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Sharp SHDC Series Instruction Manual
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Sharp SHDC Series Instruction Manual

Sharp SHDC Series Instruction Manual

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SURFACE
GRINDERS
- SHDC INSTRUCTION MANUAL -
SHARP INDUSTRIES, INC.
3501 CHALLENGER STREET, TORRANCE, CA90503, USA
TEL: 310-370-5990
FAX: 310-542-6162
E-MAIL: support@sharp-industries.com
www.sharp-industries.com

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Summary of Contents for Sharp SHDC Series

  • Page 1 SURFACE GRINDERS - SHDC INSTRUCTION MANUAL - SHARP INDUSTRIES, INC. 3501 CHALLENGER STREET, TORRANCE, CA90503, USA TEL: 310-370-5990 FAX: 310-542-6162 E-MAIL: support@sharp-industries.com www.sharp-industries.com...
  • Page 2 SHARP INDUSTRIES, INC. PREFACE 1. This instruction manual is for SHARP SHDC series ONLY. Please keep this manual in a safe place where operators can easily access to when necessary. Please read this instruction manual carefully before operating SHARP machine.

  • Page 3: Safety Instruction

    15. Keep the chuck surface clean. If it is scratched, re-grind it immediately. 16. It is obligated to wear gloves while loading sharp work pieces. Please use cranes for loading bigger-sized work pieces, especially the ones are over 25 kg.
  • Page 4 30. Please read the warning signs carefully before checking the power source. 31. Any machine modifications should be approved by SHARP. 32. All electrical components must be properly grounded and comply with the EN60204-1:1997 or the local regulations for the safety concern. Failure to do so will void the warranty.
  • Page 5 (if installed this optional accessory). Please check page 50 for more details. 38. SHARP warranty of each machine is based on an 8-hour standard operation per day. If the machine is operating more than 8 hours per day, please note that SHARP has the right to shorten the warranty period to 6-month.

  • Page 6: Hydraulic System

    SHARP INDUSTRIES, INC. W A R N I N G W A R N I N G 1. The wheel spindle turns counterclockwise. 2. The wheel should bear peripheral speed 2300 m/min or up. 3. The spindle rotation speed is 1150 (60Hz/50Hz) min 4.
  • Page 7 SHARP INDUSTRIES, INC. DO NOT COMPRESSED AIR to clean the coolant channel and working table because the airborne grits and dusts will damage the slideways. ※ The chuck surface hasn’t been grinded before delivery. ※ Please grind it after proper installation of the machine.
  • Page 8 SHARP INDUSTRIES, INC. MACHINE WITH ONE STANDARD HORIZONTAL HEAD SHDC INSTRUCTION MANUAL P. 8 OF 51...
  • Page 9 SHARP INDUSTRIES, INC. FUNCTIONS OF PANEL SA0: Emergency stop. SB1: Main power “ON”. SB0: Main power “OFF”. SB01: Door unlock. SA100: Electro-magnetic chuck switch for magnetization and demagnetization. DL100: Chuck magnetization / demagnetization display. RP101: Demagnetization time. RP102: Adjustment for magnetic attraction.
  • Page 10 SHARP INDUSTRIES, INC. MACHINE WITH ONE ADDITIONAL VERTICAL HEAD (OPTION) SHDC INSTRUCTION MANUAL P. 10 OF 51...
  • Page 11 SHARP INDUSTRIES, INC. FUNCTIONS OF PANEL SB71: Vertical grinding wheel “ON”. SB10: Vertical grinding wheel “OFF”. RP71: Vertical grinding wheel speed adjuster. RPM: Vertical grinding wheel speed meter. SB371: Vertical grinding wheel cross feed forward button. SB372: Vertical grinding wheel cross feed backward button.

  • Page 12: Table Of Contents

    SHARP INDUSTRIES, INC. -- TABLE OF CONTENTS-- 1. Loading & Transportation ............P.13 2. Installation ..................P.13 3. Foundation Plan ................P.16 4. Lubrication, Hydraulic Oil, and Maintenance ......P.16 5. Before Initial Use ................P.20 6. Consice grinding operation ............P.22 7.

