• The workblade tip surface may be too hard. We can advise materials such as high speed steel, cast iron or ampco bronze.
  
  
• If marks are wide and irregular and vary in depth, the wheel grade may to be too soft. Please contact us with component material and wheel size information, and we can advise a suitable grade for your application.
  
  
• Widely spaced spots on the component surface indicate glazed areas on the grinding wheel caused by material or coolant build up. Dress and balance the wheel, and avoid coolant build up on a stationary wheel.
  
  
• Deep marks on component surface are commonly caused by the grinding wheel being loose, or the coolant being contaminated. Ensure the wheel is fixed properly in the mount using paper washers between the wheel and flange. Clean or replace coolant, and where finer finishes are required, use a coolant filtration system.
  
  
• The quality of surface finish on a component is directly related to the grade and surface finish of the wheel. If the wheel grade is deemed to be correct, please check the dressing diamond for signs of wear, and rotate or replace if necessary.
  
  
• Always ensure that dresser feed rates and cut depths are appropriate for the wheel grade and desired surface finish. Ensure there is a good flow of coolant to the grinding wheel, especially when dressing.

• Sizing issues are most commonly caused through a fault on the infeed slide. Please ensure lubrication is sufficient at the lower slides, especially if the machine carries dovetails to these slides.
  
  
• If the machine has a hydraulic infeed attachment, ensure oil pressure is at the correct level. Also check for signs of oil leaks or damaged hydraulic hoses.
  
  
• Check tension in the main slide gib strip, to ensure it is holding the slide true and not allowing it to twist.
  
  
• If sizing problems occur when using fine feed compensation, this may indicate wear on the ballscrew or leadscrew. Please check for backlash in these units by backing the infeed slide all the way out and checking for free movement in the handwheel or a sudden pickup in movement if the machine has CNC infeed.
  
  
• A loose workblade can allow deflection of the component under the force of grinding. Ensure the workblade is clamped tightly into the workrest, and that the workrest itself is fixed securely to the lower slide.

• On a throughfeed grinding process, this problem is most commonly caused by the guide plates being deflected towards the grinding wheel. Reset guide plates parallel to the grinding wheel.
  
  
• Please also check the swivel angle of the control wheel head and compensatory angle of the control wheel dresser swivel. The dresser should always be angled just slightly less than the wheel head, around 1/4 ^O.

• On a throughfeed grinding process, this problem is most commonly caused by the guide plates being deflected towards the control wheel. Reset guide plates parallel to the control wheel.
  
  
• Please also check the swivel angle of the control wheel head and compensatory angle of the control wheel dresser swivel. The dresser should always be angled just slightly less than the wheel head, around 1/4 ^O.

• Keep the machine clean. Ensure grinding dust is prevented from gathering on all slides.
  
  
• If possible, fit a coolant wash gun for ease of maintenance. This makes it possible to clean areas where coolant doesn't naturally flow and grinding debris may build up and cause wear.
  
  
• Ensure lubrication is reaching all slides and that all oil tanks are filled regularly.
  
  
• When changing the workblade or wheels, ensure all fittings are tightened correctly prior to using the machine.
  
  
• Ensure slide covers and bellows are in good condition.
  
  
• Have the machine serviced on a regular basis, typically once every 12 months for general applications or once every 6 months when grinding harder materials, such as ceramics. Please contact our service department for further advice.
  
  
• Wherever possible, ensure a stock of wear components and tooling are stored safely with the machine to minimise downtime. Please contact our spares and tooling department for advice on necessary components.

• The centreline of the work may be too low. Set component centreline above the wheel centreline by half of the component diameter. On work above 1" diameter never exceed an offset of 1/2".
  
  
• On throughfeed applications, ensure that the first, roughing cut is not too heavy. Ensure the first cut is light at a high traverse rate to ensure maximum component straightening.
  
  
• On plunge grinding applications, ensure the component is not being run along the grinding wheel when the part is ejected.
  
