Milwright Grinders

160103c
Millwright
Grinders
FIRST PERIOD
Tools and Fasteners
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Table of Contents
Objective One ............................................................................................................................................... 2
Safety Rules for Offhand Grinders ........................................................................................................... 2
Objective Two............................................................................................................................................... 4
Hand Grinding Machines .......................................................................................................................... 4
Types of Wheels........................................................................................................................................ 8
Objective Three............................................................................................................................................. 9
Installing and Using Grinding Wheels Safely ........................................................................................... 9
Properties of Abrasives ........................................................................................................................... 11
Grinding Wheel Markings ...................................................................................................................... 13
Inspecting the Wheel and Grinder........................................................................................................... 14
Installing a Grinding Wheel .................................................................................................................... 19
Self-Test ...................................................................................................................................................... 23
Self-Test Answers ....................................................................................................................................... 25
NOTES
Grinders
Rationale
Why is it important for you to learn this skill?
Grinders are versatile tools and essential pieces of equipment in all millwright shops, as
they can cut hardened metals. You should be able to operate and care for grinders
properly, as well as employ them safely and correctly.
Outcome
When you have completed this module, you will be able to:
Demonstrate and maintain grinders.
Objectives
1. Describe safety rules pertaining to offhand grinder use.
2. Describe operation, types, parts and application of offhand grinders.
3. Describe grinding wheel selection, installation and maintenance procedures.
Introduction
This module describes selection, safety and maintenance procedures of grinders. It also
addresses how to select and install abrasive wheels.
1
160103cp21.0_updated.docx
NOTES
Objective One
When you have completed this objective, you will be able to:
Describe safety rules pertaining to offhand grinder use.
Safety Rules for Offhand Grinders

Safety awareness in grinding is extremely important because of the speed and power of
the rotating wheels or discs and the sparks, dust and particles that fly around during
grinding operations. Consider the following safety rules.
1. Always wear eye protection and a face shield when performing any type of
grinding. The eye protection should include shaded lenses; however, ensure that
the lenses are light enough to enable you to see in normal shop light.
2. Ring test a wheel before installing it on a grinder. Ring test refers to supporting
the wheel by its bore and giving it a tap with a hammer handle.
3. Never run a grinding wheel faster than recommended by the manufacturer.
4. Ensure that all guards are in place before grinding.
5. When starting a grinder, stand to one side until full wheel rpm is reached.
6. Allow a newly installed wheel to run for a minute before using it for grinding. If
it is going to break, it will probably break in the first minute of operation.
7. Always use the tool rest.
8. Make sure the gap between the face of the wheel and the work rest is set at
1
/16 inch and that it never exceeds 1/8 inch.
9. Never apply undue pressure by forcing the work into the grinding wheel.
10. Never grind on the side of the wheel unless it is designed for side grinding.
11. Grind across the full width to allow heat to affect the wheel equally.
12. When grinding the edges of sheet steel, always keep the metal flat on the tool
rest. Feeding at an upward angle toward the wheel may cause kickback and can
injure the operator and/or damage the stone.
13. Keep hands away from rotating wheels.
14. Never force a grinding wheel onto a machine spindle. Either remove one layer of
the plastic bushing or use a different wheel with a larger bore.
15. Do not use mounting flanges that are not flat and clean.
16. Always allow a grinder to freewheel to a full stop.
17. Do not use a wheel with a worn-out centre.
18. Balance a stone before it becomes too far out of round.
19. Ensure that grinding wheels or discs are tight before turning on the machine.
20. Never bother someone who is in the process of grinding. You could startle them
and cause a serious injury.
21. Absolutely no horseplay is allowed when grinding.
2
Figure 1 shows correct eye protection for grinding. NOTES
Figure 1 - Safety glasses and full face shield.
3
NOTES
Objective Two
Describe operation, types, parts and application of offhand grinders.
Hand Grinding Machines

