Mechanics of Grinding

UNIT 5 MECHANICS OF GRINDING AND and Grinding Operation

GRINDING OPERATION
Structure
5.1 Introduction
Objectives

5.2 Mechanics of Grinding

5.2.1 Chip Length
5.2.2 Chip Thickness

5.3 Active Grains Density

5.4 Force Measurement
5.5 Wheel Wear
5.6 Thermal Aspects of Grinding
5.7 Grinding Operations
5.7.1 Surface Grinding
5.7.2 Cylindrical Grinding
5.7.3 Centreless Grinding

5.8 Creap Feed Grinding

5.9 Summary
5.10 Answers to SAQs
5.11 Exercises
5.12 Nomenclature

5.1 INTRODUCTION
It is always desirable to know how a manufacturing process works and what are its
potential applications. To understand how a grinding process works, one should know
how the material removal takes place during grinding or in other words one should learn
the mechanics of grinding which would also involve the important parameters affecting
the grinding process performance. As regards the applications, one should know the kind
of operations that can be performed on a grinding machine and the constraints under
which these operations are performed. This unit will deal basically with both these
aspects of grinding.
Objectives
After studying this unit, you should be able to understand
• mechanics of grinding involving estimation of mean and maximum chip
thickness in surface grinding as well as internal and external cylindrical
grinding,
• how to measure the grinding forces and how to evaluate specific energy
during grinding,
• the mechanism of grinding wheel wear,
• various types of grinding operations like surface grinding, cylindrical
grinding, centreless grinding and creep feed grinding, and
• the applications of various types of grinding operations.

15
Abrasive Machining
Processes 5.2 MECHANICS OF GRINDING
To achieve the desired ground surface characteristics, grinding parameters should be
correctly selected. For this purpose, it is desirable to understand the mechanics of
grinding of different types of materials. However, we will restrict our discussion only to
ductile materials. There are various kinds of grinding operations like surface grinding,
external cylindrical grinding, internal cylindrical grinding, centreless grinding and creep
feed grinding. To understand the mechanics of grinding, let us consider a case of surface
grinding, wherein the cutting by a single grain of abrasive is taking place.
During surface grinding, the work-table is moving at velocity Vt (m/min) while the
grinding wheel is rotating at speed N revolution per minute. AE represents the surface
machined in the earlier cut by an individual abrasive grain and BC indicates the surface
being generated in the present cut ∠ COB = θ as shown in the Figure 5.1. It is of interest
to evaluate the maximum undeformed chip thickness ‘t’ (= EH in Figure 5.2) and chip
length ‘l’.

Figure 5.1 : Schematic Diagram Showing an Abrasive Grain Removing Metal

From Figure 5.1,
D
−d
OF
cos θ = = 2 . . . (5.1)
OC D
2
D
or, d= (1 − cos θ) . . . (5.2(a))
2
where, d is the depth of cut (= BF), and D is grinding wheel diameter.
From the geometry of Figure 5.1,
D
CF = sin θ . . . (5.2(b))
2
From Figure 5.1, and Eq. (5.1) and Eq. (5.2(b)), and using the well known relationship
sin2 θ = 1− cos2 θ, we get
⎡ ⎧ ⎫ ⎤
2
⎢ 2
⎪ d⎪ ⎥
⎛D⎞
CF 2 = ⎜ ⎟ ⎢1 − ⎨1 − ⎬ ⎥ . . . (5.3)
⎝2⎠ ⎢ ⎪ D⎪ ⎥
⎢ ⎩ 2 ⎭ ⎥⎦
⎣

⎛D⎞
2 ⎛ ⎛ 2d ⎞ ⎞
2
=⎜ ⎟ ⎜1 − ⎜1 − ⎟ ⎟⎟
⎝2⎠ ⎜ ⎝ D ⎠ ⎠
⎝

⎛ D ⎞ ⎡ ⎪⎧ 4d 4d 2 ⎪⎫⎤
2
= ⎜ ⎟ ⎢1 − ⎨1 − + 2 ⎬⎥
⎝ 2 ⎠ ⎣⎢ ⎪⎩ D D ⎪⎭⎦⎥

⎛D⎞
2
⎛ 4d 4 d 2 ⎞
=⎜ ⎟ ⎜⎜ − 2 ⎟
⎝2⎠ ⎝ D D ⎟⎠
16
Take the square root of both sides, we get Mechanics of Grinding
and Grinding Operation
D 4d 4d 2
CF = − 2
2 D D

CF = dD − d 2 . . . (5.4)

5.2.1 Chip Length

Consider BCF (Figure 5.1) as an approximate right angle triangle; the chord length BC
can be written as

BC = CF 2 + d 2

= dD − d 2 + d 2

= dD . . . (5.5)
Approximate chip length in case of external cylindrical grinding (le) and chip length in
case of internal cylindrical grinding (li) can be evaluated from the Eqs. (5.6(a) and (b)),
respectively.