  • Page 13: Loading & Transportation

    SHARP INDUSTRIES, INC. 1. Loading & Transportation 1.1 This grinding surface machine has to be loaded / unloaded by fork-lift trucks, cranes, or elevating platforms. Do not put rolling bar under the bottom of machine. 1.2 All clamps, clamp bolts, and anti-sliding wooden blocks for transition can not be removed until the machine is completely installed.
  • Page 14 SHARP INDUSTRIES, INC. SHDC INSTRUCTION MANUAL P. 14 OF 51...
  • Page 15 SHARP INDUSTRIES, INC. Figure 1.1 SHDC INSTRUCTION MANUAL P. 15 OF 51...

  • Page 16: Foundation Plan

    SHARP INDUSTRIES, INC. 3. Foundation Plan NOTE:  This foundation plan is for reference only.  The dimension of foundation plan may be varied with different models. 4. Lubrication, Hydraulic Oil, and Maintenance 4.1 Please use recommended lubricant and hydraulic oil ,and always fill it up to the full level of lubricant and hydraulic oil tank.
  • Page 17 SHARP INDUSTRIES, INC. Cross slide ways & The slide ways of column& Longitudinal table ways vertical lead screw cross lead screw 1. Automatic lubricate system. 1. Time-adjusting automatic 1. Time-adjusting automatic lubricate system. lubricate system. 2. Exchange oil every 6 2.
  • Page 18 SHARP INDUSTRIES, INC. SHDC INSTRUCTION MANUAL P. 18 OF 51...
  • Page 19 SHARP INDUSTRIES, INC. 4.5 Hydraulic Motor, Oil Tank Capacity, and Lubricant Capacity MODEL HYDRAULIC MOTOR OIL TANK CAPACITY LUBRICANT CAPACITY PSGS-2045H 1 HP 60 L PSGS 1 HP 60 L PSGS 2 HP 90 L PSGC 5 HP 120 L...

  • Page 20: Before Initial Use

    SHARP INDUSTRIES, INC. 5. Before Initial Use 5.1 Please check the following information before initial use. Are power lines properly and correctly connected with the power terminal? Are motors & pumpers turning on the right direction? C. Are the machine properly grounded? D.
  • Page 21 SHARP INDUSTRIES, INC. counterclockwise direction. If not, change any two wires of RO, SO, and TO. If the input voltage of machine is different from that of power source, refer the following steps to resolve it. 5.2.11 Change transformer connections TR1, TR2, TR3 to make them comply with the voltage of our machine;...