Hand grinding machines (commonly known as bench or pedestal grinders) are grinders
where the work is held and guided by the hand, rather than a chuck or some other
workholding device. The technique of grinding with one of these machines is called off-
hand grinding.
Bench and Pedestal (Floor) Grinders

Bench grinders attach to the edge of a bench. Pedestal grinders mount on a pedestal that
sits directly on the floor and they are larger and more powerful than bench grinders.
Bench and pedestal grinders are used for sharpening cutting tools and sometimes for
deburring (removing sharp edges) or chamfering (producing a tapered edge) workpieces
when precision is not critical.
Exhaust Tube
An exhaust tube is a collection tube that directs dust and particles away from the
operator. Exhaust tubes are built into many wheel guards.
Water Pots
Water pots are small water containers used to keep workpieces cool by quenching.
Eye Shields
An eye shield is a transparent cover that protects the face and eyes of the operator from
flying sparks and particles. Lights may be incorporated into the shields. These shields are
not designed to replace personal eye protection.
Wheel Guards
The grinding wheel is covered by a wheel guard (a metal shroud), leaving only a small
segment open for grinding. This prevents grinding particles from striking the operator
and, in the case of a broken wheel, from causing serious injury. Wheel guards should
extend 30° to 45° past the vertical, which ensures debris would be directed downward.
4
Tool Rests NOTES
A tool rest is a small platform mounted with its surface at or slightly above centre of the
wheel and is provided for resting the workpiece on. This gives a firm base for pressing
the work against the grinding wheel.
Bench and pedestal grinders (Figure 2) have two grinding wheels, both of which attach to
the same horizontal spindle. Usually, the composition of the two wheels is different, one
having a coarse grit (46) for rough work and the other having a finer grit (60) for finishing.
Figure 2 - Floor grinder.

Each wheel is held on the shaft by a nut. The nut on the right-hand side of the grinder has a
right-hand thread, while the nut on the left-hand side has a left-hand thread. When grinding,
a force is applied, which tends to tighten the nut on both the right and left-hand sides of the
grinder (Figure 3).
Figure 3 - Left-hand thread tightens the nut when in rotation.

Figure 4 shows a bench grinder.
5
NOTES
Figure 4 - Bench grinder.

The spindle is driven by a motor, which is usually less than 1 horsepower. Larger
grinders have more powerful electrical motors. These motors typically run at 1750 rpm.
Always grind on the face of the wheel when using a bench or pedestal grinder (Figure 5).
Figure 5 - Use only the face of the wheel.
CAUTION
Never grind on the side of the wheel. Pedestal grinders are not
designed for side pressure and grinding on the side of the wheel is
unsafe.
Do not apply too much pressure when grinding, as this may cause the tool or metal to
overheat. Never jam the work into the wheel because the uneven pressure promotes rapid
wheel wear at selected points and causes the wheel to be out of round. Move the
workpiece back and forth across the face of the wheel in order to distribute the wear and
heat evenly across the face of the wheel.
There are various safety guards in place on these machines. Always make sure these
guards are in place and properly adjusted.
6
Side Wheel Grinders NOTES
Side wheel grinders are the same as bench and pedestal grinders, except that the side of
the wheel is used for grinding instead of the face. These grinders are usually equipped
with a silicon carbide grinding wheel for sharpening carbide cutting tools (Figure 6).
Figure 6 - Side wheel grinder.

