Common thin parts like washers, friction plates, templates, and thin plates pose challenges during grinding due to their poor rigidity, difficulty in heat dissipation, warping after heat treatment, and deformation caused by clamping. Grinding these on a surface grinder using a magnetic chuck often results in warping. After grinding, when the magnetic force is released, the thin workpiece springs back to its original shape, making it difficult to achieve the required machining accuracy. Employing the following clamping methods ensures the workpiece is positioned and clamped in a free state and ground using double-sided grinding, yielding excellent results and meeting part accuracy requirements.
(1) Clamping with Elastic Pads
When grinding the aforementioned thin workpieces on a surface grinder, an elastic clamping mechanism is used to position and clamp the workpiece in its free state. Place a 0.5mm thick rubber pad between the workpiece and the magnetic table. When the magnetic force acts on the workpiece, the rubber compresses, resulting in minimal elastic deformation. This allows grinding a flat plane. Repeating the grinding process several times achieves the required accuracy.
(2) Temporarily Reinforcing Workpiece Rigidity
Use an epoxy resin adhesive to bond the thin workpiece in its free state onto a flat plate. Place the plate with the bonded workpiece onto the magnetic chuck. After grinding one side flat, remove the workpiece from the plate. Place the ground side onto the magnetic chuck and grind the opposite side. Before hardening, the fluid epoxy resin fills any gaps between the workpiece and the plate. Once hardened, the workpiece and plate become a single rigid unit, significantly increasing the workpiece's rigidity. Under magnetic force, the thin workpiece won't deform, creating conditions for grinding a flat surface. High-viscosity grease can also be used instead of epoxy resin to fill the gap between the workpiece and the magnetic chuck, enhancing rigidity with similarly good results.
(3) Mechanical Clamping Method
Use a small bench vice (a common surface grinder attachment). The vice itself is held onto the magnetic table. Because the vice has height, the clamping force on its jaws is reduced. Grind one side of the workpiece flat using a method where the feed rate is gradually reduced. Remove the workpiece, place the ground side onto the magnetic table, and then grind the opposite side. Repeating this process several times achieves the required flatness for both sides.
(4) Vacuum Clamping Method
This method uses atmospheric pressure to clamp thin workpieces for grinding. The principle is: The fixture body has a rubber sealing ring. Placing the thin workpiece on this ring creates a sealed cavity between the workpiece and the fixture. A vacuum pump evacuates air from this cavity via an exhaust port, clamping the workpiece. Due to the relatively small clamping force, peripheral grinding methods are suitable. After grinding one side satisfactorily, the workpiece can be flipped and clamped using the same method to grind the opposite side, achieving equally satisfactory results.
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