mrtom

At the shop where I work, we use Sait cup wheels for agressive removal of weld buildup. The ones which we normally use are A-16 heavy duty Aluminum Oxide. I think that no matter how you slice it, you will be doing a lot of grinding to level up your anvil. If it were me, I would try to have the weld decked off level on a milling machine. It would save a lot of time and trouble and should not cost too much. With the appropriate sized carbide insert face mill, you could cover the face in one pass, however it may take several passes in depth to achieve a true surface - depending on the flatness of the buildup. With the hard facing material, machining RPM will be reduced, but it will certainly be more efficient than grinding. I noticed an earlier post that mentioned using a shaper. These are great machines albeit slow. I own one and love it. It might be a difficult operation in this instance due to the hardness and the interupted cut of the weld build. As long as you can keep the tool bit in the weld, it might be fine, however 55HRC is a bit much for a high speed tool bit. I have never tried carbide in the shaper, but I don't expect that it would stand up. In this case M42 with a very slow SFM would probably be the best all around choice for shaping.