Table 4. Common Faults and Possible Causes in Surface Grinding
WORK DIMENSION
METALLURGICAL DEFECTS
SURFACE QUALITY
WHEEL CONDITION
WORK RETAINMENT
Work not flat
Work not parallel
Poor size holding
Burnishing of work
Burning or checking Feed lines
Chatter marks
Scratches on surface
Poor finish
Wheel loading
Wheel glazing
Rapid wheel wear
Not firmly seated
Work sliding on chuck
CAUSES
FAULTS
Heat-treatment stresses
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d
Work too thin Work warped Grit too fine Grit too coarse Grade too hard Grade too soft
WORK CONDITION
d d
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d
d
Abrupt section changes
d d
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d
d
d d
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d
GRINDING WHEEL
d
d
d
d
d d
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d
d d
d
Wheel not balanced Dense structure Improper coolant Insufficient coolant
d
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d d
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d
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d d
d
d
d
Dirty coolant
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TOOLING AND COOLANT
d
d
Diamond loose or chipped
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d d
d
Diamond dull
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d
d d d
No or poor magnetic force Chuck surface worn or burred
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d
d
d
d
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d d
d
d
Chuck not aligned
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d d
MACHINE AND SETUP
Vibrations in machine Plane of movement out of parallel Too low work speed
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d
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d d
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d
Too light feed Too heavy cut
d
d
d
d
Chuck retained swarf Chuck loading improper Insufficient blocking of parts Wheel runs off the work Wheel dressing too fine Wheel edge not chamfered Loose dirt under guard
d d
d
OPERATIONAL CONDITIONS
d d
d
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d
d d
d
d
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d
d
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d
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