Roughing out flat grinds with Wheel first

ashwinearl

Knifemaker / Craftsman / Service Provider
Joined
Nov 9, 2006
Messages
562
Hi All,

I've been researching and practicing different approaches to flat grinding and am curious about the hybrid approach of starting with a hollow grind first then switch to flat platen. I'd also seen the Nick Wheeler approach of creating multiple shallow hollows parallel with each other. I gave this a shot briefly but found it hard to do.

This thread briefly mentions roughing on a wheel first (https://www.bladeforums.com/threads/bevel-jigs.1499447/#post-17225644). It mentions speed and saving belts as advantages.

Those of you that do this method, can you explain your basic process.

I typically scribe my desired pre-heat treat each thickness and then grind 45degree ish bevels to the scribe lines using a worn belt. For a flat grind, I typically start at the transition of that first bevel and the flat blade and walk the grind towards the spine. So there is some meat left at the edge from the first initial bevel

Once I reach final depth I work on getting moving the flat grind back towards the edge and get rid of what was left from the initial bevel.

I have a 10" wheel to work with. Using online hollow grind calculators and depending on my steel thickness (1/8 to 5/32), it says I can grind to a height of 0.7 to 0.8" I like to flat grind higher than this typically.

Do I perform a traditional hollow grind to this max height, following the basic approach of my flat grinding, where I start the hollow grind just underneath where that initial 45degree bevel ends?

This would leaves two points of contact near the edge (but not to it yet) and that last height I left off with the hollow grind to index the flat grind off of.

I tried this once and it worked ok, I was surprised how fast it went. My problems are that success is dependent on performing the initial hollow ground decently enough to have a straight line at the top of the grind. Also plunge lines are hard for me regardless of wheel or flat platen.
 
That was how Bill Moran did it, but he went further. He did the rough grind on a big emery wheel and then refined by grinding horizontally on the belt grinder with a contact wheel. That may be why his convex grinds were much finer than some others.
 
I do this occasionally, hollow out with a 10" wheel and then goto flat platen
I learned this from the ABS video with Tim Hancock grinding.
I didn't know Nick W was an advocate of this method but they sound like the same method.

anyway, what are you finding difficult specifically?
don't take this the wrong way, but based on the rest of your post it sounds like you are overthinking this... :)
My goal in using this method is simply efficient and fast material removal, that's it.
The wheel is easier on the belts and more efficient in grinding away material.
The flat platen then just gives you the final geometry of your grind.

here's a cross section, the blue represents the hollow wheel which lets you rough out the stock. I make several and as many passes as I want and judge the depth by eye

perhaps change the way you are looking at it to be more of a roughing operation that simply removes material away quickly.

gkLySrl.jpg


MKPAEV2.jpg


regards
 
As a new maker who is on his 4th knife (focusing 100% on FFG), and someone who has a 2x72 on order this method of hogging material seems genius. What diameter wheel is ideal for this approach?
 
He really mastered it .................... :thumbsup: anybody know max . belt speed on this grinder ?
 
Man he makes it look easy, insane. I gotta try both those techniques, the contact wheel for roughing and dragging the spine across the workrest.
 
Seems like he's got a 6" drive wheel, if so with the 1750 rpm motor and a 2X jumper it would put him around 5500 SFPM max speed. A 5" drive wheel would be around 4500 SFPM grinding speed.

You're right Travis can grind a knife. Seems like he won both times he was on FiF? Is that correct?
 
Yes he did. If you notice, they now use his TW-90 Grinder on the show! Awesome machine.
 
I almost always hog out my flat grinds with an 8" wheel. Belts are much more efficient on a wheel than on a flat platen, so it makes better use of the belt and gets rid of a lot of unwanted material quickly and efficiently. And, I grind down to scribed center lines.
Then when I follow with the platen I'm just removing the high spots and there's little resistance.
I've been doing that for years.
 
I like that idea and have never tried it. Since I've been working with blades that are mostly less than .100" thick it seems there's not much metal to hog out. Does anyone thing it would be advantageous to use a contact wheel first on blades that thin?
 
I have done this with my 8" wheel, but I prefer to use up that material getting the feel of the grind for a particular knife. I guess if I had more experience then I could settle in more quickly and make more use of that strategy.
 
I just recently started my full flat grinds on the 8" wheel, and am amazed at how much more metal is removed compared to the flat platen. The physics/geometry of it make perfect sense, too. I highly recommend this approach. Like Karl said, there is just so much more material removed more effectively on the wheel compared to the platen. Once the bulk has been removed, switch to the flat platen and refine the grind.
 
I like that idea and have never tried it. Since I've been working with blades that are mostly less than .100" thick it seems there's not much metal to hog out. Does anyone thing it would be advantageous to use a contact wheel first on blades that thin?
Probably not. Not much to be gained.
 
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