Side wheel grinders offer two advantages over bench grinders when grinding cutting
tools.
• The grinding face is flat rather than convex like that of a bench grinder.
• The angle of the work rest with the face of the grinding wheel does not change as
the grinding wheel gets smaller.
Belt Grinders
Belt grinders are used for grinding and polishing operations. They use a continuous belt
of coated abrasive (Figure 7). The width of the belts ranges from 1/4 inch to 26 inches.
These machines are useful for quickly deburring and chamfering a workpiece, such as a
workpiece that has been cut off on the power saw.
Figure 7 - Belt grinder.
7
NOTES Types of Wheels
The type of wheel you use on portable hand grinders depends on the procedure.
Wire Wheels
Wire wheels are used to clean a workpiece of scale and dirt and to produce a surface
finish of uniform fine scratches (Figure 8). They do not remove metal. Wire wheels can
be very dangerous when used at normal speed. The wires can fly off with great force and
have been known to puncture rubber tires on nearby equipment. Always wear thick layers
of clothing, safety glasses and a full face shield when using a wire wheel.
Some wire brushes are designed for mounting on a bench or pedestal grinder. Others
have a straight shank, which can be held in the chuck of a die grinder or drill.
Buffing Wheels
Buffing wheels are used to polish workpieces to a high lustre. The wheels are made of
cloth and are charged with a very fine abrasive such as polishing rouge.
Grinding Discs
Grinding discs for hand grinders are used for cut-off operations (Figure 8). The abrasive
grit in a general-purpose disc is made of aluminum oxide. The bond or glue that holds the
abrasives together is resinoid (phenolic resin or plastic) to give the wheel great integral
strength and some flexibility.
Sanding Discs
Sanding discs are coated abrasives used for light finishing, deburring and chamfering
(Figure 8). They are used with disc sanders or die grinders. The sanding disc should
mount on a rubber backing plate in order to permit some flexibility when sanding an
uneven surface.
Figure 8 - Wire wheel, sanding disc and grinding disc.
Flap Wheels
Flap wheels consist of strips of coated abrasives attached to a hub. They are used for light
finishing operations, especially inside a bore.
8
NOTES
Objective Three
Describe grinding wheel selection, installation and maintenance procedures.
Installing and Using Grinding Wheels Safely

A new grinding wheel must be installed when an old wheel becomes too small or is
damaged in some way. The operator may also choose to install another wheel when a
different workpiece material is used or when a faster or slower metal removal rate is
wanted.
There are four aspects to installing and using a grinding wheel safely.
1. Select the correct grinding wheel.
2. Inspect the wheel and grinder to ensure that they are in safe working condition.
3. Mount the wheel on the shaft between flanges.
4. Dress, true and balance the wheel.
Selecting a Grinding Wheel

The selection of a grinding wheel depends on the type and hardness of the material being
ground, the rpm of the grinding machine spindle, the material removal rate and required
finish of the workpiece.
Natural Abrasives
Through the years, natural abrasives have been used for shaping, polishing and grinding
materials to create finished products. Among these, four of the most common natural
abrasives are:
• crocus, which is a reddish-brown fine powdered oxide of iron,
• corundum or aluminum oxide,
• emery, which is a mixture of iron and aluminum oxide and
• diamond.
9
NOTES Manufactured (Artificial) Abrasives
The problems encountered with natural abrasives have been overcome with the
manufacturing of more consistent artificial abrasives. Grit size, bonding strength and
purity are now much better controlled.
Aluminum Oxide
Aluminum oxide is made from bauxite ore and ranges from grey to white. Aluminum
oxide wheels make up 75% of all grinding wheels. Aluminum oxide is suitable for
general grinding on all steels and most high tensile ferrous metals except cast iron and it
allows rapid material removal.
• Grey is less pure; therefore, it is tougher and less brittle than the others.
− It can withstand abuse and is used for general grinding of steel, wrought
iron and tough bronze alloys.
• Lighter grey is purer, more brittle and not as tough.
− It is suitable for cylindrical grinding, centreless grinding and internal
grinding of steel and cast iron.
• White, which is the purest, is also the most brittle.
− White aluminum oxide is used for tool and die work, for the hardest
steels and for stellite.
Silicon Carbide
Silicon carbide is made in furnaces from silica sand, coke and sawdust. It ranges from
green to black and is harder and tougher than aluminum oxide. It is used for grinding
high-density materials, such as cemented carbides, ceramics and stone. Silicon carbide is
also suitable for low tensile materials such as cast iron, non-ferrous metals and non-
metals.
• Green silicon carbide wheels are used to grind cemented carbides, ceramics and
other hard materials.
• Black silicon carbide wheels are used to grind cast iron and soft non-ferrous
metals like brass, copper and aluminum.
Cubic Boron Nitride (CBN)

