Introduction

 Abrasive machining involves material

removal by the action of hard, abrasive
particles.
 The use of abrasives to shape parts is
probably the oldest material removal
process.
 They are important because
 They can be used on all types of materials
ranging from soft metals to hardened steels
and hard non metallic materials such as
ceramics and silicon.
 Extremely fine surface finishes (0.025 µm).
 For certain abrasive processes, dimensions
can be held to extremely close tolerances.
Types of Abrasive Machining
Processes

Grinding Honing Lapping

Superfinishing Polishing Buffing

Abrasive
Ultrasonic
water jet
machining
machining
 Grinding is a process of removing
excess material from the work piece by
the mechanical action of abrasive
particles that are held together by an
adhesive, generally in the form of a solid
wheel.
Grinding Wheel
 It is composed of thousands of small abrasive particles
held together by a bonding material (adhesive). Each
abrasive particle acts as a cutting edge, and when
several such particles rub against the surface of the
work piece, material is removed from the workpiece in
the form of fine chips.
Components of Grinding Wheel

Abrasive
Bond
Particle

Fillers/Additives
Types of Abrasives

Natural Artificial
Abrasives Abrasives
Sand stone Aluminum oxide
Diamond
Silicon carbide
Corundum
Synthetic Diamond
Emery
Garnet Cubic Boron Nitride
Bonding Process
Vitrified Bond

Resinoid Bond

Rubber Bond

Shellac Bond

Silicate Bond
Standard Designation of Grinding
Wheels

Type of Type of Grain or

Abrasive Bond grit size

Grade Structure
Type of Abrasive

Natural Artificial
Abrasives Abrasives
Type of Bond
Vitrified Bond – Designated by the letter ‘V’

Resinoid Bond – Designated by the letter ‘B’

Rubber Bond – Designated by the letter ‘R’

Shellac Bond – Designated by the letter ‘E’

Silicate Bond – Designated by the letter ‘S’

Grain or Grit Size
 Grain size refers to the measure of the
size of the abrasive particles.

Coarse Medium

Very
Fine
Fine
Type of Grain (Grit) Grain (grit) size Characteristics

Coarse 16-24 grit Coarser grit remove high volume of

material, but do not give a good
surface finish to the work piece.

Medium 36-60 grit Used in operations, which require

moderate stock removal and better
surface finish compared to coarser
grits.

Fine 80-120 grit Finer grits give a better finish, but

slower stock removal rate.

Very fine >150 Used for producing high surface

finish work pieces.
Grade
 Grade indicates the hardness (holding
power) of the bond that holds the
abrasive particles in place.
Type of Grade Grade
Very soft ABCDEFG

Soft HIJK

Medium LMNO

Hard PQRS

Very hard T to Z
Structure
 It is the spacing between the abrasive
particles within the wheel.
Type of Structure Structure Number
Dense 1–8

Open 9 – 15 or higher
Specification of Grinding Wheel
The Bureau of Indian Standards (BIS) has devised a system
for specifying a grinding wheel.
Ex: 300x30x35 W A 36 K 5 V 17

 300 = wheel diameter in mm

 30 = wheel thickness in mm
 35 = bore or hole dia for accommodating the spindle
 W = manufacturers symbol for abrasive used (optional)
 A = type of abrasive
 36 = grain size
 K = soft grade
 5 = dense structure
 V = vitrified bond
 17 = manufacturers’ private marking to identify wheel (optional)
Classification of grinding
machines
 Surface grinding machine
 Horizontal spindle type with reciprocating table
 Vertical spindle type with reciprocating table
 Horizontal spindle type with rotary table
 Vertical spindle type with rotary table
 Cylindrical grinding machine
 Center type
 Centerless type
 Chucking type
 Internal grinding machine
 Chuck type
 Centerless type
 Special purpose grinding machine
 Tool and cutter grinding machine
 Roll grinding machine
 Crankshaft grinding machine
 Thread grinding machine
 Cam grinding machine
 NC grinding machine
Surface Grinding
Horizontal spindle type with reciprocating table
https://www.youtube.com/watch?v=gcWj4OcteTk
Vertical spindle type with reciprocating table
https://www.youtube.com/watch?v=ZzE9fz46tk8
Horizontal spindle type with rotary table
https://www.youtube.com/watch?v=xCCVVpz4Irk
Vertical spindle type with rotary table
https://www.youtube.com/watch?v=15LAwfJxmhU
Cylindrical Grinding – Center type
https://www.youtube.com/watch?v=TxsMgttuQCg
https://www.youtube.com/watch?v=FfjA5ZEUhi0&t=449s
https://www.youtube.com/
watch?v=Lf_BVY76cNE
Centerless grinding machine
https://www.youtube.com/watch?v=PTU90sAR8xM
 https://www.youtube.com/watch?v=Nt
f8CnvsIgM