  • Page 22: Consice Grinding Operation

    SHARP INDUSTRIES, INC. 6. Consice grinding operation 6.1 Grinding operation 6.1.1 Turn "SA0"clockwise and press "SB1" button to turn on the power of machine. 6.1.2 Turn "SA100" switch to make the magnetizing chuck under "ON" status. 6.1.3 Adjust table dogs T1& T2 position in order to get the desired setting distance.
  • Page 23 SHARP INDUSTRIES, INC. Figure. 3 SHDC INSTRUCTION MANUAL P. 23 OF 51...
  • Page 24 SHARP INDUSTRIES, INC. 6.3 Grinding wheel cross movement functions 6.3.1 Manual cross movement function 6.3.1.1 The function is always available whether the table is moving or not. 6.3.1.2 Turn the handle wheel to the left; the grinding wheel will move toward to operator.
  • Page 25 SHARP INDUSTRIES, INC. 6.3.4 Criss-cross movement function-special option 6.3.4.1 The function is only available when the table is moving. 6.3.4.2 Turn "SA31" knob to the right. 6.3.4.3 Press"SB31" button to make the auto cross-feed attachment start to move and the grinding wheel moves toward to the operator.
  • Page 26 SHARP INDUSTRIES, INC. 6.4 The upward/downward movement functions 6.4.1 Manual upward/downward movement function. 6.4.1.1 The function is always available whether the table is moving and the cross movement is working or not. 6.4.1.2 Turn the handle wheel to the left; the grinding wheel will move upward.
  • Page 27 SHARP INDUSTRIES, INC. 6.5.3.1 Drop an oil on a filter paper. 6.5.3.2 If oil color appears bright yellow on the filter paper, that means oil still keep clean and good quality, otherwise oil need to be changed immediately. 6.5.4 Table vibration 6.5.4.1...
  • Page 28 SHARP INDUSTRIES, INC. 6.5.5 Hydraulic system- Design are subject to change in accordance with order. For GP-1012, 1015, 1022, 1215, and 1222 only 1. Oil Filter (MF-16) 9. Hydraulic Hoses (**) 2. Hydraulic Pump (DVM-4V) 10. Main Spool chamber (PST-08) 3.
  • Page 29 SHARP INDUSTRIES, INC. 1. Oil Filter (MF-16) 9. Hydraulic Hoses (**) 2. Hydraulic Pump (DVM-5V) 10a. Flow Control Valve (PST-16) 3. Electric Motor (10Hx 6P) 10b. Directional Control Valve (PST-04) 4. Pressure Gauge (0~70kg/cm²) 10c. Pilot Valve (PST-16) 11. Cylinder (ψ125xψ50x**mm) 5.
  • Page 30 SHARP INDUSTRIES, INC. 6.6 Cooling system The advantage of wet grind as follows: 6.6.1 Reduce workpiece’s deformation due to overheat. 6.6.2 Reduce the risk of scorched surface of work piece. 6.6.3 Grinding grit on a wheel can easily be came off.
  • Page 31 SHARP INDUSTRIES, INC. 6.6.11 Recommended Water-based fluid (Fluid W/O Nitrite & Glycol) BRAND SERIES ARAL Multrol G100 CINCINNATI CIMCOOL Cimtech 100 FUCHS Ecocool S CO 5 OEMETA Unimet 280 or AS 192  The main cause of paint coming off is that water-based fluid is contained with nitrite and glycol.
  • Page 32 SHARP INDUSTRIES, INC. 6.6.12 Automatic Paper Stripe Filter Coolant Pump Conveyor Belt Drive Motor Filtration Paper Roll Convey Belt Float Switch Coolant Tank Waste Container SHDC INSTRUCTION MANUAL P. 32 OF 51...

  • Page 33: Machine Level Adjustments

    SHARP INDUSTRIES, INC. 7. Machine level adjustments The level of machine is a very important matter not only for the precision surface grinder but also for the accuracy of work-pieces; therefore we suggest our customers use the spirit level, which is accurate within 0.02 mm/M, 200mm in length for the machine level adjustment.
  • Page 34 SHARP INDUSTRIES, INC. 7.2 Straightness of table motion 7.2.1 Repeat step7.1.1. to 7.1.4. 7.2.2 Move spirites at the right and left positions by table motion to compare with the reference points. Straightness tolerance of table movement in both directions is 0.02/1000mm under 1000mm, 0.02/1000mm under 1000mm-2000mm or less.
  • Page 35 SHARP INDUSTRIES, INC. SHDC INSTRUCTION MANUAL P. 35 OF 51...

  • Page 36: Maintenance

    SHARP INDUSTRIES, INC. 8. Maintenance Interval Maintaining points Remark To keep the clean and oiled surface is a Working table surface necessity after working hours. Each Time *Re-correct wheel balance and re-clean up Grinding wheel the inner hole of wheel flange and the spindle.

