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1、COMMON CAUSES OF CENTERLESS GRINDING ERRORS 无心磨削错误的常见原因Burn Marks on the Workpiece 工件灼伤标记工件灼伤标记Cutting on trailing edge of the wheel(Spiral Burn)尾缘切口（螺旋纹）Insufficient coolant(Shadow and Spots)冷却液不足（阴影和斑点）Dull or flat diamond(Shadows and Glazed Grinding Wheel)金刚笔太钝（阴影和砂轮釉面）Grinding wheel dressed with
2、 too slow a diamond traverse rate(Glazed looking Grinding wheel)砂轮修整时金刚笔速度太慢（砂轮呈现釉面）Wheel too hard 砂轮太硬Too heavy stock removal 磨削量过大Chatter颤振颤振Blade not properly clamped 托板没固定好Glazed wheel caused by dull diamond,wheel too hard,grit size too fine or dressing rate too slow 釉面砂轮成因：金刚笔太钝、砂轮太硬、砂粒太细、修整速度太
3、慢。Work too high above center 工件离中心线太远Blade too thin or warped 托板太薄或卷曲Wheel out of balance 轮子失去平衡Motors out of balance 电机失去平衡Stock removal too heavy(Line of Cut Not Set Correctly)磨削量太大（切削路线不直）Chatter Cont.颤振颤振Machine leveling screws not adjusted for even torque when machine is finally leveled 机器最后调平后
4、螺母上紧程度不均Blade being used is too long for the width of the wheel 托板相对于轮子宽度太长Outside“floor harmonics”机器外面“地面谐波”Grinding wheel mount fits loosely on spindle 砂轮松动Blade angle too steep(300 Standard)托板上表面角度太陡（标准30）Erratic Sizing 尺寸不稳定尺寸不稳定Work improperly rough ground 粗磨精度不够Parts overheating during cut,due
5、 to improper wheel or insufficient coolant 磨削时由于砂轮不好或磨削液不足杆受热过度Loose work support blade 托板松动Insufficient lubrication on lower slides causing slides to hang or jump(infeed).Too much lubrication oil(Thrufeed)下滑块润滑不够导致进刀时滑块每次进刀量不一致（切入磨）。润滑油过多（通磨）Gibs not properly adjusted on upper and lower slides 上下滑块
6、没有调整好。Erratic Sizing Cont.尺寸不稳定尺寸不稳定Regulating wheel camming 导轮凸轮板问题Soft wheel 轮子太软Wear on infeed screw and nut 进给螺钉螺母磨损Infeed lever not held tight(for thrufeed work)进给装置没有固定好Improper tension on backlash spring 消隙弹簧张力不合适Feed Lines 进料线纹进料线纹Grinding wheel not relieved on exit side 砂轮出口端没有修整好Work guide
7、s not properly set 夹板没调好On long bar fixtures excessive pressure on work piece by roller hold-down 长轴夹具-工件受压过大Finish光洁度光洁度Setup not correct 设置错误Dirty or insufficient coolant 冷却液太脏或不足Diamond dressing traverse rate too fast 修整速度太快Pick-up on blade 托板上Loose,cracked or dull diamond 金刚笔松动，裂开或太钝Regulating w
8、heel SFM excessive 导轮SFM太大 Unbalanced wheel 轮子平衡性不好Finish Cont 光洁度光洁度Blade not tight in work rest 托板没有上紧Work too high above center 工件位置太高Regulating wheel not tight on its mount 导轮松动Erratic movement of truing attachments 修整器运动不稳定Improper wheel grade 轮子不合适Oil on face of wheel 轮子表面有油Blade angle too ste
9、ep 托板上表面太陡Low Ends on Work Chamfered 工工件锥度件锥度-两端磨出倒角两端磨出倒角Work guides deflected toward regulating wheel 夹板向导轮偏离Face of regulating wheel not straight at work contact point(truing device worn or not on correct angle)导轮与工件的接触面不平（修整器磨损或修整角度不当）Low Centers High Ends 中间凹进中间凹进 两端凸出两端凸出Work guides deflected
10、toward grinding wheel 夹板向砂轮偏移Face of regulating wheel not straight at work contact point(truing device worn or not on correct angle)导轮接触工件的表面不平（修整器磨损或修整角度不当）Out of Round Work 工件圆度不好工件圆度不好Regulating wheel not dressed round 导轮没有修整圆 Flat diamond 金刚笔太钝Work not high enough above center 工件位置太低Interrupted
11、cut due to keyways,holes,flats,etc.工件上有键槽、孔、或者平面等，干涉切削Work piece bowed 工件弯曲Not enough stock to round up 磨削量太小Out of Round Work Cont.圆度差圆度差Regulating wheel speed too slow or too fast 导轮速度太慢或太快Out of balance work piece 工件平衡性不好Regulating wheel loose on mount 导轮松动Blade angle not steep enough 托板上表面角度不够大（
