Grinding

Grinding and Finishing
Illegitimi non carborundum

ver. 1
ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton
Overview
Processes Analysis
Horizontal Grinding
Horizontal grinding
Vertical grinding
Centered grinding
Centerless grinding
Creep Feed Grinding
Full depth and stock is removed with one or two passes at low work speed Very high forces are generated High rigidity and power Advantages
Increased accuracy Efficiency Improved surface finish Burr reduction Reduced stress and fatigue
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11
12
Grinding Wheels
13
Grinding Wheels
14
Grinding Wheel Information
15
Correctly Mounted Wheel
16
Grinding Wheel Surface
17
Grind Wheel Dressing
18
Grinding Wheel Dressing
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Grinding Chips
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Chip formation geometry

w
l t d
V l v
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Chip geometry
As with rolling contact length, the chip length, l
D = wheel diameter, d = depth of cut
l = Dd
Material removal rate, MRR
v = workpiece velocity, d = depth of cut, b = width of cut
MRR = v d b
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Material removal rate

The chips have a triangular cross-section, and ratio (r) of chip thickness (t) to chip width w (w)
w r = 10 to 20 t
Volchip 1 1 1 = w t l = wtl 2 2 4
So, the average volume per chip
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Chips
The number of chips removed per unit time (n), where c = number of cutting edges (grains) per unit area (typ. 0.1 to 10 per mm2, and V = peripheral wheel velocity
n =V bc
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Combining
MRR = v d b = n Volchip
1 v d b = Vbc wtl 4 w = r t l = Dd
1 v d b =V c b r t t D d 4
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Chip thickness
4v d t = V cr Dd
2
or
4v t= V cr
d D
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Specific grinding energy, u
Consist of chip formation, plowing, and sliding
u = uchip + u plowing + u sliding
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Total grinding force

Get force from power
Power = u MRR
Fgrinding V = u v d b
Fgrinding v d b = u V
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From empirical results, as t decreases, the friction component of u increases
1 u t
substituting
or
1 u = K1 t
Fgrinding
1 v d b = K1 t V
30

Substituting for t
Fgrinding
v d b = K1 V 4v d V cr D
d cr v = K1 b Dd 4V
ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. 31 ME 6222: Manufacturing Processes and Singh/Melkote/Colton Systems Prof. J.S. Colton GIT 2006
rearranging
Fgrinding
Force on a grain
The force per grain can be calculated
Fgrain = u Area
Fgrain Fgrain 1 = u wt 2
w = rt
and
1 u = K1 t
1 1 = K1 r t t t 2
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Force on a grain
substituting for t, and rearranging
Fgrain
K1 4v = r 2 V cr
vr = K1 V c d D
d D
Fgrain
ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. 33 ME 6222: Manufacturing Processes and Singh/Melkote/Colton Systems Prof. J.S. Colton GIT 2006
Grinding temperature
Temperature rise goes with energy delivered per unit area
Energy input T = K 2 area
u bl d 1 T = K 2 = K 2 K1 d bl t
T = K1 K 2 d 1 4v Vcr d D
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Grinding temperature
Rearranging
V cr T = K1 K 2 Dd 4v
Temperatures can be up to 1600oC, but for a short time.
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Grinding Ex. 1-1

You are grinding a steel, which has a specific grinding energy (u) of 35 W-s/mm3. The grinding wheel rotates at 3600 rpm, has a diameter (D) of 150 mm, thickness (b) of 25 mm, and (c) 5 grains per mm2 (c). The motor has a power of 2 kW. The work piece moves (v) at 1.5 m/min. The chip thickness ratio (r) is 10. Determine the grinding force and force per grain. Determine the temperature (K2 is 0.2oK-mm/N). Room temperature is 20oC.
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Grinding Ex. 1-2

First we need to calculate the depth of cut. We can do this from the power.
Power = u MRR = u v d b
2 m mm min 6 2000 W = 35 1 .5 d 25 mm 10 3 2 min 60 sec mm m
W s
d = 91.4 106 m
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Grinding Ex. 1-3

