| Problem | Cause | Correction |
|---|---|---|
| Bell-mouthed hole | Tipped work head |
Realign work head |
| Misalignment of center heights | Carefully "zero" centers | |
| Over traveling of wheel | Reduce over travel from both ends | |
| Burning of workpiece | Wheel too hard | Use softer grade wheel |
| Work speed too slow | Increase work speed | |
| Wheel infeed too fast | Reduce wheel infeed | |
| Poor coolant flow | Ensure coolant directed at grinding contact | |
| Chatter Marks | Wheel too hard | Use softer wheel |
| Spindle material not rigid enough | Replace spindle | |
| Defective belt | Replace belt | |
| Wheel out of balance or truth | Balance and/or true wheel... avoid use of bushed wheels | |
| Dust or other particles inside wheel pully motor | Clean inside surface of pulleys | |
| Worn spindle Machine not on solid foundation | Replace spindleAssure machine is properly aligned and not adjacent to heavy vibrating machines | |
| Chatter Marks | Out of balance | Balance carefully on own mount in and rebalance after truing operation |
| Out of round | True before and after balancing | |
| Acting too hard | Use faster dressing feed and traverse | |
| Checking or Burning of the Work | Wheel too hard Poor dress |
Use a faster dress to open the wheel |
| Diamond Lines in Work | Dressing too fast | Slow dress the wheel face |
| Feed lines or spirals on workpiece | Poor wheel dressing | Redress wheel carefully |
| Wheel too hard | Use softer wheel or reduce wheel feed | |
| Wheel head tipped | Realign wheel head | |
| Inaccuracies in Work | Improper dressing | Check alignment of dress |
| Out-of-round hole | Overheated during previous rough grinding andbecome distorted | Before finish grinding, loosen clamp and retighten one at a time |
| Rotating fixture out of balance | Balance rotating fixture | |
| Hole distorted after front face grinding | Grind front face before grinding the hole | |
| Rate of Cut too Slow | Dressing too slow | Increase the dressing rate to open the wheel face |
| Scratching of the Work | Coarse grit or loading of foreign matter in wheel | Dress the wheel |
| Scratching of work | Wheel too soft | Use harder grade wheel |
| Faulty wheel dressing | Check for cracked or loose diamond and redress | |
| Wheel too coarse | Use finer grit wheel | |
| Dirty coolant | Change coolant | |
| Tapered hole | Wheel too soft | Use harder grade wheel |
| Uneven travel past each end of hole | Adjust over travel to be equal on both ends | |
| Wheel Acting too Soft (not holding size) | Improper dress | Use lighter dressing feed Possibly slow down traverse rate |
| Wheel glazing (shiny appearance) | Wheel too hard | Use softer grade wheels |
| Wheel too fine | Use coarser grit wheel | |
| Poor wheel dressing | Check diamond sharpness and redress | |
| Poor quality/quantity coolant | Reduce oil level and increase amount of coolant | |
| Wheel Loading | Infrequent dress | Dress wheel more often |
| Wheel loading (metal lodged in wheel pores) | Wheel too fine | Use coarser grit wheel |
| Wheel too hard | Use softer grade wheel | |
| Wheel too finely dressed | Give a more open dressing to wheel | |
| Poor coolant | Increase supply and clean coolant | |
| Insufficient wheel breakdown | Increase work and traverse speeds |