  
• Ensure the grinding wheel is fitted tightly to the wheel mount using paper gaskets between the wheel and flange. Check the bearing pad settings on machines with phosphor bronze bearing pads, or for machines with rolling element bearings on the spindle ensure the bearing housing is sitting correctly in the grinding wheel head.
  
  
• Repeat the above check on the control wheel and spindle bearings, and ensure the wheel is running at the correct speed during grind, typically 30 RPM for plunge grinding applications, up to 50 RPM for throughfeed applications.

• Although a centreless grinding machine will improve component straightness slightly, it is not designed to be used as a straightening machine. Please ensure components are as straight as possible when presented to the machine.
  
  
• On large batches of smaller components, where pressing isn't viable, try to leave as much stock on components prior to grinding as possible. Typically this should be around 3 times the amount of run out on the part. Use a light cut with a slow throughput rate to give the greatest straightening effect.

• Machine vibration can be caused either through the machine not having been levelled correctly or by the grinding wheel running out of balance.
  
  
• Check the levelling screws on the machine, and ensure levelling pads are fitted with anti-vibration padding.
  
  
• Ensure the grinding wheel is mounted on the spindle correctly, and clamped properly between the flanges.
  
  
• When balancing the wheel without an auto-balancer, ensure the same wheel mount is used for the balance check as will be used in production on the machine.

• If a wheel breaks relatively evenly around the radius, it is likely that it has been mounted incorrectly. Ensure paper gaskets are used between flanges and the wheel, and that the flanges are pulled up to the wheel evenly.
  
  
• If the wheel has broken in an irregular manner, it is possible that the wheel is faulty or that it has been dropped or subjected to a hard blow. Ensure the wheel is mounted carefully onto the mount.
  
  
• Use proper lifting rigs for heavy wheels, and take care during installation.
  
  
• Avoid jamming dressing tools or work into wheels. Use proper dress cuts and feed rates for both the dresser and infeed of plunge ground parts, and take care not to exceed maximum stock removal advice on throughfeed applications.

• If the wheel is glazing over frequently, it's likely that the grade is incorrect for the material being ground. Please contact our spares and tooling department with your material specification and wheel size for advice on the correct grade.
  
  
• Grinding hardened components can cause a wheel to glaze more easily due to the residue left on parts after hardening. Try to ensure aprts are as clean as possible prior to grinding, and dress the wheel more frequently.
  
  
• Check the grinding wheel dresser slides to ensure there is no free movement which can allow the diamond tool to back away from the wheel instead of dressing.
  
  
• Check the diamond tool for signs of wear or breaks, and rotate or replace as necessary.
  
  
• Ensure coolant is clean and free of contaminants. If this problem persists, please contact our sales department for information on a variety of coolant filtration systems which are available.

• It is likely that your grinding wheel is too hard if you experience any of the following problems:
  
  
  • Loss of cutting action.
    
    
  • The wheel is loading easily.
    
    
  • Work is discoloured or burned.
    
    
  • Work is chattering or scratching.
    
    
• It is likely that your grinding wheel is too soft if you experience any of the following problems:
  
  
  • Short wheel life.
    
    
  • Wheel markings on the component.
    
    
  • The wheel is not holding the cut, and work is either over size or has a poor surface finish.
    

Please contact our spares and tooling department with your material specification and wheel size for advice on the correct grade.

• If the wheel is loading up with grinding debris, it is possible the wheel is too hard for your application. Please contact our spares and tooling department with your material specification and wheel size for advice on the correct grade.
  
  
• Grinding hardened or dirty components can cause the wheel grain to clog. Ensure work is as clean as possible.
  
  
• Dress the grinding wheel more frequently to ensure the surface remains free from debris.
  
  
• Ensure the dressing slides are not loose, allowing the diamond tool to move away from the wheel, and that the diamond is not worn or broken. Rotate or replace the dressing diamond if necessary.
  
  
• Ensure coolant is clean and free of contaminants. If this problem persists, please contact our sales department for information on a variety of coolant filtration systems which are available.