Cubic boron nitride (CBN) unites boron and nitrogen under heat and pressure. It is used
on space-age materials.
Synthetic Diamonds
Synthetic diamonds are produced for grinding and are better than natural diamonds
because specific requirements can be reached.
10
NOTES
Properties of Abrasives
Abrasives have the following properties.
• Hardness is the ability of material to scratch or penetrate another material.
• Heat resistance is the ability of material to withstand the heat of grinding without
becoming dull.
• Toughness is the ability of material to resist impact and pressures created during
grinding.
• Friability is the ability of material to fracture under stress along certain cleavage
lines so that as the cutting edges become dull, part of the grain breaks off and
presents new cutting edges.
The Abrasive Grain

Grains used in abrasives are cleaned and sized. Sizing (Figure 9) is done by passing the
grains over screens that have different mesh sizes (holes per linear inch). The smaller the
number, the larger the grit size. The larger the number, the smaller the grit size.
Figure 9 - Grit sizes range from 40 - 600.
11
NOTES Bonds
Bonds hold the grains together. The amount of bond and the type used determine the
hardness (grade) of the wheel. The three most common types of bonds are as follows.
• Vitrified is designated by the letter V. This bond is used in 50% of all wheels
produced. It is made of clay (feldspar), which fuses at high temperatures to form
a glass-like (vitrified) material around each grain. Vitrified bonds are used for
speeds up to 6500 rpm.
• Resinoid is designated by the letter B. It is used in 33% of all wheels produced.
The material is similar to that used in the manufacture of telephone receivers.
Resinoid bonds are used for speeds from 9500 to 16 000 rpm.
• Rubber is designated by the letter R. It is made by vulcanizing a mixture of grain,
crude rubber and sulphur. Because of its strength, flexibility and ability to
withstand shock, rubber bond is used extensively on thin cut-off wheels. Rubber
bonded cut-off wheels can be used at speeds up to 16 000 rpm.
The grade of a grinding wheel indicates the strength of the bond holding the abrasive
particles together in the wheel; it indicates the hardness of the wheel (Figure 10). Grade is
indicated by a letter, ranging from A for the softest wheel to Z for the hardest wheel
(strongest bond).
Figure 10 - Bonding posts of different strengths.

The structure of a grinding wheel indicates the density (grams per cubic inch) of the
wheel. Structure indicates how close the abrasive grains are to each other and how open
the spaces are between grains (Figure 11). The primary function of the space (void) is to
provide chip clearance for the metal removed by a grain. On a scale of 1 to 15, a wheel
with an open structure (15) has more chip clearance voids than one with a dense structure
(1).
Figure 11 - Different grain densities.
12
NOTES
Grinding Wheel Markings
A standard system of wheel identification makes it possible for you to select a specific
wheel and predict how it will perform. These markings are printed on the blotter, which
attaches to the side of the grinding wheel.
Each element and characteristic is capable of modification and each has its own position
within the system.
• Position 1 is the abrasive type.
• Position 2 is the grain size.
• Position 3 is the grade.
• Position 4 is the structure or density.
• Position 5 is the bond type.
• Position 6 is the manufacturer's record.
Table 1 shows the breakdown for a typical abrasive wheel marking system.
32A 46 H 8 V G
Bond Norton
Abrasive Type Grit Size Grade Structure
Type Symbol
Alundum = A Very The structure V = Vitrified Letter or numeral
Crs Med Fine Soft Med Hard
44 Alundum = 44A Fine number of a wheel S = Silicate or both to
19 Alundum = 19A 10 30 70 220 A I Q refers to the B = Resinoid designate a
57 Alundum = 57A 12 36 80 240 B J R relative spacing of R = Rubber variation or
32 Alundum = 32A 14 90 280 C K S the grains of E = Shellac modification of
abrasive; the bond or other
38 Alundum = 38A 16 46 100 320 D L T
larger the number, characteristic of
37 Crystolon = 37C 20 54 120 400 E M U the wider the grain the wheel. Typical
39 Crystolon = 39C 24 60 150 500 F N V spacing. symbols are
180 600 G O W P and G.
H P X
Y
Z
Table 1 - Abrasive wheel marking system.
13
NOTES Inspecting the Wheel and Grinder
Hand grinding machines must be used carefully and all safety precautions must be
followed. You must be aware of safety procedures and must treat grinding machines with
the utmost respect.
The first step in ensuring your safety is to do a visual inspection of the grinder before
starting it. In particular, look to see if the wheel is rated to turn at the rpm of the grinder,
that the work rest and guards are properly adjusted and that the wheel is not cracked.
If the grinding wheel and grinder appear to be in good condition, stand to one side of the
wheel and start it. Never stand directly in front of the face because, if the wheel is
damaged, it will fly apart as soon as the grinder is started. When starting a grinder with a
newly installed grinding wheel, let it run for at least a full minute before approaching it.
Speed (RPM)
A grinding wheel will explode if allowed to rotate above the recommended rpm. When a
wheel spins, its outer edge wants to continue in a straight line. If allowed to turn too fast,
the force can tear the wheel apart with potentially lethal consequences (Figure 12).
Figure 12 - Forces acting on a grinding wheel.

