Grinding spring ends by hand

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This standard identifies the competences you need to prepare bench, pedestal grinding machines, and belt linishing machines for spring end grinding operations, in accordance with approved procedures. You will be expected to prepare the equipment to grind the ends flat and square, and to the correct dimensional requirements. This will involve selecting the appropriate grinding machine/equipment and spring holding device.

In preparing the machines, you will need to check that an appropriate grinding wheel or linishing belt is fitted, and that they are free from defects. You will be expected to prepare the grinding wheels for operation by dressing the wheels, and creating any necessary relief, as applicable to the operation to be performed. You must set up the machine work rest to give sufficient wheel clearance, in keeping with safe operating methods.

Your responsibilities will require you to comply with organisational policy and procedures for the spring end hand grinding activities undertaken, and to report any problems with the grinding machines, equipment or grinding activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the grinding of spring ends using hand methods. You will understand the spring end hand grinding equipment used, and its application, and will know about the spring holding devices, grinding wheels, wheel dressing, spring materials and consumables, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is to the required specification.

You will understand the safety precautions required when working with the spring end hand grinding machines, and with their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow relevant specifications for the component to be produced
3. obtain the appropriate tools and equipment for the shaping operations and check that they are in a safe and useable condition
4. shape the materials using appropriate methods and techniques
5. check that all the required shaping operations have been completed to the required specification
6. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. the hazards associated with spring end grinding by hand  and how to minimise them and reduce any risks
3. how to start and stop the machine in normal and emergency situations
4. the importance of ensuring that the machine is isolated from the power supply before mounting grinding wheels
5. the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy
6. the basic operation of off-hand grinding and linishing machines, and typical operations that they can perform
7. how to handle and store grinding wheels, safely and correctly
8. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
9. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
10. terminology used in spring end grinding, in relation to the activities undertaken
11. the workholding devices that are used to hold the springs for hand grinding
12. the selection of grinding wheels with regard to the type of material being ground and operations being carried out
13. how to check that the grinding wheels are in a safe and serviceable condition
14. how grinding wheels are balanced, and the equipment that is used for this
15. the methods of mounting and securing the grinding wheels to the machine spindles
16. the need for frequent dressing of wheels to prevent glazing and burning of the spring surface
17. organisational quality control procedures, and recognition of grinding defects
18. problems that can occur with the hand grinding operations, and what to do if problems occur
19. the importance of completing all relevant documentation on conclusion of the spring end grinding activities
20. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the spring end grinding activities:
   1. obtain and interpret correctly the documentation for the type of spring being ground
   2. adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. check that the grinding machine and workholding device to be used is in a safe and usable condition
   4. carry out the spring end grinding activities, following good practice/approved procedures
   5. ensure that the grinding wheels are correctly dressed/formed and are in a usable condition
   6. hold components securely, without distortion
   7. ensure that correctly adjusted machine guards are in place
   8. leave the machine and work area in a safe and clean condition on completion of the grinding activities
2. Grind springs made from two of the following types of material:
   1. carbon steel
   2. alloy steel
   3. nickel based alloys
   4. stainless steel
   5. copper based alloy
   6. titanium and other special material
   7. other specific material
3. Prepare two of the following types of spring end grinding machine in readiness for production:
   1. single end
   2. double end
   3. linishing belt
4. Select and mount grinding wheels, to include carrying out all of the following:
   1. selecting grinding wheels for specific materials and applications (such as grain size, grade, structure, bond)
   2. testing wheels for soundness/cracks
   3. mounting wheels (such as paper washers, flanges, locking pressure)
   4. balancing wheels, where appropriate
   5. dressing and `trueing up' grinding wheels
5. Carry out the grinding of spring ends by hand, to include all of the following:
   1. checking springs for cleanliness and freedom from burrs
   2. mounting the springs in an appropriate holding device
   3. setting machine rests to give an appropriate wheel clearance less than the wire diameter of the spring
   4. setting guards and safety mechanisms
   5. applying appropriate pressure and technique to grind the spring ends without burning
   6. removing sufficient material from each end to give equal tip end thickness
   7. de-burring/chamfering inside and outside diameter
   8. reaming and edging if required
   9. checking that spring length, squareness and finish is to specification
6. Use four of the following whilst checking the quality of the springs produced:
   1. vernier callipers
   2. vernier protractors
   3. gauges
   4. micrometers
   5. squares
   6. jigs
   7. spring testing machines
   8. electronic measuring equipment
7. Carry out checks of the springs, to include all of the following:
   1. free length
   2. coil diameter of end
   3. finish
   4. squareness
   5. solid length
   6. tip end thickness
8. Grind spring ends by hand, in compliance with one of the following:
   1. BS, ISO or EN standards and procedures
   2. customer standards and job requirements
   3. company standards and procedures

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMMME3124

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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3113

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Mechanical engineering; spring making; grinding; spring ends; by hand; single end; double end; grinding wheels; linishing; carbon steel; alloy steel; stainless steel; nickel based alloys; copper based alloy; titanium

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