SAFETY

IN

THE

USE

OF

ABRASIVE

WHEELS

This guidebook is prepared by the Occupational Safety and Health Branch Labour Department This edition April 2008

T h i s g u i d e b o o k i s i s s u e d f r e e o f c h a rg e a n d c a n b e o b t a i n e d f ro m the o ffi c e s o f t h e O c c u p a t i o n a l S a fe t y a n d H e a l t h B ra n c h o f t h e L a b o u r D e p a r t m e n t . I t c a n a l s o b e d ow n l o a d e d f r o m w e b s i t e o f t h e L a b o u r D e p a r t m e n t a t http://www.labour.gov.hk/eng/public/content2_8d.htm. For enquiries about addresses and telephone numbers of the offices, please visit the website of the Department at http://www.labour.gov.hk/eng/tele/osh.htm or call 2559 2297. This guidebook may be freely reproduced except for advertising, endorsement or commercial purposes. Please acknowledge the source as “Safety in the Use of Abrasive Wheels” published by the Labour Department.

19

SAFETY IN THE USE OF ABRASIVE WHEELS SAFETY IN THE USE OF ABRASIVE WHEELS 1 .

............................................................................................................................ 3 OPERATING SPEED .............................................................................................. 4 MARKING SYSTEM FOR ABRASIVE WHEELS ............................................................................................................................................................................ 5 MOUNTING ..........................SAFETY IN THE USE OF ABRASIVE WHEELS CONTENTS Page INTRODUCTION ..... 7 WORK-RESTS .................................................................. 7 TRUING AND DRESSING ..... 8 SAFETY AND THE OPERATOR ......................................................................... 7 PROTECTION OF EYES .................................................................................................................... 3 SELECTION OF WHEELS ............. 10 2 ............................. 8 ENQUIRIES AND COMPLAINTS . 6 GUARDS ... 5 MOUNTING OF DEPRESSED-CENTRE WHEELS ...................................... 9 SKETCHES AND TABLES / FORMS ..................................................

* Do not use defective wheels. Selection of Wheels * Consult the manufacturer for the proper type of wheels to suit a particular job. The use of abrasive wheels in an unsafe way often causes accidents leading to personal injuries and/or damage to properties. 3 . It does not include technical aspects of grinding or operational techniques. they should be stored properly in suitable racks as in Fig. If not in use. Do not use the wheel if it sounds cracked. The main dangers are — (1) bursting of wheels as the result of: (i) defective wheel (ii) overspeeding (iii) faulty mounting (iv) misuse (2) contact with the wheel. Generally. 2. 1 with a light non-metallic tool. Check for soundness of wheels by a ‘ring test’. soft wheels are more suitable for hard materials and hard wheels for soft materials.) * Wheels should be kept dry and not exposed to extreme temperatures.SAFETY IN THE USE OF ABRASIVE WHEELS Introduction Abrasive wheels are extensively used in industries for various purposes. such as a wooden screwdriver handle. and (3) injury to the eyes from flying particles. The purpose of this guidebook is to advise readers on the precautions for the prevention of accidents in the use of abrasive wheels. It should ring. (Suspend the wheel vertically and tap the areas as shown in Fig.

it is also recommended that an automatic hose brake valve be fitted to the hose before joining the grinder. * The speed of the wheel in rpm may.SAFETY IN THE USE OF ABRASIVE WHEELS Operating Speed * Check that the spindle speed of a machine does not exceed the maximum permissible speed of the wheel as specified by the manufacturer. Consult the manufacturer or supplier in case of doubt. however. the following formula can be used for conversion into rpm: ∆ Speed in rpm = peripheral speed in ft/min x 12 3. in mm or = The conversion of speed measurement for a number of specified speeds and wheel diameters can be found in the Conversion Table shown in Fig. it should be properly maintained to prevent clogging by dust or grits. But in case the wheel is marked to give the peripheral speed in feet per minute (ft/min) or in metres per second (m/sec). ∆ Note: The maximum permissible speed of a wheel may also change upon aging of the bonding material of the wheel after prolonged use. Where a filter is incorporated in the air supply system.1416 x dia. make sure that there is a governor or other device fitted so as to control the speed of the spindle. be increased as the diameter of the wheel is reduced through wear as follows: ∆ increased speed in rpm = original speed in rpm x original diameter reduced diameter * If the spindle is air driven. Such device should be effectively maintained at all time. The spindle speed and the maximum permissible speed of the wheel should be marked in revolutions per minute (rpm). A suitable pressure reducing regulator should be fitted between the governor and the air supply outlet if the working pressure of the outlet is greater than that of the grinding machine. To prevent accidents caused by snaking hoses when severed under high pressure of air. 3. in inches peripheral speed in m/sec x 1000 x 60 3. 4 .1416 x dia.

