This page has been edited 34 times. The last was made by - gheuer gheuer on May 19, 2015 11:57 am GMT



11.2 Profile Grinder

Considerations

  • Pre-Operation Checklist is a prerequisite for ANY operation.
  • Operator clears machine and cleans work area after use.
  • Required OSHA approved personal protective equipment is worn.
  • Lock-out/Tag-out procedure is in place and followed.

Pre-Operation Checklist

Level 1

Performance Standard -
  • Verifies the wheel is sound, without cracks or chips, dressed properly.
  • Verifies the wheel is properly guarded.
  • Verifies distance between the tool rest and the edge of the wheel does not exceed 3 mm (1/8") [0.125"].
  • Verifies tool rest is adjusted and tightened securely.
  • Assures water for quenching is close at hand, ready to use.
  • Assures no combustibles are within proximity to the tool.

Level 2

Performance Standard -
  • Selects wheel(s) appropriate to tasks.
  • Select appropriate knife stock.
  • Cut, square and balance knife blanks.
  • Verifies that grinding wheel will not contact cutter head.
  • Verify axial position of cutter head and template to pin and wheel.
  • Installs wheel on hub.
  • Uses diamond dresser to side dress wheel to match tracing pin.
  • Uses diamond dresser to dress edge/face of the wheel to match tracing pin.
  • Inserts template in holder.
  • Inserts proper tracing pin.
  • Sets wheel rim at calibration point.
  • Places cutter head on grinding arbor.
  • Inserts knives into cutter head at desired projection.
  • Squares ends flush with cutter head end.
  • Installs cutter head properly for grinding.
  • Sets appropriate grinding angle.
  • Sets grinding wheel speed.
  • Set coolant supply, flow rate, and nozzle position.
  • Demonstrate ability to replace coolant and filter.


11.2.1 - Template Making

Level 1 - N/A

Level 2

Given known profile in the form of a sample or illustration, make grinding template manually.
Performance Standard -
  • Compiles dimensional data
  • Creates accurate dimensioned drawing
  • Calculates the size of the template stock required
  • Cuts and squares template blank
  • Scribes points and pattern on blank
  • Cuts and files blank to scribe marks, ±0.001"
  • Smooths profile outline, removing file marks


11.2.2 - Knife Stock Preparation

Level 1 - N/A

Level 2

Given known profile data, prepare high speed steel knife stock for profile grinding.
Performance Standard -
  • Determines length and width of knife stock required
  • Selects correct stock for cutter head ( 60° OR 90° corrugations)
  • Cuts material to length and squares one end of each knife
  • Balances knives by grinding the non-squared ends to ±0.1 gram


11.2.3 - Profile Grinding

Level 1

Given profile grinder set up and ready, grind knives to installed profile.
Performance Standard -
  • Grinds to a dimension tolerance of ±0.4 mm (1/64") [0.0156"]
  • Cut surfaces exhibit uniform grinding marks without burning or defects
  • Maintains reference point for set up where required
  • Redresses grinding wheel rim as required due to use and wear during grinding
  • Maintains side clearance to intersect with the profile, but MUST NOT alter the profile
  • Steel shows no sign of overheating (annealing)

Level 2

Given knife stock and profile data, set up profile grinder, grind the knives to profile.
Performance Standard -
  • Determines knife projection, based on profile depth
  • Sets correct wheel speed
  • Produces sharp corners where required by adjusting wheel profile with dresser
  • Grinds 5° -10° side clearance on all parts of the profile that exceed 55° away from parallel with the cutter head axis
  • Meets Level 1 performance standard