​Comparison between double disc grinding machine and surface grinding machine

In the field of modern machining, the grinding process, as a key means of high-precision processing, is widely used in the surface processing of various parts. Double disc grinder and surface grinder are two common types of grinding equipment, and there are significant differences between them in terms of structural design, working principle and application areas. In this paper, we will compare the double disc grinder and surface grinder, and analyze their respective advantages and disadvantages as well as applicable scenarios.

First. Working Principle and Structural Design

The working principle of  surface grinder is relatively simple, and its core is to grind one plane of the workpiece through the rotation of the grinding wheel. The grinding wheel is mounted on a horizontal or vertical axis, and the workpiece is usually fixed to the table by means of a magnetic suction cup. The table can be moved in a straight line while the grinding wheel is fed vertically or horizontally to complete the grinding process on the surface of the workpiece. Surface grinders generally grind only one side of the workpiece.

The double disc grinder has a more complex working principle, which uses two grinding wheels mounted opposite each other to simultaneously grind the upper and lower faces of the workpiece. The workpiece is located between the two grinding wheels, and the workpiece is driven through the grinding zone by a feed device to achieve simultaneous processing of the upper and lower faces. This design enables the machine to simultaneously grind both sides of the workpiece in one machining process, which greatly improves the machining efficiency and accuracy.

Second. Machining efficiency

Due to the difference in structural design, double disc grinding machine has a significant advantage in machining efficiency. Surface grinders can only process one plane of the workpiece at a time, and usually require two or more clamping operations to complete double-sided machining. On the other hand, a double disc grinder can process both the upper and lower faces of a workpiece in one clamping, greatly reducing clamping time and repetitive positioning errors.

In addition, double disc grinding machine has higher feed rate and grinding speed, which is suitable for mass production, especially in the field of automotive parts, bearings and other areas that require high efficiency and high precision machining, double face grinding machine can significantly improve productivity. On the other hand, Surface grinding machine is more suitable for single piece or small batch processing, with wide applicability but lower efficiency.

Third. Machining accuracy and surface quality

The machining accuracy of surface grinder mainly depends on the balance of the grinding wheel, the movement accuracy of the table and the fixing method of the workpiece. Since it can only grind on one side, the machining process is prone to thermal deformation and clamping errors, which affect the parallelism and surface quality of the workpiece. Therefore, although the surface grinder is capable of processing high-quality surfaces, its limitations are more obvious in the processing of workpieces requiring high parallelism.

Double disc grinder since two planes of the workpiece can be ground at the same time in a single pass, it is possible to obtain high-precision machining results with guaranteed parallelism. The synchronized movement of the upper and lower grinding wheels reduces the positioning error of the workpiece in multiple clamping and improves parallelism and dimensional consistency. In addition, the grinding force of the double disc grinder is uniformly distributed on both surfaces of the workpiece with less thermal deformation, which helps to improve the machining surface quality and geometric accuracy of the workpiece.

Fourth. Fields of application

Surface grinding machines are widely used for surface grinding of various parts due to their flexibility and wide range of application. Especially in mold manufacturing, tool processing and some processing scenarios that require high single-sided flatness, surface grinding machines have an irreplaceable role. Its applicable materials are also very wide, including metal, ceramics, plastics and other materials.

Double disc grinding machines, on the other hand, are mainly used in the processing of parts with high requirements for parallelism, especially in the occasions where both upper and lower planes need to be processed at the same time, such as bearing rings, gears, piston rings and other mechanical parts. Due to their high efficiency and accuracy, double face grinding machines are often used in mass production in industries such as automotive, aerospace, and home appliances. Double disc grinding machines are suitable for regular shaped workpieces, while surface grinding machines are more suitable for irregular shaped or large sized workpieces.

Fifth. Cost and equipment complexity

In terms of equipment cost, surface grinder has a relatively simple structure and low manufacturing cost, so the price is relatively more economical. They are a common choice for small and medium-sized factories and workshops due to their ease of operation and low maintenance costs.

In contrast, double disc grinder has a higher equipment cost due to its complex mechanical structure and sophisticated control system. In addition, the operation and maintenance requirements of machines are relatively high, requiring skilled technicians to ensure their stable operation. Therefore, the initial investment and maintenance cost of double disc grinding machine is higher than that of surface grinding machine, but in long-term mass production, its high efficiency and high precision can bring larger economic benefits.

Sixth. Maintenance and servicing

The maintenance of surface grinder is relatively simple, which mainly involves the replacement of grinding wheels, the maintenance of lubrication system and the calibration of table and fixture. On the other hand, the maintenance of it is more complicated due to its complex structure, which not only requires regular checking of grinding wheel wear, but also the synchronization of upper and lower grinding wheels to be calibrated. In addition, the automation control system of the double disc grinding machine also needs to be checked and updated regularly to ensure the stable operation of the equipment for a long time.

Conclusion

Double disc grinding machines and surface grinding machines have their own advantages and disadvantages and are suitable for different processing needs. Surface grinders are suitable for diversified small batch production due to their wide applicability and low cost. On the other hand, with its high efficiency and high precision, it has obvious advantages in large-volume and high-precision machining scenarios. When choosing equipment, enterprises should rationally select suitable grinding equipment according to the characteristics of processed parts, production scale and budget.