Centerless Grinder is a popular and efficient method of turning thin-material into thicker and more dense-material. This type of machining operation is quite common in the metal fabrication industry. Basically, centerless grinding utilizes abrasive contact grinding to remove material from an in-factory workpiece by using very little energy from the tool. The result is a work piece with almost no seams or ridges.
There are a variety of reasons why a company would choose to use a centerless grinder over another similar process such as belt grind. First of all, it allows for a much more economical way of acquiring high quality parts because less energy is required. This is especially critical in applications where the part quality and accuracy is extremely important. In addition, because the grinding is done at the receiving end of the component, it leaves little or no margin for error. With a belt machine setup, mistakes can often be amplified when the diameter of the part increases or decreases during the grinding process. In most cases, this is not an issue because the diameter of the part being ground changes little if at all during the course of the grinding process anyway.
How does a centerless grinding wheel actually work? The working mechanism consists of two major components: an abrasive wheel and a stationary work piece. The wheel has a slot which accepts either abrasive material or a ball bearing. In the case of a stationary work piece, the work piece is located between the abrasive wheel and the stationary work piece. Depending on the type of machine setup used, there may also be a trigger attached to the grinding unit which will activate the grinding action if the work piece moves beyond a pre-determined tolerance level.
With a centerless grinder, there are several advantages to consider. First, it is possible to use less force to grind a given work piece by utilizing a smaller, lighter machine. Because the wheel does not have a hub, the work piece does not have to be as large in order to provide a steady support while the grinding operation is in progress. In addition, using a centerless grinder reduces back chatter as well as mechanical errors that are common when using a manually operated machine. The result is that a centerless grinder allows a much smoother performance during the grinding process.
Another advantage of a centerless grinding machine is that it can be fully automated. There are a number of different software packages available which allow for complete automation of the centerless grinding operation. These programs can control the feed rate of the abrasive material, determine the best work speeds for each workpiece and also program the machine to avoid chattering. Depending upon the type of machine and its configuration, it may also be possible to program the machine to perform additional operations such as the addition of balls or other material. In other cases, it may be possible to incorporate the use of laser engraving into the grinding operation. All of these additional capabilities result in a far smoother performance of the grinding process, as well as greater accuracy in the output from the machine.
Centerless grinders are typically manufactured using an aluminum alloy, and they are often used to manufacture motorcycle wheels and other parts quality control components. The ability to produce a high quality product at a low cost is one of the primary reasons for their popularity with both industrial and personal users. Because the centerless grinder does not require a secondary grinding plate to hold the workpiece in position, the amount of steel necessary to produce the desired level of quality is substantially reduced. This enables users to cut down on their overall production costs, which is especially important where the number of parts to be produced is above a certain level.