At what point of wear should grinding wheels be replaced?

Grinding wheels should not be used until completely worn out. When wear reaches a critical state, they must be replaced immediately. The specific criteria for replacement are as follows:

First, monitor the distance between the effective grinding layer and the flange. When the effective grinding layer wears down to within 10mm of the flange edge, cease use and replace the wheel. At this point, the wheel's overall strength significantly diminishes; continued use risks fracture due to uneven stress distribution. Simultaneously, an excessively small grinding radius concentrates grinding force near the flange, intensifying equipment vibration and compromising machining accuracy.

Second, observe the grinding wheel's operational condition. If severe clogging occurs—where the abrasive surface is covered by swarf and cannot regain sharpness even after dressing with a specialized tool—or if localized damage, deformation, or loss of roundness appears, along with abnormal noises or intense vibration during grinding, the wheel must be replaced immediately regardless of wear level.

Additionally, if the grinding wheel has been subjected to impact or dropped during use, it should be scrapped even if no visible damage is present. This prevents potential internal cracks from going undetected.