Grinding wheels are core consumables for grinding, cutting and polishing operations, and their working condition directly affects processing quality, operational efficiency and personal safety. Regular inspection and accurate judgment of wear degree are essential for every operator. There are multiple visible, tactile and operational signs to determine whether a grinding wheel has reached the end of its service life and requires timely replacement.

First of all, observe the outer diameter and edge wear of the grinding wheel. With continuous use, the wheel’s overall diameter gradually decreases. When the diameter shrinks to close to the minimum size marked on the product specification or the equipment manual, it must be replaced immediately. Besides, the working edge will become uneven, rounded or chipped after long-term grinding. A sharp wheel has a neat and angular edge for efficient cutting and grinding; once the edge turns round and blunt, the material removal rate drops obviously, and the surface finish of workpieces will become rough. If there are irregular gaps, large chipping or local collapse on the edge, the wheel loses its normal working performance and cannot be used any longer.

Secondly, check the surface condition and abrasive grain status. The surface of a new grinding wheel is covered with sharp and protruding abrasive grains. After prolonged friction, the abrasive grains will be polished flat, passivated or even fall off in large areas. When most grains lose sharpness, the wheel will slip on the workpiece surface instead of cutting normally. You may notice excessive friction heat, loud abnormal noise and obvious vibration during operation. In addition, if the wheel surface appears glazed, hardened or loaded with adhered metal chips that cannot be cleaned away, it means the pores between abrasive grains are blocked. This situation not only reduces processing effect, but also easily causes local overheating and wheel cracking.

Thirdly, pay attention to structural damage and deformation. Carefully check the whole wheel for tiny cracks, cracks or radial fractures. Even fine invisible cracks will expand rapidly under high-speed rotation and heavy load, leading to wheel burst and serious safety accidents. Meanwhile, if the grinding wheel has obvious eccentricity, warping or uneven thickness after wear, it will produce severe runout during rotation. The violent vibration will damage the grinding machine, affect machining precision, and bring huge risks to operators. Any wheel with structural damage or permanent deformation must be discarded directly.

Fourthly, judge according to operational performance changes. If you need to apply much greater pressure than before to complete the same grinding work, and the processing speed is far slower than normal, it is a clear signal of severe wear. What’s more, abnormal phenomena such as strong spark deviation, harsh screeching sound and continuous jitter during operation all prove that the grinding wheel is no longer in good condition. Never continue to use it reluctantly for the sake of cost.

In daily work, operators should inspect the grinding wheel before each startup. Do not use worn, damaged or unqualified wheels. Timely replacement is not only to guarantee processing quality and working efficiency, but also the most important measure to prevent safety accidents in grinding work.