  • Page 37: Wheel Mounting, Dismounting, Balance & Inspection

    SHARP INDUSTRIES, INC. 9. Wheel Mounting, Dismounting, Balance & Inspection Instructions & Conditions How to mount wheel Figure. 6 Wheel Mounting Check and inspect the wheel. The inspection progress is listed at Section D below. Insert the wheel (Part ) into the body of flange (Part ).
  • Page 38 SHARP INDUSTRIES, INC. How to dismount wheel Open the wheel cover and loose the spindle fixed bolt (Part ) by turning clockwise. Dismount the wheel from the spindle by using the wheel extractor (Part ). Loose screws (Part ) to separate the flange body (Part ) from the flange lock nut (Part ).
  • Page 39 SHARP INDUSTRIES, INC. C. Wheel balance The good wheel balance will cause the results not only in the high grinding precision but also in promoted longer lift of wheel, spindle, and bearings. Select appropriate wheel according to the requirements of your application.
  • Page 40 SHARP INDUSTRIES, INC. D. How to inspect the wheel Before using the wheel, the user have to check it up with their eyes to make sure of no cracks on the surface of wheel, then the user need to do the "ring"...
  • Page 41 SHARP INDUSTRIES, INC. D-1 To correct the level of wheel balance with spirit Spindle Fixed Bolt Extractor SHDC INSTRUCTION MANUAL P. 41 OF 51...
  • Page 42 SHARP INDUSTRIES, INC. Figure. C SHDC INSTRUCTION MANUAL P. 42 OF 51...
  • Page 43 SHARP INDUSTRIES, INC. D-2 The recommended wheels Surface Grinding The shape of horizontal wheel The shape of vertical wheel Hardness under 206-355 356-510 Cylinder / Ring Segmental wheel wheel Steel Carbon Under WA 46K WA 46J WA 36J WA 30J...
  • Page 44 SHARP INDUSTRIES, INC. NOTES:  Before adjusting the frequency of spindle motor inverter (optional), please calculate peripheral speed in accordant with a following formula. V=πDN D=wheel diameter (ψm), π=3.14, N=R.P.M. (spindle motor), V=peripheral speed (m/min), N=(120x f)/np, f=frequency (Hz), np=polar number (spindle motor) ...
  • Page 45 SHARP INDUSTRIES, INC. E-3. Table longitudinal traverse: Table Traverse Fast Slow Grinding Resistance Large Small Heat Produced Less Much Surface Finish Rough Fine Wheel Worn-out Much Little E-4. The peripheral speed of wheel for the table traverse: m/min Workpiece Heat-Treated...
  • Page 46 SHARP INDUSTRIES, INC. E-6. Down feed for grinding Workpiece Down Feed Material Cast Iron, Stainless & Cross Feed Soft Steel & Heat Resistant Tool Steel Grinding Hardened Steel Steel Feed amount is 0.0006~0.0012" 0.0008~0.0012" 0.0008~0.0016" smaller than the 1/2 Rough 0.015-0.03mm...

  • Page 47: Directional Control Arm Adjustment

    SHARP INDUSTRIES, INC. 10. Directional control arm adjustment If the table of machine is blocked at one side end, it can not be reversed by hydraulic system. When the above mentioned situation happens, the direction control arm L2, which have separated from its original position needs to be re-adjusted again.
  • Page 48 SHARP INDUSTRIES, INC. 10.1 Release the fixed screwdriver L5 after making a mark where the directional control arm L2 was stopped(Fig.10B). 10.2 Follow Fig.10D to disassemble the arm L2. 10.3 Slightly turning the arm L2 opposes direction with the desirable returning direction of table.

  • Page 49: Cross Traverse Setting System

    SHARP INDUSTRIES, INC. 11. Cross Traverse Setting System 11.1 The function and operation of electric touch cross traverse setting system. 11.1.1 The advantage of the electronic ' one-touch' system is to quickly electronically pre-set the beginning and end surface width of cross grinding to be accomplished.

  • Page 50: Electro Magnetic Chuck

    SHARP INDUSTRIES, INC. 12. Electro magnetic Chuck The electro magnetic chuck is an indispensable attachment for surface grinding machine. It requires a perfect flat mounting surface to be clamped to the machine table, otherwise table will be subjected to deformation due to the huge magnetic attracting force of chuck.
  • Page 51 SHARP INDUSTRIES, INC. Clamp the magnetic chuck to the machine table. 3.1 Rough grinding the chuck surface same as the grinding of the underside of the chuck, but with different clamping method. 3.2 Switch on the magnetic chuck and then fine grinding the surface with 0.005-mm wheel in-feed.