⎡ ⎤
⎢ ⎥
le = ⎢ dD ⎥
. . . (5.6(a))
⎢⎛ D ⎞⎥
⎢ ⎜1 + ⎟⎥
⎣⎢ ⎝ Dw ⎠ ⎦⎥

⎡ ⎤
⎢ ⎥
li = ⎢ ⎥
dD
. . . (5.6(b))
⎢⎛ D ⎞⎥
⎢ ⎜1 − ⎟⎥
⎢⎣ ⎝ Dw ⎠ ⎥⎦

where, Dw is workpiece diameter.

5.2.2 Chip Thickness
The uncut chip shape can be approximated as a triangular shape as shown in Figure 5.2.
Let us consider a case of surface grinding. The chip thickness in surface grinding (ts =
EH) can be expressed as

⎛d d2 ⎞
ts = CE sin θ = 2 CE ⎜ − 2⎟ . . . (5.7(a))
⎜D D ⎟
⎝ ⎠
2
d ⎛d⎞
Since is very small so its square ⎜ ⎟ will be still smaller hence it can be safely
D ⎝D⎠
neglected.
d
Therefore, t s = 2 CE . . . (5.7(b))
D

Figure 5.2 : Simplified Representation of the Grinding Chip

17
Abrasive Machining In Figures (5.1) and (5.2), CE is the distance moved by the table during the time the
Processes
grinding wheel makes 1/ N′ revolution. Here, N′ is the number of active abrasive grains
on the grinding wheel surface. Let, Vt be the worktable speed and N be the grinding
wheel speed (RPM).
Then,
Vt
CE = . . . (5.8)
NN ′
From Eq. (5.7(b)) and Eq. (5.8),

Vt d
ts = 2 . . . (5.9)
NN ′ D
Let there be ‘C’ grains per unit cutting area of the grinding wheel, and average width of
each cut be ‘b’, then total number of active grains on the wheel periphery be
N′ = (πDb) C . . . (5.10)
Then, from Eqs. (5.9) and (5.10),

2Vt 1 d
ts = . . . (5.11)
(πDb ) C N D

But, wheel peripheral speed (Vw) is given by

Vw = π DN . . . (5.12)
Therefore, from Eqs. (5.11) and (5.12)

Vt d
ts = 2 . . . (5.13)
bC Vw D

In the similar manner, the expression can be derived to determine maximum undeformed
chip thickness for external and internal cylindrical grinding, respectively, as follows :

4 ⎛ Vt ⎞ d d
te = ⎜ ⎟ + . . . (5.14)
bC ⎝ (Vw + Vt ) ⎠ D Dw

4 ⎛ Vt ⎞ d d
ti = ⎜ ⎟ − . . . (5.15)
bC ⎝ (Vt + Vw ) ⎠ D Dw

where, Dw is diameter of workpiece, te is maximum undeformed chip thickness in

external cylindrical grinding and ti is the maximum undeformed chip thickness in internal
cylindrical grinding.

5.3 ACTIVE GRAINS DENSITY

In the above derivations, active grains density (number of active grains per unit area)
becomes very important parameter. Various methods have been proposed to evaluate the
value of N′. For this purpose, a soot coated plate is prepared on which a dressed grinding
wheel is rolled. Total numbers of contact points are counted on the enlargement made
using the plate as a negative.
Another method to determine the value of N′ is cumbersome in which the number of
chips produced in a given time period are counted. This method is based on the
assumption that active grain density initially increases with the increase in undeformed
chip thickness, and beyond a certain value of ‘t’ it almost remains unchanged (Figure
18 5.3).
 Mechanics of Grinding
and Grinding Operation

Figure 5.3 : Effect of Chip Thickness on Active Grains

5.4 FORCE MEASUREMENT

Force acting on the workpiece and grinding wheel interface can be measured by the
dynamometer (say, strain gauge type dynamometer). Three components of the force
acting on the workpiece during surface grinding are shown in Figure 5.4.

