The key to successful grinding is the proper selection and proper application of the cutting fluid. Generally, the longer the arc of cut, the greater the need for more of a wetting/cooling, synthetic fluid, as opposed to the smaller arc lengths where highly lubricating fluids with EP (Extra Pressure) additives will be necessary. Companies are becoming more discerning with regard to the performance as well as the environmental impact of the cutting fluids they purchase.

It is peculiar that such importance is given to the chemistry, yet the mechanics of actually applying the fluid correctly is almost reckless. Large volumes of fluid are squirted toward grinding wheels in the vain hope that with enough pressure the fluid might just get between the grinding wheel and the workpiece and even into the arc of cut.

The matching of the speed of the fluid exiting the nozzle to the velocity of the grinding wheel ensures proper fluid application. So, few companies design their nozzles scientifically, settling for a bent piece of copper pipe or a flexi-joint piece of plastic hose to direct the fluid in some “good looking” direction.

Ideally, the grinding machines of the day need to have higher wheel speeds, be constructed with higher rigidity and exhibit good vibrational stability – all in a small footprint. They also need to be fully enclosed, yet easy to clean and service as well as not leak fluid or fumes. A precious few machine tool builders are embracing those ideals.

The potential for advances in grinding applications, especially over the conventional “large-chip” making processes is phenomenal, but they are not for everyone. Look to the types of materials and the complexity of the form on the surface of those parts. Look carefully at the condition of those machine tools. The next time you are looking for a new “large-chip” making machine, perhaps consider grinding as the alternative.