Grinding has traditionally been associated with small rates of material removal and fine finishing operations. However, grinding can also be used for large metal removal operations.
In creep feed grinding, the wheel depth of cut (d) is as much as 6mm and the workpiece speed is low. The wheels are mostly softer grade resin bonded and with open structure, to keep temperatures low and improve surface finish. The machines used for creep feed grinding have special features, such as power up to 225KW, high stiffness, high damping capacity, variable spindle and work table speeds and ample capacity for grinding fluids. Grinders with capabilities for continuously dressing the grinding wheel with a diamond roll are now available.
Creep feed grinding is competitive with other machining processes and economical for specific applications such as the grinding of shaped punches, key seats, twist drill flutes, the roots of turbine blades and various complex and super alloy parts.
Because the wheel is dressed to the shape of the workpiece to be produced, the workpiece doesn’t have to previously milled, shaped, broached. Therefore near net shape castings and forgings are suitable parts for creep feed grinding. Although, generally one pass is sufficient, a second pass may be necessary for improved surface finish.