Grinding Wheel Dressing – Wheel Dresser Types & Specification
Table of Contents
Grinding Wheel Dressing
Dressing may be broadly defined as any operation performed on a wheel face to change the nature of its cutting action.
Why Grinding Wheel Dressing Needed?
Dressing is necessary when the individual grain crystal in the wheel face become dulled and the rate of stock removal is constantly decreasing as the grinding operation is prolonged without dressing.
Dressing is also necessary when the abrasive crystals or bond pores become loaded with metal or foreign matter, since this loading seriously affects the grinding action of the wheel.
Also Read : Grinding Machine Safety Precautions and Checklist PDF
Grinding Wheel Dressing Tools ( Wheel Dressers)
1) Diamond Dressers
Diamonds for dressing and truing grinding wheels are of several types, each having different characteristics.
“Multi-point”-An arrangement of twelve small set in a single plane in such a way that all stones contact the grinding wheel face simultaneously.
“Multi-Edge”-Three diamonds set in a line one behind the other, parallels to the wheel face. This tool is applied to the grinding wheel at a “down angle” and when the stones are flattened on one side from use, the tool is turned over.
2) Star Dressers
The Huntington or star type dresser has pointed discs loosely mounted on a pin, with solid discs as separators.
This type is exclusively used for dressing coarse grit wheels for snagging and offhand grinding and also for dressing segmental surface grinding wheels. It is low cost but requires some little skill in operation.
The Huntington dresser is the most efficient tool from the point of view of removing metal filling in general and the abrasive wheel type dressers are next in efficiency.
3) Precision Steel Type
This is popular and frequently used in place of diamond dressers for commercial grinding on precision grinding machines.
4) Abrasive Stick Dressers
These are of two shapes – square for hand manipulation and round for magazine mounting. Magazine mounting sticks find use in forming wheels for profile grinding and for dressing and truing relatively thin wheels.
Also Read : Grinding Wheels Types, Material & Specifications
5) Abrasive Wheel Dressers
These consist of properly bonded silicon carbide wheels rotably mounted in a suitable holder with high grade bearings. They will, in many cases, entirely replace the diamond on both center and centre less types of cylindrical grinding.
Their use imparts a smooth, clean cutting face which leaves no dressing marks on the work. With a few exceptions, since coolants are not generally used with the abrasive wheel dresser.
Diamond Dressers Specification
| Diamond Dressers | Carat | Use (Diameter) |
|---|---|---|
| HS010 | 1 | 350-450mm |
| HS015 | 1.5 | 450-500 mm |
| HS020 | 2.0 | 600 mm & above |
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FAQs about Dressing a Grinding Wheel
Dressing of a grinding wheel refers to the process of re-shaping the abrasive particles on the surface of the wheel to restore its cutting ability.
This is done by using a “dressing tool” which is typically a separate tool or a device built into the grinding machine. Dressing can be done manually or automatically and it can be done on a regular basis to maintain the quality of the grinding wheel.
Dressing and truing are both processes used to maintain the quality and condition of a grinding wheel, but they are different in terms of their specific purpose and the methods used to accomplish it.
Dressing refers to the process of reshaping the abrasive particles on the surface of the wheel to restore its cutting ability. This is done by using a dressing tool, which is typically a separate tool or a device built into the grinding machine. The dressing tool removes worn abrasive particles, revealing new sharp edges and creating a uniform surface on the wheel.
Truing, on the other hand, is the process of making sure that the wheel is running concentrically and true. This is accomplished by using a truing tool, which is also typically a separate tool or a device built into the grinding machine. Truing is done to correct any run-out or wobbling of the wheel, and it is done to ensure that the wheel is round, straight and that its running face is square to the wheel axis.
Dressing a grinding wheel involves the following steps:
1- Secure the wheel in the grinding machine and turn on the machine.
2- Hold the dressing tool (e.g. a diamond dresser) against the wheel, with the tip touching the surface of the wheel.
3- Apply light pressure to the tool and move it across the wheel surface in a uniform manner.
Continue this process until the desired shape or condition is achieved.
4- Inspect the wheel for any remaining defects and repeat the process if necessary.
5- Turn off the machine and carefully remove the wheel.
It’s important to note that the specific steps and tools used may vary depending on the type of grinding wheel and the machine being used. It’s always recommended to check the machine and wheel manufacturer’s instructions before attempting to dress a wheel.
Also, it’s very important to use the correct type of dressing tool, as using the wrong one may damage the wheel or cause safety hazards. And also, it’s very important to wear proper personal protective equipment (PPE) such as eye protection and gloves while dressing a wheel.
A wheel dresser, also known as a dressing tool, is a tool or device used to dress or reshape the abrasive particles on the surface of a grinding wheel. The purpose of dressing a wheel is to restore its cutting ability and create a uniform surface on the wheel. This ensures that the wheel cuts consistently, reduces chatter and vibration and increases the wheel’s lifespan.
Wheel dressers come in a variety of types and designs, each suited for specific types of grinding wheels and machines. The most common types of wheel dressers are:
1- Single-point diamond dressers: These are used to create a specific shape on the wheel, and are typically used for precision grinding operations.
2- Multi-point diamond roll dressers: These are used to true the wheel surface and are typically used for heavy-duty grinding operations.
3- Stick or star dressers: These are made of tungsten carbide or steel and are used to true and maintain the shape of the wheel.
The frequency of dressing a grinding wheel depends on the type of wheel, the material being ground, and the grinding conditions. However, as a general rule of thumb, the wheel should be dressed at least once for every 10 grinding sessions.
The dressing ratio for a grinding wheel is the ratio of the volume of abrasive material removed from the wheel to the volume of dressing material used for the process. This ratio is an important parameter that indicates the efficiency of the dressing process.
Grinding wheels should be regularly dressed to maintain their geometry and cutting efficiency. Dressing helps to remove dull abrasive grains and expose fresh grains, which enhances the grinding performance and prolongs the wheel life.
Overlap ratio in dressing is the ratio of the width of the dressing tool to the width of the grinding wheel. This parameter affects the quality and efficiency of the dressing process. A higher overlap ratio means that more material is removed from the wheel per pass, which leads to a more aggressive dressing action but can also result in higher dressing forces and increased risk of wheel damage.