How To Square Up A Workpiece A Surface
Nearly every injection mold component has, at one point, had to be ground square in
order to be further machined. Knowing how to square up a workpiece on a surface grinder is very basic, and
If the cavity block, for example, is out of square, every other operation done will
be affected. The Wire EDM, high speed machining, Sinker EDM, and assembly all depend on the cornerstone work done
on the surface grinder.
Most injection mold components are able to be ground on either a manual surface
grinder or an automatic CNC wet surface grinder. In either case, the process is similar.
Basically, there are three common methods used to grind a workpiece square.
Grinding using a precision vise
Grinding using an angle plate
Grinding using a magnetic squaring block
Each of these methods works well and are quite interchangeable. Very often, the size
of the workpiece determines which method works best. You just wouldn't want to grind a tiny core block using a
magnetic squaring block on a large wet surface grinder, for example.
How to square up a block using a
Supposing that you have a heat-treated piece of S-7 tool steel
that has been milled reasonably square, proceed as follows:
Remove any obvious burrs or dings from one of the largest, flattest surfaces.
Grind this surface flat.
Grind the opposite side to your desired size. You now have two flat and
Clean off one of the longest perpendicular surfaces to lay on the bottom of
the grinding vise. It is a good idea to indicate the workpiece once it is mounted in the precision vise.
Set the workpiece so that one end is protruding beyond the edge of the vise.
Now grind the long side so that it cleans up, set the vise on it's side and
grind the 4th side clean.
Now you can simply use the magnetic chuck to hold your workpiece, or use the
vise again, if this works better.
How to square up a workpiece
using an angle plate
Follow steps 1-3 above, but use a C-clamp or Kant Twist clamp to hold the
workpiece to the angle plate. This method is rather old school, but still comes in handy once in a
Grinding a workpiece square
using a magnetic squaring block
Follow steps 1-3 above, only now you use the magnetic block to hold the
workpiece. You can also avoid turning the block on it's side by using the rail to align your block, once
you have the long perpendicular side ground clean.
A tip for bigger cavity blocks is to use the magnetic squaring block side
rail, but mount a 1-2-3 block on the opposite side. Now run a screw or threaded rod through the 1-2-3 block
to push the workpiece against the side rail. This helps overcome gravity and saves your hand from having to
push the block against the rail, while turning on the magnet.
Obviously, the precision squaring block, angle plate, and magnetic squaring block
must be absolutely square for this process to work reliably. Once you have a good set-up, take great pains to keep
it that way. The surface grinder is only as good as the tools and toolmaker.
There are numerous methods for checking squareness, each one has
advantages. The surface grinder can do very high quality work, but it requires skill and patience.
Use a square cylinder and dial indicator mounted on a special height
Use a magnetic cylinder mounted to the workpiece and check with an
Compare perpendicular sides with a dial indicator mounted in a height