How to Extend the Life of a Centerless Grinding Machine？

Centerless grinders are high-precision grinding machines primarily used for batch processing of cylindrical workpieces (such as shafts and bearings). Their lifespan is affected by factors such as mechanical wear, proper operation, and maintenance. Proper use and maintenance can extend the lifespan of the machine and reduce the failure rate.

1. Standardize operation to reduce abnormal wear
Reasonably select grinding parameters
Grinding wheel linear speed: control within 30~35 m/s (too high will easily cause vibration, too low will affect efficiency).
Feed rate: increase appropriately during rough grinding, reduce during fine grinding to avoid overload.
Workpiece speed: match the grinding wheel speed to prevent surface burns or vibration.
Avoid overload operation
It is forbidden to process workpieces that exceed the rated size or hardness of the machine tool (such as hardened steel without annealing).
The machine should be stopped intermittently during long-term continuous operation to prevent overheating of the motor and spindle.
Proper clamping and adjustment
Ensure that the center of the workpiece is aligned with the guide wheel and the grinding wheel center to reduce eccentric wear.
Regularly check the guide wheel inclination to avoid spiral marks on the workpiece due to angle deviation.

2. Maintenance and care of key components
(1). Grinding wheel system
Dynamic balancing correction: Dynamic balancing must be performed after the new grinding wheel is installed to reduce vibration (check once every 3 months or after replacing the grinding wheel). Dressing frequency:
Coarse grinding: Dress every 4~8 hours.
Fine grinding: Dress every 1~2 hours (use a diamond dressing pen).
Storage conditions: The grinding wheel must be protected from moisture and collision to prevent aging of the resin adhesive.
(2). Lubrication system
Guide rails and screws: Use ISO VG32~68 guide rail oil and manually lubricate before each shift.
Spindle bearings: Use high-speed lithium-based grease for lubrication and replenish every 500 hours.
Hydraulic system: Replace the filter element regularly (recommended every 6 months), and control the oil temperature at 30~50℃.
(3). Transmission components
Belt tension: Too loose will cause slippage, and too tight will increase the bearing load (pressing with your finger should result in 5~10mm deformation).
Guide wheel bearings: Check the clearance every 2000 hours. If it exceeds 0.02mm, it needs to be replaced.

3. Daily maintenance and inspection
Daily maintenance
Clean up grinding chips and coolant residue to prevent rust. Check the coolant concentration (5%-10% is recommended for emulsions) and filter out impurities.
Weekly Inspection
Tighten the anchor bolts and motor base screws.
Test safety devices (such as emergency stop buttons and limit switches).
Quarterly Maintenance
Disassemble and clean the hydraulic valve assembly and inspect the piping for leaks.
Calibrate the machine tool level (tolerance ≤ 0.02 mm/m).

4. Optimize Environment and Usage Habits
Dust and Moisture Prevention: Maintain workshop humidity between 40% and 60% to prevent short circuits in electrical components.
Train operators: Prohibit illegal operations (such as sudden speed changes and forced tool feed).
Spare Parts Management: Stock up on consumable parts (such as bearings and belts) to minimize downtime.

Common Problems and Solutions