Optimization of Grinding Wheel for Improving Productivity and Life

Abstract

The life of a grinding wheel is a critical factor influencing the efficiency and cost-effectiveness of grinding operations. Premature wheel wear leads to increased downtime for wheel replacement and dressing, reduced machining accuracy, and higher production costs. The key aspects of optimizing grinding wheel life through a comprehensive approach that considers various process parameters, wheel characteristics, and advanced optimization techniques.The optimization process involves a detailed analysis of the grinding process, identifying the dominant factors that contribute to wheel wear. These factors include, but are not limited to, the grinding parameters (e.g., depth of cut, feed rate, wheel speed), the workpiece material properties (e.g., hardness, toughness). The grinding wheels are mostly used in fabrication industries as well as in metal foundry industries and in construction sides also. The life of grinding wheel is depending on the RPM of grinder and the material where the grinding wheels use to perform the grinding function and raw material used to manufacture a grinding wheel. From last few months out customer facing breaking issue specially in 9” DCD (Depressed Center Disc) wheels. To resolve this issue and improve the life of 9” DCD wheel a case study is conducted to find out the possible causes of wheel braking by using a Fish Bone Diagram and 5Why and 1H methodology. The outcomes of this optimization study are expected to provide practical guidelines and parameter recommendations for industrial grinding operations to significantly enhance grinding wheel life, reduce operational costs, improve machining quality, and contribute to more sustainable manufacturing practices. The findings will offer valuable insights into the complex interplay of factors affecting grinding wheel wear and pave the way for more efficient and predictable grinding processes.

Introduction

Grinding wheels are composite wheels embedded with abrasive particles used in grinding and machining operations. Typically made from coarse abrasive particles bonded in a matrix, they can also be metal discs with bonded abrasives. Manufacturing these wheels involves precise control to ensure safety and durability due to the high rotational stresses involved. Grinding wheels wear over time as abrasive grains dull and are shed, exposing fresh grains, which is a predictable process.

Literature Review:

• Grinding is crucial in manufacturing high-precision components, with ongoing research exploring environmental sustainability, advanced lubrication techniques, textured and ultrasonic grinding wheels, 3D printing of wheels, and AI integration. Recycling grinding swarf is a growing research area.

• Experimental studies focus on the micro-scale cutting effectiveness of grinding grits using novel high-speed scratch testers, analyzing forces and material removal at various speeds and depths.

• Theoretical considerations describe grinding wheels as expendable tools with abrasive grains acting as cutting edges, essential for shaping hard materials and achieving high surface precision. Grinding parameters and forces are mathematically related to optimize performance.

Problem Definition:

Premature and unpredictable breakage of grinding wheels during operations poses safety hazards, increases costs, and causes downtime. Causes include excessive speed, improper mounting, high forces, imbalance, machine defects, and workpiece issues. The problem demands better understanding, prediction, and prevention to improve safety and efficiency.

Objectives:

Key goals include extending wheel lifespan, reducing consumption and downtime, identifying factors influencing wear, developing predictive wear and failure models, optimizing grinding parameters and wheel specifications, implementing real-time monitoring, enhancing machining accuracy, ensuring operator safety, and reducing waste.

Research Methodology:

The research involves studying failure modes, especially fracture/breakage, and examining manufacturing and molding data (parameters like temperature, pressure, time, speed, force) to control wheel quality. Monitoring and optimization techniques are to be developed using this data.

Conclusion

It is observed that grinding will can be break due to low GSM of GFD and high RPM of grinders can cause damage of grinding wheel. Due to high stiffness of GFD may be result into grinding wheel breakage.There is a moisture in the atmosphere which can absorb by grinding wheel from the air can damage the grinding wheel. Improper Mounting of the Wheel may cause the damage of grinding wheel. Impropermachine Conditions can damage the grinding wheel which can reduce the life of grinding wheel. Grinding wheel grade (Soft grade) against the hard grade material may cause damage of wheel. By taking all the above precautions we can avoid the breakages of thin wheel grinding wheel and improve the life of grinding wheel and productivity also.Aways select a thin wheel specifically designed for the material being cut. Using a wheel on harder materials than it\'s intended for will lead to rapid wear and potential breakage. Thin wheels are generally better suited for softer materials like aluminum and copper. Adhere to the manufacturer\'s recommended operating speed for the wheel and the material. Excessive speed generates more heat, causing faster wear.Employ a consistent and appropriate cutting technique, maintaining a steady cutting pressure and the correct angle. Avoid excessive force or twisting, which can damage thin wheels due to their inherent fragility.Invest in high-quality thin wheels from reputable manufacturers. The abrasive material and bonding agent quality significantly impact the wheel\'s longevity.Ensure the thin wheel\'s dimensions are compatible with the grinder and suitable for the specific task. Using an undersized or oversized wheel can reduce its lifespan and increase the risk of failure.Always prioritize safety by using appropriate guards and personal protective equipment. Misuse or excessive force on thin wheels can lead to breakage and potential injury. By carefully considering these factors and implementing appropriate operating and maintenance practices, the lifespan and performance of thin wheel grinding wheels can be significantly improved.

References

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Copyright

Copyright © 2025 Mr. Dayasagar R. Jiwane, Swapnil Choudhary, Dr. Vijayashri Mohobiya. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.