KEVOS® MAKEOS · Manufacturing
Surface Grinding Planner (Speeds, Removal Rate, Power and Time)
What wheel speed, removal rate and spindle power does this surface grinding job need, and how long will it take?
Plan of a reciprocating surface grinding operation with the wheel covering the work width: wheel surface speed against the wheel’s maximum operating speed, speed ratio, contact length (as the grinding geometry tool), equivalent chip thickness, specific removal rate and removal rate, grinding power from your specific grinding energy against the spindle power, and passes and time for the stock with spark-out passes.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Wheel diameter | mm | Diameter of the grinding wheel. |
| Wheel speed | rpm | Spindle speed. |
| Wheel maximum operating speed (marked) | m/s | Maximum operating speed marked on the wheel; never exceed it. |
| Table speed | m/min | Table (work) speed. |
| Depth per pass | mm | Down-feed per pass. |
| Width ground | mm | Width of the ground surface (the wheel covers it in each pass). |
| Work length | mm | Length of the work. |
| Overtravel each end | mm | Overtravel beyond the work at each end. |
| Stock to remove | mm | Total depth to remove. |
| Spark-out passes | Passes with no down-feed at the end. | |
| Specific grinding energy | J/mm³ | Specific energy to grind the material with this wheel (your value from tests or the wheel maker; much higher for fine finishing cuts). |
| Spindle motor power | kW | Rated power of the spindle motor. |
| Spindle efficiency | % | Share of motor power available at the wheel. |
Method and formulas
- Wheel speed v_s = π d_s n_s ÷ 60 000; speed ratio = v_s ÷ v_w.
- Contact length l_g = √(a_e d_s) (as the grinding geometry tool); equivalent chip thickness h_eq = a_e v_w ÷ v_s.
- Removal rate Q = a_e b_w v_w; power = u Q.
- Passes = stock ÷ a_e (rounded up) + spark-out; time = passes × (L + 2 overtravel) ÷ v_w.
- Example: the wheel runs at 34.034 m/s; removing 100 mm³/s takes 3 kW and the job takes 0.51333 min.
Limitations
- One stroke per pass (wheel at least as wide as the work); cross-fed grinding needs more strokes.
- Specific energy varies strongly with wheel sharpness and depth of cut.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Plan a surface grinding operation
- Check the spindle power for a deeper cut
- Check a wheel speed against its marked maximum
Who it is for
- Grinding machinists
- Process planners
- Manufacturing engineers
What you get
- Wheel speed, speed ratio and contact length
- Removal rate and grinding power
- Passes and grinding time
Interpreting the result
- Halving the depth per pass halves the power but doubles the passes; a faster table can keep the time down.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1199–1268. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
Open the Surface Grinding Planner (Speeds, Removal Rate, Power and Time) calculator