* Flanges should not be less than one-third of the diameter of the wheels and their bearing surfaces should be true and free from burrs. * Clamping nuts and screws should be tightened uniformly in pattern formation (diametrical sequence) and only sufficiently to hold the wheel firmly. 5 . * With the exception of the single flange used for threaded-hole wheels.SAFETY IN THE USE OF ABRASIVE WHEELS Marking System for Abrasive Wheels Abrasive wheels are marked to identify their characteristics. * Flanges on both sides of the wheel should have the same outside diameter and diameter of recess. either paper or other compressible material. (See form in Fig. if any.) * A wheel should not be mounted on a machine for which it is not intended and certainly not on any make-shift apparatus or where there is vibration of the machine. Persons responsible for wheel mounting should be able to recognise the specifications marked on the wheel (See Fig. threaded-hole wheels. all flanges should be properly recessed or undercut. 5 for appointment of a competent person. Mounting * All mountings shall only be done by competent persons appointed in writing by the proprietors. except tapered wheels. and the hub section of depressed-centre wheels. should be used with all bonded abrasive wheels. * Do not mount a wheel on a machine the speed of which exceeds the maximum permissible speed of the wheel. Competent persons should be well trained and have the practical experience in the mounting job. 4). cylinder wheels. should not project beyond the sides of the wheel. Washers should be slightly larger than the flanges and there should be no wrinkles in them. * Washers. * Check for soundness of the wheel before it is mounted. discs. * The bush. * The wheel should fit freely but not loosely on the spindle.

12. A paper washer should not be used on the hub section of a depressed-centre wheel. * When re-mounting factory-mounted wheels and points.750 mm (12 inches . This ensures that clamping pressure is exerted only at the centre of the hub section. 6) for a particular diameter of mandrel.30 inches) above 750 mm (30 inches) diameter of protection flanges at least half the diameter of wheel at least the diameter of wheel minus 150 mm (6 inches) at least the diameter of wheel minus 200 mm (8 inches) * Study carefully Fig. 6 . When the adaptor has been tightened. 2. Mounting of Depressed-centre Wheels Depressed-centre wheels should only be mounted with a flange as shown in Fig. * Protection flanges are used on tapered wheels which are not provided with safety guards. 3. but not so long as to contact the abrasive material. Also there should be sufficient length of the mandrel in the collet or chuck. 11 which show the correct mounting of certain types of wheels commonly used. there should be a slight clearance between the flange and the wheel at (A). 7 to Fig. 12. Consult the manufacturer for details of overhang permissible for a particular wheel. Both these flanges and the tapered wheels should be equally tapered to at least 6% and with the following dimensions: diameter of wheel below 300 mm (12 inches) 300 mm . speed and size of a wheel should not be exceeded. cylinders or cones should be long enough to engage a sufficient length of thread. the overhang (distance between end of support and base of wheel as illustrated in Fig.SAFETY IN THE USE OF ABRASIVE WHEELS * Screws for inserted nut for mounting of discs. Three points should be noted: 1. The outer part of the face of the flange adjacent to the wheel should be tapered as shown in Fig. This allows the full width of the flange to support the wheel during the grinding operation.

SAFETY IN THE USE OF ABRASIVE WHEELS Guards * Unless the nature of the work absolutely precludes its use. For maximum protection. 7 . Work-rests For bench and floor stand grinders. See Fig. a work-rest has to be provided and properly adjusted as close as possible. Lack of adjustment is the cause of many serious accidents in that the workpiece was jammed between the wheel and the work-rest which forced the operator’s fingers against the wheel face. to the wheel. shields or fixed shields shall be provided to employees engaged in: 1. a guard shall be provided and kept in position at every abrasive wheel for the following purposes: (1) to hold the wheel parts in the event of breakage. 2. Protection of Eyes Persons carrying out dry grinding operations and truing or dressing an abrasive wheel should wear properly fitted eye protectors or be protected by suitable transparent screens which are fitted in front of the exposed part of the wheel so as to intercept flying particles. * Guards must be of rigid construction. the guards have to be adjusted to limit the exposure angles as in Fig. Truing or dressing of an abrasive wheel. Dry grinding of metals or articles of metal applied by hand to a revolving wheel. proper dimensions and securely anchored to the machine frame. in any case not exceeding 3. (3) to prevent the operator from coming into contact with the wheel.2mm (1/8 inch). (2) to protect the wheel from accidental damage. Regulation 5 of the Factories and Industrial Undertakings (Protection of Eyes) Regulations requires that approved eye protectors. band or disc driven by mechanical power. 14. (4) to prevent an oversized wheel from being fitted. 13.

