Wheel Mounting

Wheel Mounting Procedures:

• Only a qualified, trained, and certified individual who is capable of performing the task may mount the wheel. 

• A grinding wheel must be examined for damage and put through a "ring test" to make sure it is in excellent condition before mounting. 

• Only the machine for which the wheel was made should have it installed. 

• A grinding machine should have an unobstructed region around it. Splash guards should be available for wet grinding operations to prevent slick flooring around the machine. 

• Before running a wheel, wheel protectors need to be properly installed. By confining or directing the pieces of an accidently broken wheel, this will safeguard the operator. 

• Work rests should be set up as near to the grinding wheel as practicable.

• Under no circumstances can the speed indicated on the machine surpass the speed indicated on the wheel blotter or any other document. When wheels are operated faster than what is implied by the term "MOS," they may shatter and result in tragic accidents. 

• The wheel should fit on the spindle freely yet securely.

• The flanges must be secured tightly and run true to the spindle in order to attach the grinding wheel to the spindle without exerting any effort. They should have flat, burr-free bearing surfaces. Any foreign object in the space between the wheel and the flange may produce localised pressure or tension, leading to the breakage of the wheel.

• If a bush is employed, it shouldn't extend past the wheel and blotters. 

• A wheel must run unrestricted and at its maximum operational speed for at least one minute after installation. This test run is appropriate for both new and used wheels that have been installed again for grinding. 

• Never grind something that the wheel isn't made to handle. 

• Except when the wheel is made for such purpose, avoid grinding on the side of the wheel. 

• The operator should always wear safety goggles and face shields since grinding operations produce sparks and swarf. To help the operator operate safely and effectively, protective gear including aprons, gloves, and safety shoes should also be used.

• Operators should be given dust masks for specific grinding operations when the production of swarf or dust is particularly high. 

• Never apply pressure or force to the face or perimeter of wheels to stop them. The wheel should be permitted to stop on its own instead.

FOR SAFE GRINDING, THE RIGHT MOUNTING 

Despite the fragility of all grinding wheels, they are safe to use as tools when handled and used correctly. They can, however, provide substantial safety risks if misused. 

Studies have shown that inappropriate mounting accounts for a significant portion of all accidents that occur on the factory floor, making it the most prevalent kind of abuse. There are now laws in several nations that require training in the proper installation of abrasive wheels.

Grinding wheels can endure significant compressive loads, but they rapidly give way under tensile or bending forces. Near the bore, all significant stresses that manifest in a grinding wheel during operation reach their peak levels. The mounting flanges are made such that only compressive stresses which operate on the wheel away from the bore are applied to wheels. A large portion of the wheels are supported by symmetrical flanges. The bearing region is suitably far from the hole, and these flanges are alleviated close to the bore. The bearing area is influenced by the wheel's size and external pressures. The flanges must be sufficiently robust and withstand deflection when they are fastened onto the wheel. They should be constructed from high-quality mild steel or a comparable material.

Types of mounting 

The size, shape, and kind of grinding operation all affect how wheels are mounted.

1. Straight Wheels with small holes

Bench and pedestal grinders often utilise these wheels. 

The wheel is supported by two flanges of equal diameter. To prevent slippage between the flange and the spindle, the driving flange is essential. Other than that, both flanges are symmetrical. The recessed areas divert the increasing loads from the hole. The stresses concentrate in the bore area because the flanges are not recessed and there is no blotter to offer a cushioning effect when the nut is tightened between the wheel face and flanges. Wheel damage can be readily caused by this mounting style.

2. Straight Wheels with large holes 

High speed snagging frequently uses straight wheels with big holes. Adaptor flanges are utilised in place of putting the wheel directly on the spindle. The corner's undercut makes it easier to place things correctly. 

Sleeve flanges are used to instal large precision grinding wheels. One of the flanges for holding the wheel is machined into the wheel holder, or collet. The collet is secured in place by a lock nut and fits the tapered end of the spindle. It is common practise to maintain wheels with varying specifications installed on the sleeve and available so that the entire installation may be changed quickly.

3. Cylinder Grinding Wheels

These wheels are attached to a wheel head or rear plate using mechanical clamps or cement. Mechanical clamps should fit the OD of the wheel and offer strong holding when employed.

4. F-Type Grinding Wheels (Nut inserted Grinding Wheels). 

Commonly used for disc grinding operations, these wheels are attached using steel nuts that are recessed into the side. The face plate's hole and the wheels' nuts should precisely line up. In order to prevent the nut from being pulled off the wheel, the screw's penetration should be smaller than the depth of the nut. The face plate needs to be flat and of a sufficient thickness to offer consistent support throughout a sizable region of contact. The face plate has to be carefully cleaned before installation. The screws need to be snugly tightened in a diametrical order.

5. Segments Grinding Wheels

The common configurations for mounting segments are shown in a typical mounting for abrasive segments. 

Dovetailed wedges installed on the chuck's outside edge hold these pieces in place. Blotters should be placed between the segments and the wedges. To ensure that worn-out wedges are not utilised for clamping, these wedges should be frequently inspected. Such wedges will shatter as a result of unequal mounting pressures. Theoverhangofthesegmentshouldnotexceeditsthickness.

6. Cup Grinding Wheels

For sharpening cutting tools on fixed equipment, cup wheels are frequently employed on tool and cutter grinding machines. The sleeve type flanges mentioned before are comparable to the flanges used for attaching cup wheels.

Cup wheels with plain or threaded holes are used with portable machines. Adaptor flanges are used to instal plain wheels as seen in Screws are used to attach wheels with threaded holes to the machine's spindle end up against the flange. The flange should not be recessed and should be flat. The threaded bushings would be put under strain by recessed flanges. Blotters are superfluous.