Figure 5.4 : Three Components of Force Acting during Horizontal Surface Grinding
Another important parameter to be evaluated is specific energy (u). It is defined as the
energy required for removing unit volume of the workpiece material. Its value depends
upon workpiece material and grinding conditions. However, it has been reported that it is
very high in grinding compared to that in single point cutting. However, its value
decreases as the undeformed chip thickness (t) increases. Such behaviour of high specific
energy in grinding has been attributed to the ‘size effect’ as well as the mechanism of
material removal at that value of ‘t’. Depending upon the normal force (or value of ‘t’),
the mechanism of material removal changes from rubbing (at very low value of ‘t’) to
ploughing, and from ploughing to cutting (at high value of ‘t’). Specific energy can be
calculated from the following equation :
F p Vw
u= . . . (5.16)
Vt B d
where, B is the width of the grinding wheel.
Table 5.1 : Comparison of Range of Specific Energy Required in Conventional
Grinding and Some of the Advanced Machining Processes
Sl. No. Process Workpiece Material Specific Energy (J/mm3)
1. Conventional Grinding -- 5-60
2. AFM -- 10-110
3. LBM Mild steel 8-45
4. ECSM -- 1900-4547
5. ECG Tool steel 85-250
6. EDM with rotating disc HSS 4000-7000
7. EDDG HSS 500-3000

[AFM – abrasive flow machining, LBM – laser beam machining, ESCM – electrochemical spark
machining, ECG – electrochemical grinding, EDM – electric discharge machining, EDDG – electric
discharge diamond grinding.]
19
Abrasive Machining Table 5.1 shows specific energy required in some of the advanced machining processes.
Processes
Some of these processes have been discussed in Block 4. This table indicates how
efficient a particular process is compared to other processes.

5.5 WHEEL WEAR

The relationship between grinding wheel wear and volume of the material removed is
very similar to three stage flank wear curve for a single point cutting tool (Figure
3.2(a),
Block 1). Rapid wear in the stage I is due to the protrusion of sharp grains in large
number. Stage 1 lasts for a very short period of time. In stage II, the rate of wheel wear
remains almost constant. This stage indicates the time period of useful life of the grinding
wheel after which it requires dressing. The grinding wheel should not be permitted to
enter in the stage III to avoid heavy dressing, loading and glazing of the wheel. Excess
vibration in stage III increases grinding force, leading to high temperature of the
workpiece. Further, in case of rough grinding (dashed line in Figure 5.5) would be
followed which means very large wheel life because during rough grinding self
dressing/sharpening action of the grinding wheel occurs automatically.

Figure 5.5 : Variation in Grinding Wheel Wear with Volume of Material Removed [Lal, 1996]

How Grinding Wheel Wear Takes Place?

To understand how the grinding wheel wear occurs, consider a part of grinding
wheel-work contact area. In Figure 5.6, ‘A’ indicates attrition wear of the grain at
the grain-workpiece interface which is gradual in nature and results in wear flat on
the grain tip. In this way, due to microfracture of the cutting point, plastic flow at
the grain tip and crumble of the sharp edge result in attrition wear [Lal, 1996].
The attrition wear gets aggravated due to high temperature at the interface.

Figure 5.6 : Schematic Diagram to Show Attrition Wear (A), Grain Fracture (GF)
and Bond Fracture (BF)

GF in Figure 5.6 indicates grain fracture (known as fracture wear) which occurs
due to high stresses acting on the grains. In such a case, the bond strength is more
than grain strength. If the grain is stronger than the bond (specially in case of soft
wheel) then the fracture of the bond material takes place (shown by BF) resulting
into bond-post fracture wear. Sometimes, when the grain is stronger than the
bond post strength then the grain may get pulled out of the wheel also. All these
phenomena lead to the grinding wheel wear. The high temperature at the interface
also plays a significant role in grinding wheel wear.
20
 Mechanics of Grinding
5.6 THERMAL ASPECTS OF GRINDING and Grinding Operation

In grinding operation, there are three sources of the heat generation similar to that
encountered in single point cutting (Figure 2.1, Block 1). First is due to plastic
deformation of workpiece material leading to chip formation. Second source of heat
generation is due to friction between the sliding chip and the front face of the abrasive
grain. Thirdly, the heat is generated due to the friction at the wheel-workpiece interface
zone. The grinding zone temperature is quite high and it results in high wheel wear due to
high temperature of workpiece which sometimes is responsible for the induced residual
thermal stresses and surface micro-cracks. It may even result in micro-structural
changes in the ground surface due to very high temperature.
Workpiece surface and sub-surface temperature can be measured using thermocouple
technique.