All wheels are marked with a maximum safe rpm. Look for the rpm on the blotter and
make sure the speed of grinder (in general) does not exceed it.
14
Tool Rest and Spark Guard Adjustment NOTES
The tool rest, sometimes called a work rest, is used to support the workpiece while it is
being ground (Figure 13). There is a gap between the wheel and the tool rest, and this gap
gets larger as the wheel wears. At some point, if the gap gets too large, the workpiece can
be caught by the wheel and dragged down between the wheel and the guard. The
operator's fingers can be drawn into the grinding wheel.
Figure 13 - Wheel guard, spark guard and tool rest.

You must set the gap between the wheel and the tool rest at 1/16 of an inch (Figure 14). If
the tool rest needs adjustment, turn off the grinder and unplug it. Never adjust a tool rest
while the grinder is in motion. Loosen the nuts holding the tool rest in place and
reposition as required. Once the rest is adjusted, rotate the wheel by hand to check for any
high spots before replacing the electrical plug and switching on the power. Neglecting
this procedure is dangerous because high spots on the wheel could strike the tool rest
when the power is switched on.
Figure 14 - Gap between the wheel and tool rest.

The gap between the tool rest and the face of the wheel must not exceed 1/8 inch to
prevent the work from wedging between the work rest and the wheel. The gap increases
through wheel dressing and normal wear and you should always check it before operating
the grinder. The work rest must not be set below the centreline of the grinding wheel.
The spark guard protects the operator's hands from sparks during normal operation and
from fragments if the wheel shatters. The gap between the spark guard and the periphery
of the wheel should be between 1/16 and 1/4 inch.
15
NOTES Ring Test
Grinding wheels are made of clay, are brittle and will crack if dropped or abused. Small
cracks are hard to see, but they weaken the wheel and present a potential danger of wheel
explosion.
One way to check for cracks is to perform a ring test before installing a wheel or any time
you suspect a wheel is damaged (Figure 15). To perform a ring test, follow these steps.
1. Remove the wheel from its flange.
2. Suspend the wheel by the bore.
3. Tap the wheel lightly in several places with a non-metallic object and listen to the
sound. If the wheel makes a clear ringing sound, like a bell, the wheel is not
cracked. If it makes a dull thud, the wheel is cracked and must be discarded.
Figure 15 - Ring test.
16
Inspecting the Grinder NOTES
Before mounting a new wheel, check the general condition of the grinder. Check the
following points in particular.
• Are the guards in place and in good order?
• Are the nuts and flanges used to hold the wheel in good condition?
• Are the threads damaged or stripped?
• Are the flanges bent?
• Are the flanges of equal clamping diameter?
• Are the electrical connections sound and without frayed wires?
• Are the bearings loose or worn?
Grinding wheels are held between flanges. On hand grinders, one flange is permanently
attached to the spindle. The other slides over the spindle and is held in place with a nut.
Flanges should be at least one-third the diameter of the wheel. Both flanges must be the
same diameter; otherwise, they set up internal stresses in the wheel when tightened and
the wheel could crack. Never mount a wheel without a pair of flanges (Figure 16).
Figure 16 - Grinding wheel installation.