* Do not operate a grinding machine unless you have been properly trained in its safe use. * Before operating a bench or floor stand grinding wheel. Switch it off before you leave. It is the job for a competent person appointed by the proprietor. both of which reduce the cutting action.SAFETY IN THE USE OF ABRASIVE WHEELS Truing and Dressing * The wheel should be dressed when necessary to remove loading or glazing at the wheel surface. Eccentric force will be created at wheels used for hand grinding rendering them out of balance if they are not trued. it may damage the spindle and cause the wheel to burst. and if the force becomes excessive. Safety and the Operator * Ensure that the floor in the vicinity is in good condition. * Do not allow the wheel to revolve unattended. 8 . ensure the proper provision and adjustment of: (1) the wheel guards with minimum exposure angle (2) the clearance between the work-rest and the wheel should be less than 3. * Remember grinding on the sides of straight-sided wheels is dangerous. choose the one which does not exceed the maximum permissible speed of the wheel. free from obstruction and not slippery.2 mm (1/8”) (3) the protective screen (or wear eye protectors) * Always report any fault or unusual signs of the machine to your foreman or supervisor. * If there is more than one speed of the machine. * Do not mount an abrasive wheel yourself. * Do not apply sudden pressure to the wheel.

labour.gov.SAFETY IN THE USE OF ABRASIVE WHEELS Enquiries If you wish to enquire about this guidebook or require advice on occupational safety and health.hk. you can contact the Occupational Safety and Health Branch of the Labour Department through: Telephone Fax E-mail : : : 2559 2297 (auto-recording after office hours) 2915 1410 enquiry@labour. Information on the services offered by the Occupational Safety and Health Council can be obtained through hotline 2739 9000.hk Information on the services offered by the Labour Department and on major labour legislation can also be found by visiting our homepage at http://www. Complaints If you have any complaints about unsafe workplaces and practices.gov. please call the Labour Department’s occupational safety and health complaint hotline at 2542 2172. 9 . All complaints will be treated in the strictest confidence.

1: Tap points for the “ring test” Fig.SAFETY IN THE USE OF ABRASIVE WHEELS Sketches and Tables / Forms 45 o 45 o 45 o 45 o TAP HERE FLOOR Fig. 2: Proper storage of wheels 10 .