5.7 GRINDING OPERATIONS

Grinding operations are generally classified based on the type of surface produced. The
grinding operations can be categorized as
(i) Surface grinding
(ii) Cylindrical grinding
(a) External cylindrical grinding
(b) Internal cylindrical grinding
(iii) Centreless grinding
(a) External centreless grinding
(b) Internal centreless grinding
(iv) Creep feed grinding
5.7.1 Surface Grinding
Surface grinding is used for producing flat surfaces. Surface grinders are somewhat
similar to milling machine as regards the construction and the motions involved.
Surface grinders are of two types :
(i) Horizontal Spindle
(a) With rotating table (Figure 5.7(a)),
(b) With reciprocating table (Figure 5.7(b)).

(a) (b)
Figure 5.7 : Schematic Diagrams of Surface Grinding for Horizontal Spindle :
(a) with Rotating Table; and (b) with Reciprocating Table [Rao, 2002]
21
Abrasive Machining Reciprocating motion to the table is given by hydraulic power. Further, the
Processes
grinding wheel should over travel the workpiece at its both the ends. At the end of
each table motion, the wheel is given a cross feed motion.
(ii) Vertical Spindle
(a) With rotating table (Figure 5.8(a)),
(b) With reciprocating table (Figure 5.8(b)).

(a) (b)
Figure 5.8 : Schematic Diagrams of Surface Grinding with Vertical Spindle :
(a) with Rotating Table; and (b) with Reciprocating Table [Rao, 2002]

In this case, usually the width of the grinding wheel is wider than the workpiece. Hence,
no traverse feed is required. The configuration allows a number of pieces to be ground in
one setup.
During surface grinding, the workpiece (magnetic material) is held by a magnetic chuck
attached to the worktable as shown in Figure 5.9. Non-magnetic material workpiece is
held by vices, special fixtures, or some other device. A grinding wheel is mounted on the
horizontal spindle of the grinder. The size of the surface grinder is determined by the
surface dimensions that can be ground on the machine.

Figure 5.9 : Schematic Diagram of a Horizontal-Spindle Surface Grinder [Kalpakjian, 1989]

5.7.2 Cylindrical Grinding

Cylindrical grinding is done for both external cylindrical surfaces as well as internal
cylindrical surfaces.
External Cylindrical Grinding
Cylindrical grinding can be performed on external cylindrical surfaces to provide
good surface finish. It is commonly used for the grinding of spindles, pins, rollers,
etc. To grind the full length of the parts, either grinding wheel or the workpiece
can have lateral reciprocating motion along the axis, depending upon the machine
configuration.
To hold the workpiece during grinding, either chuck or face plate is used. But it is
quite common to hold the workpiece between the centers. Figure 5.10 shows a
typical cylindrical grinding machine in which two separate drives are used to run
the grinding wheel, and workpiece independently. The workpiece rotates at much
lower speed than the wheel, and both have opposite direction of rotation.
22
 Cylindrical grinding can also grind axi-symmetric cylindrical shapes provided the Mechanics of Grinding
and Grinding Operation
wheel is dressed to that shape (Figure 5.11) which is to be ground.

Figure 5.10 : Cylindrical Grinding Machine [Gerling, 1965]

To grind tapered surfaces, universal grinding machines are used in which

workpiece and grinding wheel axes can be moved and swiveled around a
horizontal plane. Such machines are computer numerical controlled (CNC) which
can produce accurate parts repeatedly.
Cylindrical grinding can also be used for thread grinding while using specially
dressed grinding wheel matching the shape of the threads (Figure 5.12). This
produces most accurate and very fine surface finish threads. The workpiece and
grinding wheel movements should be synchronized to produce accurate pitch of
the threads.

