2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16
Shaft grinding or, in principle, the grinding operation is a workpiece processing procedure, which consists in the use of a cutting tool made of abrasive material. The surface after such treatment is a set of microtraces. They are left by abrasive grains present on the tool. The surface of the finished product is characterized by minimal roughness.
Description of grinder
Shaft grinding is carried out using a grinding wheel. This circle is a porous body type, consisting of a large number of abrasive grains. These grains are held together by a bunch. In addition, pores are located between these grains and ligaments. The grains themselves are made of a very durable material, and their number reaches tens or even hundreds of thousands.
As for the working profile of the shaft grinding wheel, it consists of cutting edges of abrasive type grains. They are located at different distances from the surface. In addition, the grinding process is a procedure during which theshavings. Due to the fact that large amounts of chips are removed, this leads not only to grinding of the material, but also to a significant release of heat in the contact zone. It is for this reason that this operation is carried out only in the presence of a constant supply of a large amount of cutting fluids.
General types of grinding
Today, there are three main types of shaft grinding - this is thin, preliminary, finishing. When applying the preliminary type of grinding, it is possible to achieve an accuracy of 8-9 in terms of quality. As for the second important factor - roughness, it ranges from 0.4 to 6.3 microns. Fine-type shaft grinding can only be carried out after the workpiece has undergone heat treatment. This procedure allows increasing the accuracy to 6-7 in terms of quality and reducing the roughness to 0.2-3.2 microns. The most accurate method is fine grinding, which achieves a roughness of 0.025-0.1 µm. The process is also divided into two types - it is round and centerless.
Round type grinding
The machine for grinding the crankshaft journals or for any other products of round and cylindrical type is performed on cylindrical grinding machines. In this case, the workpiece will be mounted in the center, in the chuck or collet of the device. To date, there are two main types of cylindrical grinding - this is the longitudinal feed and the plunge method.
As for the first type, this is a procedure that takes place with the help of a returnprogressive movements. In this case, the part is moving relative to the grinding wheel.
Plunge grinding is carried out with a circle whose width must be greater than the length of the area to be machined. In this case, the circle will have a feed of only a transverse type. If you use a shaped circle, then you can process several parts at the same time. Since this method is more productive than longitudinal feed, it is used much more often in large-scale and mass production.
Centerless grinding
This operation is carried out on machines of centerless grinding type. In this case, traverse and plunging methods are also used.
As for the traverse operation, it is used for machining smooth shafts. The plunging procedure is used to machine shafts that have a collar. In this way, it is possible to process parts that are characterized by a conical surface. For this, a leading circle is usually used, tucked into a cone.
It is worth adding that when using the cutting method, the circle gradually loses its shape and cutting ability. Quite often this is referred to as brining the circle. In order to return the wheel to its original state and thereby return its performance to its previous level, a dressing procedure is used. This procedure is carried out with diamonds in frames, diamond pencils, etc. The dressing process itself does not affect the polishing, but if carried outpoor quality, then the characteristics of the circle will deteriorate, which means that it will perform the operation worse.
Crankshaft Machines
Today a good solution would be to use an AMC-SCHOU crankshaft grinder.
This equipment is made from heavy duty castings. The device has a hydraulic circle supply, as well as locking pins. A distinctive feature of the device is a fairly quick adjustment of the wheel feed, which is carried out without feedback.
The main procedure that is required when repairing the crankshaft is grinding. This operation allows you to correct the geometry of the device, fix chips, increase engine life, and also reduce the risk of new problems.
Grinding the crankshaft journals now allows you to eliminate scoring and wear. The process of grinding this fixture itself is an option that requires special machine equipment, as well as high specialist skills.
Grinding the steering rack
Grinding the steering shaft is also a fairly common operation. Experts recommend using it only if the rust on the fixture is of a surface type. In addition, the maximum reduction in diameter is allowed no more than 0.1 mm. In the event that corrosion is considered deep, then grinding of the part by 0.5 mm, no more, is allowed. If grinding occurs independently, it is very important thatthe working area of the shaft was perfectly polished. Most often, in manual processing, sandpaper is used for this. Processing usually starts with very rough P80 paper. Further, the graininess is reduced, and the finest sandpaper is used for the final processing.
Factory works
As for grinding the steering rack shaft in the workshop or in production, a special machine is used for this, which must be operated by an experienced turner. At the same time, it is important to know that during operation it is necessary to constantly monitor the deviation of the form. It must be in accordance with the regulations. Before starting the repair, it is necessary to conduct a visual inspection of the part in order to conclude that it is advisable to grind the shaft.
Today, a rather important aspect of the procedure has become its cost. It depends on factors such as rod type, amount of work and thickness of the corroded layer. The main advantage of grinding the power shafts of the rails in the workshops is that they have stands to check the performance of the product. If any shortcomings appear, then there is the possibility of their immediate elimination.
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