If the bore of the grinding wheel does not fit the shaft properly, a bushing can be inserted
to make up the difference. Although the bushing should fit closely to the bore, never
force a bushing into the bore or the wheel may crack.
17
NOTES Blotters Wheels
Blotters are pieces of paper attached to each side of the grinding wheel (Figure 17). The
purpose of the blotters is to protect the flanges from the abrasive grit of the wheel and to
display important information about the wheel, such as its physical properties and
maximum safe rpm. Blotters also serve to compensate for uneven surfaces on the sides of
the grinding wheel. Do not mount a wheel without blotters on both sides.
Figure 17 - Blotter on a grinding wheel.
18
NOTES
Installing a Grinding Wheel
To install a grinding wheel or disc on a hand grinder, follow these steps.
1. Clean the shaft and flanges of any grit or dirt and inspect the threads on the shaft
and in the nut for any damage.
2. Read the blotter to find the maximum safe rpm of the wheel. Make sure the speed
of the grinder does not exceed this maximum.
3. Make sure the bore of the wheel matches the size of the shaft. If it does not
match, use a bushing.
4. Make sure you select the correct type of abrasive wheel. Aluminum oxide
abrasive discs are used for grinding steel and are identified by the letter A,
indicated on the blotter. A letter C on the blotter indicates a silicon carbide
abrasive. Silicon carbide abrasive wheels are used for grinding carbide and non-
ferrous metals. Always check the manufacturer's specifications.
5. Slide the wheel over the shaft and seat it firmly against the fixed flange.
6. Slide the other flange onto the shaft and use a wrench to tighten the nut. The left
side spindle has a left-hand thread. Do not overtighten the nut, as grinding wheels
are brittle and break easily. The starting torque of the grinder tends to tighten the
nut.
7. Reinstall and adjust all guards.
Dressing a Wheel
The face of a grinding wheel is made up of numerous tiny abrasive particles. These
abrasive particles are the cutting edges of the wheel and, like all cutting edges, they must
be in good condition if they are to do their job.
DANGER
Dressing, truing or balancing any abrasive grinding wheel creates

harmful dust. Wear a respirator or dust mask at all times.
There are two conditions that might prevent these abrasive particles from cutting
efficiently.
• The abrasive particles may become dull. When abrasive particles become dull,
the wheel takes on a shiny appearance and is said to be glazed.
• The spaces between the particles may become jammed with the material being
ground. When this happens, the wheel takes on the colour of that material and is
said to be loaded.
In either case, the wheel stops cutting until it has been dressed. Dressing a wheel removes
the top layer of abrasive particles to expose the fresh ones beneath. A grinding wheel can
be dressed with a mechanical dresser, an abrasive stick, an abrasive wheel or a diamond
dresser.
19
NOTES Mechanical Dressers
The wheels in a mechanical dresser rotate when in contact with the grinding wheel. When
a spoke strikes the face of the wheel, it breaks away an abrasive grain.
To use a mechanical dresser, place the head of the dresser on the work rest, with the lugs
down. Press the tool firmly against the grinding wheel and feed the dresser back and forth
across the face of the wheel. Continue until all evidence of glazing or loading has been
removed (Figure 18).
Figure 18 - Mechanical dresser (star wheel).
Abrasive Sticks
An abrasive stick is made of the same material as a grinding wheel, but with a much
stronger bond. That way, the wheel wears instead of the stick. Abrasive sticks come in a
variety of shapes and sizes and can be held in a holder to protect the hands (Figure 19).
The advantage of an abrasive stick is that it leaves a smoother finish on the face of the
wheel than a mechanical dresser does.
Figure 19 - Using an abrasive stick to dress a wheel.