Figure 5.11 : Plunge Grinding of a Workpiece on a Cylindrical Grinder

with the Wheel Dressed to a Stepped Shape

(a) (b)
Figure 5.12 : Thread Grinding : (a) Traverse; and (b) Plunge Grinding

Internal Cylindrical Grinding

Grinding of internal cylindrical surfaces can be done on internal grinding machine
(Figure 5.13). In some configurations, workpiece and grinding wheel both rotate in
opposite direction (say, in the application of grinding of rings, bushes, etc.) while
in others only grinding wheel rotates (say, during grinding of car cylinder,
connecting rod, etc.). In internal grinding, the workpiece is usually held in a
rotating chuck and the grinding wheel rotates at high RPM (say, 30,000 RPM or
more). To grind the tapered workpiece, the headstock of the internal grinder is
23
Abrasive Machining swiveled with reference to horizontal plane. Depending upon the internal grinding
Processes
machine, the feed can be given to the workpiece or to the grinding wheel.

(A) (B)
Figure 5.13 : Two Configurations of Internal Cylindrical Grinding (A) a-Grinding Wheel,
b-Workpiece Motion, c-Down Feed of the Wheel, d-Lateral Feed. (B) a–Headstock,
b-Chuck, c-Workpiece, d-Grinding Wheel, e-Grinding Spindle, f-Grinding Head [Gerling,1965]

Figure 5.14 : Schematic Diagram of Planetary Grinding Machine Showing Different Motions of the
Grinding Wheel, a-Cutting Motion, b-Rotary Motion, c-Lateral Feed, d-Down Feed

For internal grinding of parts, which cannot be rotated, the internal grinding
machine with planetary spindle is used. As shown in Figure 5.14, the grinding
spindle is capable to provide cutting motions as lateral feed, down feed, and
planetary motion (circular motion) to the bore to be ground.
5.7.3 Centreless Grinding
In centreless grinding process, the cylindrical surfaces are ground in which the workpiece
is not supported between the centres (hence called centreless) or chucks, but by a blade
(Figure 5.15 and Figure 5.16). In this process, separately no workpiece rotation is
provided. This can be seen in Figure 5.16, in which the workpiece is supported by a
workpiece rest blade. The larger wheel is the grinding wheel while the smaller one is the
regulating wheel, which is mounted at an angle of α to the grinding wheel. Angle α
controls the axial feed of the workpiece, and it varies between 10 to 50 m/min. The
regulating wheel is usually rubber bonded. The workpiece centre is kept above the
grinding wheel centre (Figure 5.16), and it (work) rotates at the peripheral speed of the
regulating wheel.

a : Guide
b : Grinding Wheel
c : Feed Wheel

Figure 5.15 : Centreless Grinding

A typical class of parts that can be ground by this process are shaft, piston pins, roller
bearings etc., having diameter as small as 0.1 mm.
There are three types of centreless grinding operations: through feed, in feed and end
feed operations. The above discussion relates to through feed centreless grinding.
Sometimes centreless grinding may produce lobe shaped parts instead of cylindrical
parts.
24
Infeed or plunge centreless grinding can grind the parts like bolt or distributor shafts, Mechanics of Grinding
and Grinding Operation
which have variable diameters (Figure 5.16(b)). This process is useful in grinding those
workpieces that have an obstruction, which will not permit them to traverse past the
grinding wheel. The workpiece can be loaded only when the work-rest blade and the
regulating wheel are withdrawn.

(a) Centreless Grinder – Through Feed Grinding (b) Centreless Grinder – Plunge Grinding
Figure 5.16 : Schematic Illustration of Centreless Grinding Operation

Endfeed centreless grinding is used to grind the tapered workpieces. For grinding
internal cylindrical surfaces, internal centreless grinding process is used in which the
workpiece is supported between three rolls and ground.
It should be noted that centreless grinding process is not suitable for large workpiece
sizes but good for large volume of production. It requires less grinding allowance and
eliminates deflection of the workpiece.

5.8 CREEP FEED GRINDING

In this grinding process, the entire depth of cut is cut in one single pass only but the feed
rate is very small. The depth of cut can be as high as 30 mm while feed rate may be as
small as 0.025 m/min. However, the cutting force and hence the power requirement
increases as compared to conventional grinding. The grinding wheel should be
continuously dressed for its efficient working. Usually soft and open wheels are used to
accommodate large volume of chips generated in the process. The grinding wheel speed
is comparatively low (around 18 m/s). It uses oil based grinding fluids in flood condition
to dissipate high heat generated during the process. The infeed rates used are very low of
the order of 0.005 mm/pass.
Example 5.1
During surface grinding the table speed is kept as 30 m/min, and grinding wheel
peripheral speed is 1800 m/min. The depth of cut is 0.05 mm and active grains
density is 2 per mm2. The wheel diameter is 200 mm. Find out
(a) Spindle speed of the grinding wheel,
(b) Chip length (in mm), and
(c) Chip thickness in microns.
Solution
We are given with
Vt = 30 m/min, Vw =1800 m/min, b = 0.1 mm (assumed), C = 2/mm2, d = 0.05 mm,
and D = 200 mm.
(a) We know the formula to find out the rotational speed of a grinding wheel as
V
Nw = w
πD
where, Vw is in m/min, D is in m and N in RPM.

