-J6-VFM Cutting-off (dry) C2A601-R9-B90 Stellite (also Rexalloy, Tantung) Cylindrical Cutter Grinding Surfacing (cups, cylinders) Surfacing (discs) Surfacing (straight wheels) Cutting-of 97A461-M4-VFM 9A46-J6-VFM 9A46-G6-VFM 97A361-J9-B90 9A46-H6-VFM 6C46-R9-B90 Stove Parts (Cast Iron) Surfacing Tops Automatic Roughing Finishing Surfacing (discs) 6C36-Q6-VSC 6C80-Q6-VSC C2A241-I9-B90 Tantalum Cylindrical Surfacing 97A601-K6-VFM 97A461-J6-VFM Tantung (see Stellite) Tappets (centerless) Steel Roughing Finishing Cast Iron Roughing Finishing _ 97A601-O4-VFM 97A801-N6-VFM 6C46-N6-VSC 6C80-M6-VSC Taps (also see Tool Room Section) Fluting (small taps) (large taps) Grinding Relief Squaring Ends Threading Precut 2 through 6 8 through 12 14 through 24 2A100-W-R 2A100-U-R 9A60-K6-VFM 97A601-N6-VFM 9A80-J6-VFM 9A100-K6-VFM 9A150-L6-VFM Taps Threading Solid 4 through 12 14 through 20 24 through 36 40 and finer Shanks (cylindrical) 9A100-K6-VFM 9A120-L6-VFM 9A180-N4-VFM 9A220-N4-VFM 97A801-M6-VFM Tile Cutting-off Disc 6C36-O9-B90 6C36-I9-B90 MIL 000285 20 20-9 Titanium Precision Grinding Surface Vertical Spindle Internal Cylindrical Centerless Thread Rough Grinding Tools - Single Point See Tool Room Section Carbon & High Speed Steel Roughing Finishing Tools - Single Point Wet Tool Grinders 12 to 24" diameter wheels Over 24" diameter wheels Machine Grinding Type 1 Wheels 15" Diameter wheels 24" Diameter wheels Cup or Cylinder wheels Tool Steels (See Tool Room Grinding Section) Tubing, Steel Centerless Cutting-off Steel Stainless Steel Chrome - Molybdenum Tubing (Cut-off) Brass, Bronze Tungsten Cylindrical Rolled Tungsten Sintered Tungsten Centerless Rolled Tungsten . Sintered Tungsten Surfacing - 2000 SFPM - 6000 SFPM Tungsten Carbide (see Carbide) Udimet Surfacing (Form Grinding) Valves (Automatic) Refacing Stems Cylindrical Centerless Cutting-off Surfacing Ends (discs) Valve Lifter Bodies Internal 9A60-J6-VFM 5C60-J6-VSC 5C60-J6-VSC 5C60-J6-VSC 6C60-J6-VSC 6C54-L6-VSC 7C2201-R9-B90 7C601-Q9-B90 97A361-04-VFM 97A601-M4-VFM 97A361-M4-VFM 97A241-M4-VFM 97A361-L4-VFM 97A241-M4-VFM 97A241-L6-VFM 97A601-K6-VFM 97A601-K9-B90 C2A60-M9-B90 C2A60-M9-B90 C2A601-R9-B90 9A54-L4-VFM 6C60-J6-VSC 9A46-N4-VFM 6C60-K6-VSC 97A461-J6-VFM 6C46-J6-VSC 97A601-I6-VFM 97A601-J6-VFM 6C80-N6-VSC 97A801-J4-VFM 97A601-N4-VFM 97A601-M6-VFM 97A601-R9-B90 97A461-J9-B90 97A901-M6-VFM 20-10 Valve Seat Inserts - Regrinding Roughing Cast Iron Alloy Steel Stellite Finishing All Seats Valve Seats (steel) Internal Valve Tappets Centerless Cylindrical Vascaloy - Ramet (see Cemented Carbide) Vitallium Cylindrical Surfacing Waspalloy (with straight oil) Surface Form Grinding Type 1 Wheel Vertical Spindle Internal Cylindrical Centerless 6C80-M6-VSC 9A80-M6-VFM 9A80-K6-VFM 6C150-L6-VSC 9A70-P4-VFM 97A801-M6-VFM 97A541-M4-VFM 9A60-J6-VFM 9A60-I6-VFM 97A601-I6-VFM 97A601-J6-VFM 9A46-I6-VFM 9A46-F10-VFM 9A60-J4-VFM 9A60-J4-VFM 97A601-J6-VFM Important -- The wheel gradings listed in this section are general starting recommendations. They should not be considered as optimum for the listed jobs. The Products Division of Cincinnati Milacron Marketing Co. has a well-trained staff of application Grinding Systems Engineers (GSE) as well as a well-rounded force of Field Representatives in grinding, grinding wheels, and metalworking fluids. We welcome the chal lenge to apply our finest products to your everyday grinding jobs, or your most complex operations. Give us a try, and see what we can do for you. Call us today for all of your metalworking needs. MIL 000286 IMPORTANT -- Before using any of the products described herein, read and follow the safety precautions contained in this Guide and other safety related materials referred to herein. The information contained in this Guide is subject to change without notice. WARNING: In order to clearly present details of grinding wheel applica tions, the photographs and sketches in this manual may not show all essential guarding in position. Ensure that all such protective devices are properly installed before operating any equipment. CINCINNATI MILACRON IS SUPPLYING THE INFORMATION IN THIS GUIDE WITHOUT ANY REP RESENTATION OR WARRANTIES WHATSOEVER REGARDING THE VALIDITY, PROPRIETARY OR USEFULNESS OFTHE INFORMATION CONTAINED HEREIN INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. CINCINNATI MILACRON SHALL NOT HAVE ANY LIABILITY WHATSOEVER FOR LOSS OF USE OR FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL, ATTORNEY'S FEES OR OTHER DAMAGES IN CONNECTION WITH OR ARISING OUT OFTHE FURNISHING OFTHE INFORMATION IN THIS GUIDE. CINCINNATI, CINCINNATI MILACRON, CIMCOOL, CIMSTAR, CIMPERIAL, CIMFLO, CIMTECH, CIMCLEAN, CIMGUARD, CENTERSAVER, CIMPLUS, SUPER CIMFORM, CIMFORM, TWIN-GRIP, ACRAMATIC and MICRO-CENTRIC are trademarks registered in the U.S. Patent and Trademark Office. MARATHON and MSL are trademarks of Cincinnati Milacron Inc. A special thanks to the Grinding Wheel Institute for their assistance in supplying information for this publication. Also thanks to the following for photos, specifications or other contributions: APMD of Cincinnati Milacron; Gold Crown Inc.; Tschudin Grinders; Okamoto; Speedfam; Mattison; Bryant; Gallmeyer & Livingston; KO Lee; ELB; Reischauer; and Oliver. Cincinnati Milacron Marketing Co., 1995 MIL 000287 NOTES MIL 000288 NOTES MIL 000289 NOTES MIL 000290