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**Reasons and Analysis of the Disadvantages of Bearing Surface Grinding**
Bearing surface grinding is a critical process in manufacturing, where the workpiece surface is ground using a high-speed rotating grinding wheel. However, if the equipment is not properly adjusted according to the operating instructions, various defects can appear on the bearing's surface, which may affect its overall quality.
During fine grinding, the roughness requirements are very high, and visible grinding marks can be observed with the naked eye. These marks often take the form of interlaced spiral patterns, which are mainly caused by poor straightness of the grinding wheel’s surface. Additionally, the presence of concave and convex areas on the workpiece surface can result from limited contact between the grinding wheel and the workpiece. When the workpiece or the grinding wheel reciprocates multiple times, the surface pattern becomes more pronounced, forming visible spirals that are not parallel to the axis of the grinding wheel.
Several factors contribute to these spiral patterns:
1. Poor trimming of the grinding wheel, with unchamfered corners and insufficient coolant.
2. Excessive lubricating oil on the workbench guide, causing it to float.
3. Inaccurate machine tool settings.
4. Excessive grinding pressure applied during the process.
In addition, other causes include:
1. Insufficient rigidity in the V-shaped guide rail, leading to misalignment during grinding.
2. Unstable workbench speed or low precision during wheel dressing.
3. Poor rigidity in the workpiece itself.
4. Broken or fallen abrasive grains on the grinding wheel, which can cause scratches on the workpiece surface.
5. Improper dressing of the grinding wheel, resulting in uneven surfaces.
Another common issue is the fish-scale-like appearance on the workpiece surface. This occurs when the cutting edge of the grinding wheel is dull, leading to "squatting" during the grinding process and excessive oscillation. Causes of this include:
1. Contamination of the grinding wheel surface with oil or dirt.
2. Failure to dress the wheel regularly.
3. Dull or improperly dressed grinding wheels.
4. Poor-quality diamond tools or weak fastening frames.
5. Uneven hardness of the grinding wheel.
The presence of fluffing marks on the surface is typically due to coarse abrasive particles falling off the grinding wheel during the process. These can remain on the workpiece if not properly cleaned, especially after rough grinding. Other contributing factors include:
1. Residual marks from previous grinding steps that were not fully removed.
2. Uncleaned coolant particles or fine abrasive dust.
3. Abrasive particles left behind after coarse grinding.
4. A grinding wheel that is too soft or has exceeded its useful life.
5. Incompatible abrasive resistance and workpiece material.
Straight waveform traces on the workpiece surface often resemble sine waves, appearing as periodic undulations along the axis. These are usually caused by oscillations between the grinding wheel and the workpiece, either due to external forces or self-oscillation. The main reasons for such patterns include:
1. Excessive clearance in the grinding wheel spindle.
2. Overly hard grinding wheel.
3. Poor static balance or dull grinding wheel.
4. High workpiece speed.
5. Large horizontal feed rate.
6. Worn bearings in the grinding wheel spindle, leading to radial runout.
7. Poor compaction of the grinding wheel or workbench movement issues.
Burn marks on the workpiece surface are another serious concern. These can appear as dark black patches, lines, or intermittent spots, depending on the type of burn. Common causes include:
1. A grinding wheel that is too hard or has an excessively fine grain size.
2. Too high a feed rate and insufficient cooling fluid.
3. Low workpiece speed and high grinding wheel speed.
4. Excessive vibration in the grinding wheel.
5. Untimely or improper dressing of the wheel.
6. Sharp diamonds that do not produce a smooth finish.
7. Deep burns during rough grinding that are not corrected during fine grinding.
To detect burning, the workpiece should be pickled and inspected under magnification. A normal surface will appear evenly dark gray, while burned areas may show irregular dark spots or cracks.
If any of these issues occur, they must be analyzed promptly and addressed through proper adjustments and maintenance. Finally, the surface roughness of the bearing may not meet standard requirements due to various factors, including:
1. Low grinding speed or excessive feed rate.
2. High workpiece speed or excessive shaft oscillation.
3. A grinding wheel that is too thick or too soft.
4. Fast dressing speed or large trimming settings.
5. Dull or poor-quality diamond tools.
6. Poor-quality ultra-precision oilstone or incorrect device orientation.
7. Low-quality kerosene or insufficient super-fine grinding time.
By understanding and addressing these issues, manufacturers can significantly improve the quality and performance of their bearings.
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