Now for the total grinding force
Fgrinding
Fgrinding
v d b = u V
mm 91.4 103 mm 25 mm W s min = 35 rev mm m mm3 3600 150 min rev 1000 mm 1500
Fgrinding = 70.7 N
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Grinding Ex. 1-4

Next, the force per grain
Fgrain
Fgrain
1 = u wt 2
1 = u r t t 2
and
w = rt
we need t
t=
4v V cr
mm d 91.4 103 mm min = mm grains D 150 mm 3600 150 10 5 min mm 2 4 1500

t = 1.32 103 mm
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Grinding Ex. 1-5

Substituting
Fgrain 1 1 = u r t t = 35 10 1.32 103 2 2
4
Fgrain = 3.05 10 J / mm
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Grinding Ex. 1-6

For the temperature, we need K1 and K2. K2 is given, so we need to calculate K1.
Fgrain = u
1
1 1 1 1 r t t = K1 r t t = K1 r t 2 t 2 2
1 3.05 10 N = K1 10 1.32 10 6 m 2 3 N K1 = 46.2 10 m

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Grinding Ex. 1-7

substituting
1 T = K 2 K1 d t
K m N 1 6 T = 0.2 46.2 91 . 4 10 m = 640 K 6 N m 1.32 10 m
T = Tinitial + T = 20 + 640 = 660C

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Honing and Superfinishing

Honing tool used to improve the surface finish of bored or ground holes. Schematic illustrations of the superfinishing process for a cylindrical part. (a) Cylindrical mircohoning, (b) Centerless microhoning.
Lapping
(a) Schematic illustration of the lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on cylindrical surfaces.
Polishing Using Magnetic Fields
Schematic illustration of polishing of balls and rollers using magnetic fields. (a) Magnetic float polishing of ceramic balls. (b) Magnetic-field-assisted polishing of rollers. Source: R. Komanduri, M. Doc, and M. Fox.
Abrasive-Flow Machining
Schematic illustration of abrasive flow machining to deburr a turbine impeller. The arrows indicate movement of the abrasive media. Note the special fixture, which is usually different for each part design. Source: Extrude Hone Corp.
Robotic Deburring
A deburring operation on a robot-held die-cast part for an outboard motor housing, using a grinding wheel. Abrasive belts or flexible abrasive radial-wheel brushes can also be used for such operations. Source: Courtesy of Acme Manufacturing Company and Manufacturing Engineering Magazine, Society of Manufacturing Engineers.
Economics of Grinding and Finishing Operations

Increase in the cost of machining and finishing a part as a function of the surface finish required. This is the main reason that the surface finish specified on parts should not be any finer than necessary for the part to function properly.
Summary
Overview of processes Analysis of process Example problem
49

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Grinding and Finishing

Illegitimi non carborundum

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Creep Feed Grinding

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Grinding Wheel Information

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Correctly Mounted Wheel

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Grinding Wheel Surface

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Grind Wheel Dressing

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Grinding Wheel Dressing

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Chip formation geometry

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Material removal rate

So, the average volume per chip

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Specific grinding energy, u

Consist of chip formation, plowing, and sliding

u = uchip + u plowing + u sliding

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Total grinding force

Total grinding force

Total grinding force

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Temperatures can be up to 1600oC, but for a short time.

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Grinding Ex. 1-1

Grinding Ex. 1-2

Grinding Ex. 1-3

Grinding Ex. 1-4

mm d 91.4 103 mm min = mm grains D 150 mm 3600 150 10 5 min mm 2 4 1500

Grinding Ex. 1-5

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Grinding Ex. 1-6

1 3.05 10 N = K1 10 1.32 10 6 m 2 3 N K1 = 46.2 10 m

Grinding Ex. 1-7

T = Tinitial + T = 20 + 640 = 660C

Honing and Superfinishing

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton

Polishing Using Magnetic Fields