To use an abrasive stick, grasp it firmly in an appropriate holder. Place the end of the
stick on the work rest and drag it smoothly across the face of the wheel. The flat side of
an abrasive stick can be used to produce a flat surface on the grinding wheel.
20
Abrasive Wheels NOTES
A grinding wheel can be dressed with an abrasive wheel mounted in a housing. The
wheel rotates in the housing, much like a mechanical dresser, and is set at a slight angle
to provide a shearing action when the dresser is pressed against the wheel (Figure 20).
Figure 20 - Abrasive wheel dresser.
Diamond Dressers
A diamond dresser is used when a very fine finish is required. It is seldom used on a hand
grinder. The diamond is mounted on a handle and fed across the face of the wheel. The
depth of cut should be very light (0.001 inch) and the tool should be held at a 15° drag
angle and a 30° lead angle to reduce chatter and keep the diamond sharp (Figure 21).
Figure 21 - Diamond dresser.
21
NOTES Truing a Wheel
Truing a wheel is very much like dressing it. The same tools are used to remove the
outermost layer of abrasive particles. Truing, however, restores the shape of the wheel
and makes the outer surface of the wheel concentric with its bore (Figure 22).
Figure 22 - The face should be flat, parallel and concentric.

Over time, the face of a wheel wears unevenly. Grooves might develop in the middle of
the face or the corners might become rounded. The periphery of the wheel may no longer
run true to the axis of the shaft, which means that the outside of the wheel is no longer
concentric to the wheel axis. Truing the wheel corrects all these conditions. To true a
wheel, follow the same procedure as for dressing it.
Balancing a Wheel
An out of balance wheel vibrates as it turns, wears out the bearings in the grinder and
produces a poor surface finish on the workpiece. Most hand grinder wheels are
adequately balanced when they come from the factory and few are equipped with any
provision for balancing.
When a used wheel goes out of balance, you may be able to dress it into balance with a
mechanical dresser. If the star-shaped wheels on the dresser are too loose for controlled
engagement with the grinding wheel, use an abrasive stick, abrasive wheel or diamond
dresser for a more solid and consistent depth of cut. Take light passes. A balanced wheel
gives a much better finish to your work.
If the wheel is badly out of balance, you must balance it with an abrasive stick or
diamond dresser first, followed by a mechanical dresser to rough up the face. Mark the
entire face of the wheel with a black metal marker before balancing it. This shows you
where any remaining low points are as the high spots are being removed. After balancing
the wheel, use the star dresser only enough to rough it up and expose new cutting edges.
You now have a balanced grinding wheel.
If the vibration persists, remove the wheel from the spindle, check for shaft runout and
bearing condition, then remount the wheel.
22
NOTES
Self-Test
1. On a pedestal grinder, the gap between the grinding wheel and work rest should not
exceed:
a) 1/16 inch.
b) 1/32 inch.
c) 1/8 inch.
d) 1/4 inch.
2. The kind of abrasive material used in grinding wheels for general purpose
applications is:
a) silicon carbide.
b) boron carbide.
c) aluminum oxide.
d) diamond.
3. A blotter is used on a grinding wheel to:

a) keep the grinding wheel from turning between the flanges.
b) prevent the flanges from crushing the grinding wheel.
c) serve as a spacer when the grinding wheel is too narrow for the flanges.
d) protect the flanges from the abrasive grit of the wheel, display information
about the wheel and compensate for the uneven surfaces on the wheel.
4. Flanges should be at least:

a) 1/8 the diameter of the wheel.
b) 1/2 the thickness of the wheel.
c) 1/3 the diameter of the wheel.
d) 1/4 inch thick.
5. The best wheel to use for cleaning scale and dirt off a workpiece is the:
a) wire wheel.
b) grinding disc.
c) buffing wheel.
d) polishing wheel.
6. What is a natural abrasive?
7. Under properties of abrasives, to what does the term hardness refer?
8. The is the part of the wheel that holds the grains together.
9. Markings for wheel identification can be found on the .
23
NOTES 10. What is the recommended speed to run a grinding wheel?
11. How should you start a grinder?
12. Is 46 or 60 the coarser grit?
13. What are the two (2) most commonly used abrasive materials?
a)
b)
14. For what purpose is the diamond dresser used?
24
NOTES
Self-Test Answers
1
1. c) /8 inch.
2. c) aluminum oxide.
3. d) protect the flanges from the abrasive grit of the wheel, display information about
the wheel and compensate for the uneven surfaces on the wheel.
4. c) one third the diameter of the wheel.
5. a) wire wheel.
6. A natural abrasive is made of natural rather than synthetic materials.
7. the ability of a material to scratch or penetrate another material
8. The bond is the part of the wheel that holds the grains together.
9. Markings for wheel identification can be found on the blotter.
10. Never run a grinding wheel faster than the speed recommended by the manufacturer
of the grinding wheel.
11. Stand to one side when starting a grinder until full wheel rpm is reached.
12. 46
13. a) aluminum oxide
b) silicon carbide
14. when a very fine finish is required
25
NOTES
26
This learning material is the result of a collaborative effort between the Northern
Alberta Institute of Technology, the Southern Alberta Institute of Technology, and the
following Alberta apprenticeship training providers:
Grande Prairie Regional College | Keyano College | Lakeland College

Lethbridge College | Medicine Hat College | Northern Lakes College
Olds College | Portage College | Red Deer College
The Individual Learning Modules Initiative is committed to continuous
updating and is interested in your comments regarding technical accuracy
and clarity of presentation. Please visit our website to register your
comments. To view the ongoing discussion, go to the Bulletin Board:
http://ilm.nait.ca
The Individual Learning Modules Initiative would like to thank the many
individuals and companies for their contribution and gratefully
acknowledges their valuable input.
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Milwright Grinders

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160103c

Safety Rules for Offhand Grinders

Figure 1 - Safety glasses and full face shield.

Hand Grinding Machines

Bench and Pedestal (Floor) Grinders

Figure 2 - Floor grinder.

Figure 3 - Left-hand thread tightens the nut when in rotation.

Figure 4 - Bench grinder.

Figure 5 - Use only the face of the wheel.

Figure 6 - Side wheel grinder.

Figure 7 - Belt grinder.

Figure 8 - Wire wheel, sanding disc and grinding disc.

Installing and Using Grinding Wheels Safely

Selecting a Grinding Wheel

Cubic Boron Nitride (CBN)

The Abrasive Grain

Figure 9 - Grit sizes range from 40 - 600.

Figure 10 - Bonding posts of different strengths.

Figure 11 - Different grain densities.

Table 1 - Abrasive wheel marking system.

Figure 12 - Forces acting on a grinding wheel.

Figure 13 - Wheel guard, spark guard and tool rest.

Figure 14 - Gap between the wheel and tool rest.

Figure 15 - Ring test.

Figure 16 - Grinding wheel installation.

Figure 17 - Blotter on a grinding wheel.

Dressing, truing or balancing any abrasive grinding wheel creates

Figure 18 - Mechanical dresser (star wheel).

Figure 19 - Using an abrasive stick to dress a wheel.

Figure 20 - Abrasive wheel dresser.

Figure 21 - Diamond dresser.

Figure 22 - The face should be flat, parallel and concentric.

3. A blotter is used on a grinding wheel to:

4. Flanges should be at least:

6. What is a natural abrasive?

7. Under properties of abrasives, to what does the term hardness refer?

9. Markings for wheel identification can be found on the .

11. How should you start a grinder?

12. Is 46 or 60 the coarser grit?

14. For what purpose is the diamond dresser used?

Grande Prairie Regional College | Keyano College | Lakeland College

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