Fig. 3: CONVERSION TABLE From peripheral speeds in feet per minute (metres per second) to wheel speed in rpm =mbofmebo^i=pmbba RIRMM SIMMM SIRMM TIMMM TIRMM UIMMM UIRMM VIMMM VIRMM NMIMMM NOIMMM NQIMMM TNKN SMKV RMKU QUKO QRKT QPKN QMKS PUKN PRKS PP PMKR OTKV NSIMMM UNKP SAFETY ÑíLãáå QIMMM QIRMM RIMMM ãLëÉÅ OMKP OOKU ORKQ IN aá~ãÉíÉê çÑ=ïÜÉÉä áå ãã =obslirqflkp=mbo=jfkrqb ONIMMU NMIRMQ TIMMP OOIVNU NNIQRV TISPV OQIUOU NOIQNQ UIOTS OSITPT NPIPSU UIVNP OUISQT NQIPOU VIRQV PMIRRU NRIOTU NMINUS POIQST NSIOPU NMIUOO PQIPTT NTINUU NNIQRV PSIOUT NUINQP NOIMVS PUINVS NVIMVU NOITPO VIRQV TISQM SIPSS RIQRS QITTR QIOQQ PISOV PIMOP OIRVO OINQV NIVNM NITNV NIQTS NIPRP NIOQU NIMVO NIMNU VRQ UQP TVR TRQ SSV SPS SMU RUO RRU RMP QNQ PQR QQS PTN TNS SUO SRN SOQ RVT RPV QTU PVU UVU UQU UMQ TSQ TPO SVQ SSS SPS RTS RNM QOQ NINRV NIMUO NIMNQ VRR VMO URQ UNO TTR TPT TMU STS SNO RQO QRN NIRSO NIQPP NIPOO NIOOU NINQS NIMTQ NIMNN VRQ VMQ USM UNU TUM TRM TNS SQU RTQ QTT OIOSU NIMNS NIUNQ NISQV NIRNO NIPVR NIOVS NIONM NINPQ NIMST NIMMT VRR VMU USP UOQ TVN TRS SUP SMS RMQ PIUOM PINUP OITOU OIPUT OINOO NIVNM NITPS NIRVN NIQSU NIPSQ NIOTQ NINVQ NINOQ NIMSN NIMMS VRS VMU USU UPO TVS TOM SPU RPM VIMTO TIORU SIMQU RINUP QIRPR QIMPO UIRVR SIUTS RITOV QIVNN QIOVT PIUOM PIQPU OIUSQ OIQRR UINNS SIQVQ RIQNN QISPU QIMRU PISMS PIOQT OITMR OIPNV OIMOV NIUMP NISOP TISQM SINNO RIMVO QIPSS PIUOM PIPVS PIMRS OIRQS OINUO NIVNM NISVU NIROU NIPUU NIOTQ NINTS TINSO RITPM QITTR QIMVO PIRUM PINUO OIUSR OIPUS OIMQS NITVN NIRVN NIQPO NIPMO NINVQ NINMN NIMOP VRR UVR SISUR RIPQU QIQRS PIUOM PIPQO OIVTM OISTQ OIOOU NIVNM NISTO NIQUR NIPPT NIONR NINNR NIMOU VRR UVN UPS TUS TQO TMQ SIOMT QIVSS QINPU PIRQT PINMP OITRU OIQUP OIMSV NITTP NIRRO NIPTV NIOQN NINOU NIMPQ VRR UUT UOU TTS TPM SVM SRP SOM RVN RSQ RQN RNT QSU RITOV QIRUQ PIUOM PIOTQ OIUSR OIRQS OIOVO NIVNM NISPT NIQPO NIOTP NINQS NIMQO VRR UUN UNU TSQ TNS STQ SPT SMP RTP RQR RON RMM QTU QPO PUT PNU RIORO QIOMO PIRMN PIMMN OISOS OIPPQ OINMN NITRN NIRMM NIPNP NINST NIMRM VRR UTR UMU TRM TMM SRS SNU RUP RRP ROR RMM QTU QRU QPU PVR PRM OVN QRIUPS OOIVNU NRIOTU NNIQRV VINSU TISPV SIRQU RITOV RIMVO QIRUQ PIUOM PIOTQ OIUSR OIRQS OIOVO OIMUQ NIVNM NITSO NISPT NIROU NIQPO NIPQU NIOTP NIOMS NINQS NIMVM NIMQO NIMMM VRS USQ TTQ SPT RPIQTQ OSITPT NTIUOS NPIPSU NMISVS UIVNP TISQM SISUR RIVQM RIPQU QIQRS PIUOM PIPQO OIVTM OISTQ OIQPM OIOOU OIMRS NIVNM NITUO NISTO NIRTO NIQUQ NIQMU NIPPU NIOTO NIONS NINSQ NINNS NIMMS UVO TQO SNINNS PMIRRU OMIPTO NRIOTU NOIOOQ NMINUS UITPO TISQM SITVO SINNO RIMVO QIPSS N O P OR RM TR NRIOTV TISPV RIMVP NTINUV UIRVQ RITOV NVIMVU VIRQV SIPSS THE Q R S NMM NOR NRM PIUOM PIMRS OIRQS QIOVT PIQPU OIUSR QITTR PIUOM PINUP T U V NTR OMM OOR OINUP NIVNM NISVU OIQRR OINQU NIVNM OITOU OIPUT OINOO USE NM NO NQ ORM PMM PRM NIROU NIOTP NIMVN NITNV NIQPO NIOOU NIVNM NIRVN NIPSQ OF NS NU OM USU TVS TPQ SUO SPT RVT RSO RPM RMP QTU QRQ QPQ QNS PVU PSM PNV OSR QMM QRM RMM VRR UQV TSQ NIMTQ VRR URV NINVQ NIMSN VRR PIUOM PIPVS PIMRS OITTS OIRQS OIPRO OINUO OIMPS NIVNM NITVS NISVU NISMU NIROU NIQSQ NIPUU NIPPO NIOTO NINRO NIMOM UQV OO OQ OS RRM SMM SRM SVQ SPT RUU TUN TNS SSN ABRASIVE OU PM PO TMM TRM UMM RQS RMV QTT SNQ RTP RPT PQ PS PU URM VMM VRM QQV QOQ QMO RMR QTT QRO QM QO QQ NIMMM NIMRM NINMM PUO PSS PQT QPM QMV PVM WHEELS QS QU RP NINRM NIOMM NIPOR PPP PNU OUU PTR PRU POQ SM TO NIRMM NIUMM ORR ONO OUT OPV 11 .