25
Abrasive Machining 1800
Processes ∴ Nw =
π × 0.2
Nw = 2865 RPM
(b) Chip length in surface grinding is given by

l s = dD

= 0.05 × 200

ls = 3.16 mm
(c) The chip thickness (t) is given as

2Vt d
t=
bCVw D

Substitute all the values.

2 × 30 0.05
t=
0.1 × 2 × 1800 200

5
= 0.1666
2000

= 0.00264
t = 2.64 mm
Example 5.2
A steel workpiece of 100 mm width and 250 mm length is being ground on a
horizontal grinder having a grinding wheel of diameter as 250 mm and width as
20 mm. The table speed on which the workpiece is mounted is 10 mm/min and the
grinding wheel RPM is 1528. Find out the time required to finish the workpiece.
Take the infeed rate as 4 mm per pass.
Solution
The approach allowance (i.e., the distance beyond which the wheel traverses) in
surface grinding is usually taken as equal to D/2. Hence,
A = D/2 = 250/2 = 125 mm.

A+ L
Time required for one pass =
Vt

where, L is workpiece length.

250 + 125 + 125

Therefore, t1 =
10 × 1000

t1 = 0.05 min
Number of passes, Pt = 100/4 = 25

∴ Total grinding time, tt = Pt × t1

= 25 × 0.05

26 tt = 1.25 min
Example 5.3 Mechanics of Grinding
and Grinding Operation
A cylindrical shaft having diameter equal to 40 mm and length equal to 400 mm is
to be ground. The shaft speed (Ns) is given as 100 RPM. The grinding wheel
diameter is 300 mm, width is 40 mm and down feed adjustment per cycle is 0.1
mm (or machined depth per cycle). Take grinding allowance as 0.20 mm and
grinding wheel speed as 1400 RPM. Calculate
(a) Peripheral speed of the shaft and grinding wheel in m/s.
(b) Total time (tt) required for grinding the shaft.
Schematic diagram is given in Figure 5.17.

Figure 5.17

Solution
(a) The peripheral speed (Vs) of the shaft is calculated as
π ds Ns
Vs =
1000
π × 40 × 100
=
1000
= 12.57 m/min
Vs = 0.21 m/s
π D Nw
Also, Vw =
1000
π × 300× 1400
=
1000
Vw = 1319 m/min
2Li
(b) Total time required for machining the shaft, tt =
s nw
where, L = length of the shaft, s = feed rate in mm/rev of the workpiece,
i = number of cuts to be made. We do not know i.
i = grinding allowance/down feed adjustment
= 0.20 / 0.01 = 20
i = 20 passes
2 × L × 20
Therefore, tt =
s × 100
Feed in mm per revolution of the workpiece is usually taken as half of the
width of the grinding wheel.
Therefore, s = 40/2 = 20 mm
Grinding length, L = 400 mm
27
Abrasive Machining 2 × 400 × 20
Processes Therefore, tm =
20 × 100
tm = 8 min.
Example 5.4
In Example 5.3, calculate
(a) Chip thickness, and
(b) Chip length.
Assume appropriate values for the missing data from Unit 4.
Solution
(a) Chip thickness in external cylindrical grinding is given by

4 ⎛ Vt ⎞ ⎛ d d ⎞
te = ⎜ ⎟ ⎜ + ⎟
bC ⎝ Vt + Vw ⎠ ⎝ D Dw ⎠

From Example 5.3, we know

d = 0.01 mm, D = 300 mm, Dw = 40 mm, Vw = 0.21 m/s
Vt = 1319 m /min.
Assume C = 2 per mm2

