Grinding is one of the common processing methods in industrial production. During the grinding process, the grinding tool and abrasive will process the surface of the object to achieve a smooth and precise surface effect.
However, waviness (also known as sand marks or grinding marks) may occur during the grinding process, which will have a negative impact on surface quality. Therefore, how to avoid the generation of waviness in the grinding process has become a significant issue of concern.
This article will introduce the causes and effects of waviness problems in the grinding process, as well as effective measures to avoid the generation of waviness. By learning from this article, you can better understand the nature of waviness problems, improve the stability and consistency of surface quality in the grinding process.
What is waviness, and how is it formed?
During the grinding process, the vibration marks refer to the surface shape that resembles ripples formed on the object surface due to the interaction between the grinding tool, abrasive, and the object being ground. These vibration marks can negatively impact surface quality, such as surface irregularities, uneven cutting or grinding.
The formation of vibration marks is caused by the interaction between the abrasive, grinding tool, and the surface of the object during the grinding process. When the abrasive and grinding tool encounter the object surface, they will generate vibrations, and these vibrations will form a ripple-like shape on the surface.
The shape and size of vibration marks depend on several factors, including the size, shape, hardness of the abrasive particles, grinding pressure, grinding speed, as well as the shape and material of the grinding tool. In addition, uneven wear of the grinding tool may also cause the formation of vibration marks. When the grinding tool is unevenly worn, the abrasive will form bumps and depressions on the surface, which in turn causes the formation of vibration marks.
Surface waviness caused by vibration during the grinding process can have various negative effects on surface quality, ultimately leading to a degradation of the surface quality. The following are the main types of damage to surface quality caused by waviness:
| Main damages: | How it causes damage: | negative effects |
| Uneven surface | Vibration marks cause surface irregularities by creating wave-like surface shapes. | It will have a negative impact on the surface appearance and optical performance, especially for products with higher requirements for surface quality. |
| Uneven surface | The formation of vibration marks causes surface irregularities, which results in uneven cutting or grinding. | It will affect the size and shape of the surface, thereby affecting the overall performance of the product. |
| Uneven cutting or grinding | Vibration marks can create micro-cracks on the surface, which leads to a decrease in surface quality. | This is particularly detrimental for products that require high surface quality, such as optical components and precision instruments. |
How to prevent the generation of vibration marks?
Here are some tips to avoid the generation of chatter marks during the grinding process:
Choose appropriate grinding parameters
Reasonable selection of grinding parameters, such as grinding force, feed rate, and speed, can reduce the possibility of vibration. Generally, low grinding force and feed rate should be used, while speed should be increased appropriately.
Control the temperature during grinding
Excessive temperature during grinding can also cause chatter marks. Therefore, the temperature during the grinding process should be controlled, such as by increasing the amount of coolant used or reducing the grinding time.
Select appropriate grinding tools
Different grinding tools have different effects on surface quality. Choosing suitable grinding tools can reduce the generation of vibration. For example, using grinding discs and heads with high flatness and rigidity.
Proper processing sequence
For complex-shaped workpieces, the processing sequence during grinding will affect the surface quality. Usually, rough grinding should be performed first, followed by fine grinding, and then polishing, which can reduce the generation of vibration.
Use appropriate abrasives
The selection of abrasives also affects surface quality. Using abrasives with higher grinding efficiency and lower grinding force can reduce the generation of vibration.
Conclusion
To avoid the generation of chatter marks during the grinding process, control and adjustments must be made from multiple aspects, and appropriate adjustments should be made according to the actual situation.