SAFETY IN THE USE OF ABRASIVE WHEELS Maximum operation speed TESTED AT 6445 R. 51A 36 L 5V 23 Fig.P. 4: Marking system sequence of symbols M Order of marking Example Type of abrasive* 51 N Nature of abrasive A O Grain size P Grade Q Structure* R Nature of bond V S Type of bond etc* 23 36 L 5 Aluminium abrasives Silicon carbides A C Spacing from the closest to the most open V S R B BF îáíêáÑáÉÇ ëáäáÅ~íÉ êìÄÄÉê resinoid (synthetic resins) resinoid (synthetic resins) reinforced coarse medium fine very fine U NM NO NQ NS OM OQ PM PS QS RQ SM TM UM VM NMM NOM NRM NUM OOM OQM OUM POM QMM RMM SMM M N O P Q R S T U V NM NN NO NP NQ ÉíÅK E ëÜÉää~Å Mg ã~ÖåÉëá~ Soft Medium Hard A B C D E F G H I J K L M N O P Q R S T U V W X Y Z * Optional symbols – The symbols 0 and 6 are the manufacturer’s own setting 12 . OPER.P.M. SPEED NOT TO EXCEED 3600 R.M.

5: Form* (Regulation 7(2)) Factories and Industrial Undertakings (Abrasive Wheels) Regulations k~ãÉ=çÑ =fåÇìëíêá~ä=råÇÉêí~âáåÖ ^ÇÇêÉëë=çÑ =fåÇìëíêá~ä=råÇÉêí~âáåÖ ^ééçáåíãÉåí=çÑ =`çãéÉíÉåí=mÉêëçåë=íç=ãçìåí=~Äê~ëáîÉ=ïÜÉÉäë Date of Appointment Name of competent persons appointed Identity card number Address of competent person Signature of proprietor Signature of competent person * This is not a prescribed form because the law does not require one. This form is merely offered for the convenience of proprietors for the purpose of appointing a competent person.SAFETY IN THE USE OF ABRASIVE WHEELS Fig. 13 .

6: Sketch defining “overhang” washers fitted inner flange keyed on spindle flange recessed here Fig.SAFETY IN THE USE OF ABRASIVE WHEELS chuck mounted wheel overhang Fig. 7: A straight-wheel with a small bore 14 .

9 : A threaded-hole wheel 15 .SAFETY IN THE USE OF ABRASIVE WHEELS washers fitted inner flange keyed on spindle flange undercut here Fig. 8: A straight-wheel with a large bore Flat flange. no relief — to provide proper support for steel bushing and wheel Fig.

11: A tapered wheel 16 . no relief Spindle is shorter than hole and sufficiently threaded Fig.SAFETY IN THE USE OF ABRASIVE WHEELS Flat flange. 10: A cone wheel wheel tapered to 6% flange tapered here equally Fig.

EXPOSURE 65º MAX. 13: Maximum exposure angles for various grinding applications 17 . 65º MAX. 60º MAX. 90º MAX. EXPOSURE 180º MAX. EXPOSURE BENCH AND FLOOR STAND GRINDERS (WHEEL CONTACT IN GENERAL) BENCH AND FLOOR STAND GRINDERS (GREATER WHEEL CONTACT BELOW. 15º MIN. 15º MIN. 12 : Flange assembly for a depressed-centre wheel. 180º MAX.SAFETY IN THE USE OF ABRASIVE WHEELS Tapered surface A Fig. 125º MAX. The outer part of the flange adjacent to the wheel should be tapered as shown and there should be a slight clearance at A. OR OF SPINDLE IS REQUIRED) TOP GRINDER 65º MAX. EXPOSURE 150º MAX. EXPOSURE SWING-FRAME GRINDER CYLINDRICAL GRINDER SURFACE GRINDERS AND CUTTING-OFF MACHINES Fig.

14 : A grinding wheel fitted with wheel guard. work-rest and protective screen. 18 .SAFETY IN THE USE OF ABRASIVE WHEELS protective screen wheel guard.2mm maximum (1/8”) work-rest Fig. with minimum exposure angle 3.

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