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A
jig grinder is a machine tool used for grinding complex shapes and
holes where the highest degrees of accuracy and finish are required.
The
jig grinder is very similar to a jig borer, in that the table
positioning and spindles are very accurate (far more so than a manual
milling machine or lathe). It is almost exclusively used by tool and
die makers in the creation of jigs or mating holes and pegs on dies.
There are usually many peripheral elements to a large jig grinder,
including separate hydraulic motors, air compressors, and various
cooling systems for both the hydraulic circuit and supplying coolant to
the work and machine itself.
The machine operates by a high
speed air spindle rotating a grinding bit. The air spindles are
removable and interchangeable to achieve varying surface speeds. Some
spindles are fixed speed (60000 rpm), others are adjustable
(30000-50000 rpm), and still others are very high speed (175000 rpm).
The machines have a standard X-Y table with the notable exception of
knee travel. All axes are indexed to .0001" via a vernier scale on the
handwheels, with higher accuracy available with the use of measuring
bars. The machine head has two vertical travels, one rough head
adjustment and the other a precise spindle adjustment. The spindle to
which the detachable air spindle mounts also rotates at a variable
speed and can typically outfeed .100" while running, again with an
accuracy of .0001" on the handwheel or greater, for very precise hole,
peg and surface grinding. A well-kept jig grinder will reliably
position work to a higher degree of accuracy than is possible with
handwheels alone. These features are all critical in positioning a hole
and peg system a precise distance from a reference surface or edge.
The
most important factor on a jig grinder is the dual-spindle
configuration. The main spindle is roughly positioned with between 1"
or 2" of travel for setup, and then the .100" of outfeed is used during
machine operation to outfeed into the work. A spacer bar may be used
between the grinder and main spindle, allowing large (9" radius or
larger) work to be completed. The main spindle has a wide range of
speeds to ensure proper grinder feed rates are maintained.
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