4 ⎛ 1319 ⎞ ⎛ 0.01 0.01 ⎞

∴ te = ⎜ ⎟ ⎜ + ⎟
40 × 2 ⎝ 12.6 + 1319 ⎠ ⎝ 300 40 ⎠

= 0.0495 (3.3 × 10 − 5 + 2.5 × 10 − 4

te = 0.00083 mm

dD Dw
(b) le =
Dw + D

0.01 × 300 × 40
=
300 + 40
le = 0.594 mm
SAQ 1
(a) Surface grinding is commonly used for
(i) bulk removal of the material
(ii) finishing operation
(iii) none of these
(b) Chip length in surface grinding is inversely proportional to
(i) work table speed
(ii) grinding wheel speed
(iii) wheel diameter
(iv) none of these
28
 (c) During surface grinding, the depth of cut is increased by a factor of 2 and Mechanics of Grinding
and Grinding Operation
grinding wheel diameter is decreased by a factor of 2. But, peripheral speed
of wheel is retained same. The chip length is
(i) increased
(ii) decreased
(iii) remains unchanged
(d) In the Question (c), the chip thickness is
(i) increased by a factor of 2
(ii) remains unchanged
(iii) decreased by a factor of 2
(iv) none of these.
(e) For the exactly same grinding conditions, the chip length in external
grinding compared to internal grinding is
(i) more
(ii) less
(iii) same

5.9 SUMMARY
This unit deals with the mechanics of grinding operation. It presents the analysis to
evaluate theoretically the chip thickness and chip length during surface grinding as well
as cylindrical external and internal grinding in terms of parameters known in priori. Such
analysis helps in parameters selection and improvement in the performance of the
process. It also explains how to measure the active grain density and three types of forces
acting during grinding. It is also important to understand how the grinding wheel wear
takes place, and how efficient is this process compared to other advanced machining
processes like EDM, AFM, MAF, etc.
This unit illustrates various types of grinding operations such as surface grinding,
cylindrical grinding (internal and external both), centreless grinding (internal and
external both) and creep feed grinding. Each section emphasises on the applications of
various kinds of grinding operations. Finally some solved examples are also included.

5.10 ANSWERS TO SAQs

SAQ 1
(a) (ii)
(b) (iv)
(c) (iii)
(d) (i)
(e) (ii)

5.11 EXERCISES 29
Abrasive Machining Exercise 1
Processes
How is grinding different from other conventional machining operations?
Exercise 2
Derive an equation to calculate chip thickness and chip length for the following :
(a) Surface grinding
(b) External cylindrical grinding
(c) Internal cylindrical grinding
Exercise 3
Briefly explain the special features of the creep feed grinding.
Exercise 4
Write some (say, 5) applications of centreless external grinding.
Exercise 5
During plunge cut surface grinding of a 10 mm wide workpiece, table speed is
41.7 mm/sec. The depth of cut is 0.025 mm, and the tangential and thrust forces
are
25 N and 40 N, respectively. The wheel diameter is 200 mm and its width is 20
mm. The active grain density is 2.5 per mm2 and the wheel speed is 2500 RPM.
Calculate specific energy and chip thickness. Assume missing data if required.

5.12 NOMENCLATURE
b – average width of each cut
B – width of the grinding wheel
C – grains per unit cutting area of the grinding wheel
d – depth of cut
D – grinding wheel diameter
Dw – workpiece diameter
fp – tangential component of the grinding force
l – chip length in surface grinding
le – chip length in external cylindrical grinding
li – chip length in internal cylindrical grinding
N – revolution per minute
N′ – active grains on the grinding wheel surface
t – undeformed chip thickness
te – undeformed chip thickness in external cylindrical grinding.
ti – undeformed chip thickness in internal cylindrical grinding.
ts – undeformed chip thickness during surface grinding
Vt – worktable velocity
θ – angle

BIBLIOGRAPHY
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Gerling H. (1965), All About Machine Tools, Willey Eastern Ltd., New Delhi. Mechanics of Grinding
and Grinding Operation
Kalpakjian S. (1989), Manufacturing Engineering and Technology, Addison-Wesley
Publishing Co., New York.
Lal G. K. (1996), Introduction to Machining Science, New Age International Publishers,
New Delhi.
Pandey P. C. and Singh C. K. (1998), Production Engineering Science, Standard
Publishers Distributors, Delhi.
Rao P. N. (2000), Manufacturing Technology : Metal Cutting and Machine Tools, Tata
McGraw-Hill Publishing Co. Ltd., New Delhi.

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