https://www.youtube.com/watch?v=G_su61ed6vI
Cylindrical Grinding
 External and Internal grinding
Finishing Processes
 The surface finish that can be obtained by
regular machining operations is not high.
Though a regular machined surface is
sufficient for general engineering purposes,
some times higher surface finish is desired
in certain special applications for obtaining
perfect fits and accuracy.
 To achieve this, various surface finishing
operations are to be done, which are also
called superfinishing or micro finishing
operations.
Superfinishing operations
Lapping

Honing

Super finishing

Polishing

Buffing

Pickling and oxidizing

Electroplating

Galvanising

Metal spraying

Metallisation
Lapping
 Lapping is an abrasive surface finishing
operation used to produce surfaces
smoother than those produced by grinding.
 It is a low speed, low pressure final
abrasion finishing operation that produces
extreme dimensional accuracy, corrects
minor imperfections of shape, refines
surface finish and produces close fit
between mating surfaces.
 Both flat and external cylindrical surfaces
can be finished by lapping.
Principle of operation
Lapping Methods & Machines

Hand Machine
Lapping Lapping
Hand Lapping
 Machine Lapping
Vertical spindle lapping machine

https://www.yout
ube.com/watch?
v=Z6togIVqC4M
Advantages
 Highly accurate plain, spherical or cylindrical
surfaces may be generated or imparted by lapping.
 Good surface finish and close dimensional
tolerances can be achieved.
 Any material, hard or soft, metallic or non metallic
can be lapped.
 Due to low cutting speeds, the heat generated in
minimized.
 Since the parts are not clamped during operation,
there is no warping of lapped components.
 No burrs are created. In fact burrs generated in
milling, drilling and other processes are eliminated.
Limitations
 Requires experience and skilled
operators to obtain consistent and
accurate results.
 Trial and error may be needed to get
optimum results.
 It is a costly process.
Applications
 Gauges
 Piston rings
 Valves
 Gears
 Roller bearings
 Dies and metal moulds
 Surface plates
 Washers and a variety of other parts.
Honing
 Honing is a low velocity abrading
process primarily used for finishing
internal cylindrical surfaces of previously
machined parts. It is also used to correct
out of roundness, taper and axial
distortion of internal surfaces in work
pieces.
 However this process can also be used
for finishing external cylindrical and flat
surfaces.
Principle of Honing
Honing Machines

Horizontal Vertical
honing honing
machine machine
Horizontal honing machine
Vertical honing machine

https://www.youtube.com/watch?v=dTAoAO
cTBK8
Advantages
 The workpiece need not be rotated by
power. Hence chucks, faceplates or
rotating tables are not required.
 Good surface finish and close
dimensional tolerances can be
achieved.
 Honing can be done on most materials
from aluminum to hardened steel
carbides, ceramics and glass.
Limitations
 The process is slightly slower.
 Horizontal honing may create oval
shaped holes unless the work is rotated
and supported.
Applications
 Cylinder blocks
 Liners
 Engine cylinders
 Gun barrels
 Long tubular parts
 Connecting rods
 Gears
 Injection pump parts
 Hydraulic valves and a variety of other
parts.
Super finishing
 Superfinishing is similar to honing, used
to produce extremely high finishes. The
material removed in this process is of
the order 0.005 to 0.02mm.
 This process can be used to finish
external or internal cylindrical surfaces
and flat surfaces.