Medium-speed grinding is a process that utilizes a grinding wheel to refine the surface of a metal component at medium speed. The process is primarily used to shape and clean up profiles, as well as to produce accurate tolerances on internal and external surfaces. As its name implies, it is a process that operates at a speed somewhere between the slowest and fastest speeds used in grinding such as traverse or creep feed grinding and high-speed grinding.
The process is mainly used when a high degree of surface smoothness, accuracy, and/or shape are required. This is a more common process than creep-feed grinding because its slower speeds of operation makes it more controllable. The speed control from slow to medium allows the use of a wide range of grinding wheel strengths and sizes without losing the accuracy of the surfaces. In some cases it can be used on hardened surfaces which are difficult to machine with conventional methods.
Medium speed grinding relies on the rotation of a grinding wheel that is mounted over an abrasive compound, such as aluminum oxide, silicon carbide, or diamond. Grinding fluid is typically used in the process to cool the area and help reduce wear on the grinding wheel. Temperatures can be monitored in the grinding area to ensure that they remain at the correct levels.
The process involves a combination of the grinding wheels rotation, combined with the feed rate of the workpiece. This helps to create a precise surface finish. The process works better the harder the workpiece material. As the material gets harder, the chip size decreases, and the process removes microscopic chips of material at a time.
The type of machine used in medium speed grinding also affects processes and components. Depending on the material being ground and the desired finish, both surface grinding machines and centerless grinders can be used. In both cases, the grinding surfaces spin simultaneously and may include workstations for multiple parts.
Today, the most popular use for medium-speed grinding is the production of components for automotive and aerospace industries. The process can be used to grind components such as brake rotors, crankshafts, and engine blocks down to tight tolerances. It can also be used on complex parts like turbochargers to produce surfaces with a large degree of accuracy and a high surface finish.
Due to the nature of medium speed grinding, it is best suited for parts that require finer surface finishes, need to be shaped accurately, or require closer tolerances than are possible with conventional grinding processes. It is also the best choice when high production rates are an important factor. The process is mainly favored for its accuracy, repeatability, and ability to grind hard materials down to very tight tolerances.