12、不够陡）Grinding wheel not properly graded for job 砂轮不适合On infeed only,end stop or ejector may be worn on locating surface 仅适用于切入磨：弹出器可能磨损Taper 锥度锥度Work guides not set properly 夹板没有调好Dirt under workrest or blade 托架或托板有污染Loose gibs 夹条松动Failure to keep parts butted end to end on thrufeed 工件之间没对接好Too much
13、feeding pressure(race grinding fixture)进给压力过大Non-uniform spark out time from one piece to the next(infeed setup)光磨时间不均（切入磨设置）Wheel not cutting freely(part expands due to surface temperature immediately behind lading end.This results in tapered part with leading end high.)砂轮切削不畅（表面温度升高导致工件膨胀。这将导致工件的锥
14、度，件前端过高）。Dull Diamond Grinding Wheel Truing Attachment 金刚笔太钝金刚笔太钝 砂轮砂轮修整器修整器Diamond nib not turned periodically 金刚笔没有定期车削Excessive infeed of diamond(should not take more than 0.001”depth of cut under normal conditions)金刚笔进的太多（一般情况下，每次的深度不超过0.001英尺）Fish Tails 末端呈鱼尾状末端呈鱼尾状Dirty coolant 冷却液太脏Loose grit
15、 in wheel 轮子上砂粒没粘紧Grinding Wheel Too Hard 砂轮太硬砂轮太硬May cause burn marks 可能导致杆上有烧伤痕迹Can cause squeal because it is not free cutting 刺耳的噪音Glazing may occur on wheel face 砂轮表面出现釉面Soft materials may“load”wheel 材质软的材料可能附在砂轮上Often produce chatter on work piece 制造噪音Sizing trouble,due to no spark out 尺寸问题May
16、 cause heat checks or cracks 可能导致热龟裂或裂开Grinding Wheel Too Soft 砂轮太软砂轮太软Sizing trouble,because wheel breaks down rapidly 尺寸问题，因为砂轮磨损过快Chatter may develop 可能有颤振High Above Center of Workpiece 工件位置太高工件位置太高If too high,chatter can develop 位置太高时，可能颤振Optimum rounding action will not occur if center height i
17、s too low 中心高度太低时达不到最优圆度Intermittent Cut 间歇性磨削间歇性磨削Grinding wheel not correctly trued 砂轮没修整好Regulating wheel“camming”导轮形状没修整好Warped work piece 工件弯曲Jumpy Truing Device 修整器颠簸修整器颠簸Slides not lubricated properly 滑块润滑不当Gib adjusted improperly 夹条没调好Loading of Wheels 轮子粘上杂质轮子粘上杂质See grinding wheels too har
18、d(3 above)见砂轮太硬部分Wheel to fine.Larger grain size allows more chip clearance.需要细砂轮。砂粒越大，间隙越大，越容易塞进杂质Ineffective cutting fluid due to the lack of lubricity of cutting fluid,chips adhere to grit of wheel.切削液失效-由于切削液润滑性能不好，磨屑附在砂料上。Change to coolant with greater lubricity or increase amount of concentrat
19、ion in mix.应更换润滑性能更好的磨削液或增大浓度。Pick-up on Blade 托板上有杂质托板上有杂质Cutting fluid no lubricating work-to-blade contact point.Use cutting fluid with greater lubricity or increase concentration.磨削液润滑性能不好。请用润滑性能更好的磨削液或增大浓度。Blade too hard for material being ground(use cast iron or bronze blade)托板太硬（使用铸铁板或铜板）Regu
20、lating Wheel“Camming”导轮形状没修整好导轮形状没修整好Collet screws loose 夹筒螺钉松动Bearings worn 轴承磨损Regulating wheel spindle eccentric or out of round 导轮主轴偏心或不圆Spiral Chatter 螺旋纹螺旋纹 Hard spots in wheel 轮子上有坚硬凸起Chipped edge of wheel 轮子棱破损Loose machine elements 机器部件松动Straightness 垂直度垂直度Work not straightened sufficiently
21、 before grinding 磨前没有调直Insufficient grinding stock left on work piece，磨前工件尺寸不够Too much stock removal on first pass 第一次磨削量过大Wheel not cutting freely(part heats up,relieving internal stresses causing part to bow)砂轮切削不畅（工件受热升温，内应力降低导致工件弯曲）Insufficient coolant(same thing happens)冷却液不足（同上）Vibration 振动振动C
22、heck outside sources 检查外部环境Leveling screws not snug against floor 螺钉没有固定在地面Motors not balanced or drive belts too loose 电机不平衡或传动带太松Faulty hydraulic pump causing erratic pressure vibrations to be transmitted to machine 液压泵失效，向机器施加的力不稳定Warped work(Usually Long Bar or Truing)工件弯曲（杆太长或修整问题）工件弯曲（杆太长或修整问题）Insufficient flow of coolant 冷却液流量不足Wheel not cutting efficiently.Either dressed too fine or too small grit size 轮子切削不畅。或者修整的太细，或者砂粒太细。Work piece not straightened before grinding 磨前没有调直