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CH 25
CH 25
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-1
Examples of Bonded Abrasives
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-2
General Characteristics of Abrasive Machining
Processes and Machines
TABLE 25.1
Maximum dimension
Process Characteristics (m)*
Surface Flat surfaces on most materials; production rate depends on table size and Reciprocating table L : 6
automation; labor skill depends on part; production rate is high on Rotary table D : 3
vertical-spindle rotary-table type.
Cylindrical Round workpieces with stepped diameters; low production rate unless Workpiece D : 0.8
automated; labor skill depends on part shape. Roll grinders D : 1.8
Universal grinders D : 2.5
Centerless Round workpieces; high production rate; low to medium labor skill. Workpiece D : 0.8
Internal Bores in workpiece; low production rate; low to medium labor skill. Hole D : 2
Honing Bores and holes in workpiece; low production rate; low labor skill. Spindle D : 1.2
Lapping Flat surfaces; high production rate; low labor skill. Table D : 3.7
Ultrasonic Holes and cavities of various shapes, particularly in hard and brittle —
machining nonconducting materials.
*Larger capacities are available for special applications. L=length; D=diameter.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-3
Workpiece Geometries
Figure 25.2 The types of workpieces and operations typical of grinding: (a) cylindrical surfaces,
(b) conical surfaces, (c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or
slotting with thin wheels, and (g) internal grinding. See also the illustrations in Section 25.6.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-4
Knoop Hardness for Various Materials and
Abrasives
TABLE 25.2
Common glass 350–500 Titanium nitride 2000
Flint, quartz 800–1100 Titanium carbide 1800–3200
Zirconium oxide 1000 Silicon carbide 2100–3000
Hardened steels 700–1300 Boron carbide 2800
Tungsten carbide 1800–2400 Cubic boron nitride 4000–5000
Aluminum oxide 2000–3000 Diamond 7000–8000
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-5
Grinding Wheel
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-6
Common Grinding Wheels
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-7
Superabrasive Wheel Configurations
Figure 25.5 Examples of superabrasive wheel configurations. The annular regions (rim) are
superabrasive grinding surfaces, and the wheel itself (core) is generally made of metal or
composites. The bonding materials for the superabrasives are (a), (d), and (e) resinoid, metal, or
vitrified, (b) metal, (c) vitrified, and (f) resinoid.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-8
Marking System for Aluminum-Oxide and
Silicon-Carbide Bonded Abrasives
Figure 25.6 Standard
marking system for
aluminum-oxide and
silicon-carbide bonded
abrasives.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-9
Standard Marking System for Cubic Boron
Nitride and Diamond Bonded Abrasives
Figure 25.7
Standard marking
system for cubic
boron nitride and
diamond bonded
abrasives.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-10
Grinding Chips
(a) (b)
Figure 25.8 (a) Grinding chip being produced by a single abrasive grain. (A) chip, (B) workpiece, (C)
abrasive grain. Note the large negative rake angle of the grain. The inscribed circle is 0.065 mm (0.0025 in.)
in diameter. Source: M. E. Merchant. (b) Schematic illustration of chip formation by an abrasive grain with
a wear flat. Note the negative rake angle of the grain and the small shear angle.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-11
Grinding Wheel Surface
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-12
Surface Grinding and Plowing
Figure 25.10 Schematic illustration of the surface
grinding process, showing various process
variables. The figure depicts conventional (up)
grinding.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-14
Shaping Using Computer Control
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-15
Speed and Feed Ranges and Grinding Wheel
Recommendations
TABLE 25.4 Typical Range of Speeds and Feeds for Abrasive Processes
Conventional Creep-feed
Process variable grinding grinding Buffing Polishing
Wheel speed (m/min) 1500–3000 1500–3000 1800–3600 1500–2400
Work speed (m/min) 10–60 0.1–1 — —
Feed (mm/pass) 0.01–0.05 1–6 — —
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-17
Surface Grinding
Figure 25.14 Schematic illustration of a
horizontal-spindle surface grinder.
Figure 25.16 Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge
grinding, and (c) profile grinding. Source: Okuma Machinery Works Ltd.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-19
Plunge and Noncylindrical Grinding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-20
Thread and Internal Grinding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-21
Cycle Patterns in Cylindrical Grinding
Figure 25.20
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-22
Centerless Grinding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-23
Creep-Feed Grinding
Figure 25.23 (a) Schematic illustration of the creep-feed grinding process. Note the large wheel depth of cut,
d. (b) A shaped groove produced on a flat surface by creep-feed grinding in one pass. Groove depth is
typically on the order of a few mm. (c) An example of creep-feed grinding with a shaped wheel. This
operation can also be performed by some of the processes described in Chapter 26. Source: Courtesy of
Blohm, Inc., and Manufacturing Engineering Magazine, Society of Manufacturing Engineers.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-24
General Recommendations for Grinding Fluids
TABLE 25.6
Material Grinding fluid
Aluminum E, EP
Copper CSN, E, MO FO
Magnesium D, MO
Nickel CSN, EP
Refractory metals EP
Steels CSN, E
Titanium CSN, E
D: dry; E: emulsion; EP: Extreme
pressure; CSN: chemicals and synthetics;
MO: mineral oil; FO: fatty oil.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-25
Ultrasonic Machining and Coated Abrasives
Figure 25.24 (a) Schematic illustration of the ultrasonic machining process. (b) and (c) Types of parts made
by this process. Note the small size of holes produced.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-26
Belt Grinding
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-27
Honing and Superfinishing
Figure 25.27 Schematic illustration of a honing
tool used to improve the surface finish of bored or
ground holes.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-28
Lapping
Figure 25.29 (a) Schematic illustration of the lapping process. (b) Production lapping on flat
surfaces. (c) Production lapping on cylindrical surfaces.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-29
Polishing Using Magnetic Fields
Figure 25.30 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.
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-30
Abrasive-Flow Machining
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-31
Robotic Deburring
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-32
Economics of Grinding and Finishing
Operations
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 25-33