Grinding

PRESENTERS ARE
Prashant Sankaran 100106251 Pragyan Kumar 100106246 Omender Sharma 100106233 Omar Ebadur Raheman 100106232

Overview
Grinding Wheels. Abrasives, Bonds. Cutting action. Specifications. Wear: Attrition wear, Fracture Wear. Dressing and Truing. Max chip thickness and Guest Criteria. Surface, Cylindrical Grinding and Centre-less Grinding.

GRINDING WHEELS

What is grinding?
Grinding is a material removal and surface generation process used to shape and finish components made of metals and other materials. The precision and surface finish obtained through grinding can be up to ten times better than with either turning or milling.

All applications of abrasive products are intended to generate surfaces:

Industrial challenges in grinding J.F.G. Oliveira (1)a,*, E.J. Silva b, C. Guo (2)c, F. Hashimoto (1)d a IPT

The requirements for efficient grinding include

Abrasive components which are harder than the work Shock- and heat-resistant abrasive wheels Abrasives that are friable. That is, they are capable of controlled fracturing.

What is a Grinding wheel?

A grinding wheel is an expendable wheel that is composed of an abrasive compound used for various grinding (abrasive cutting) and abrasive machining operations. They are used in grinding machines.

The wheels are generally made from a matrix of coarse particles pressed and bonded together to form a solid, circular shape, various profiles and cross sections are available depending on the intended usage for the wheel.
They may also be made from a solid steel or aluminium disc with particles bonded to the surface.

Characteristic of a Grinding Wheel

There are five characteristics of a cutting wheel: material, grain size, wheel grade,

grain spacing, &

bond type.

Abrasives
An abrasive is a material, often a mineral, that is used to shape or finish a work piece through rubbing which leads to part of the work piece being worn away. While finishing a material often means polishing it to gain a smooth, reflective surface it can also involve roughening as in satin, matte or beaded finishes. Abrasive ranges from a macroscopic grains as large as about 2 mm to microscopic grains about 0.001 mm in diameter. Some naturally occurring abrasives are: sand and calcite. And some artificial abrasives are ceramics and Borazon.

Materials
The actual abrasive, is selected according to the hardness of the material being cut. Accordingly some materials are: Aluminium Oxide (A) Silicon Carbide (S) Ceramic (C) Diamond (D, MD, SD) Cubic Boron Nitride (B)

 Grain size, from 8 (coarsest) 1200 (finest), determines the physical size of the abrasive grains in the wheel. A larger grain will cut freely, allowing fast cutting but poor surface finish. Ultra-fine grain sizes are for precision finish work. Wheel grade, from A (soft) to Z (hard), determines how tightly the bond holds the abrasive. Grade affects almost all considerations of grinding, such as wheel speed, coolant flow, maximum and minimum feed rates, and grinding depth.
Grain spacing, or structure, from 1 (densest) to 16 (least dense). Density is the ratio of bond and abrasive to air space. A less-dense wheel will cut freely, and has a large effect on surface finish. It is also able to take a deeper or wider cut with less coolant, as the chip clearance on the wheel is greater.

Wheel Bond
how the wheel holds the abrasives, affects finish, coolant, and minimum/maximum wheel speed. Vitrified (V) Resinoid (B) Silicate (S) Shellac (E) Rubber (R) Metal (M) Oxychloride (O)

CUTTING ACTION

DEPTH OF CUT
It is the thickness of the material removed in surface grinding for one cut. Depth of cut in grinding depend on the: Cutting load Power of the machine Finish required

GRINDING WEAR

Grinding wear
The principle characteristics of Grinding wear are: They are primarily caused by particles under high stress under relatively low speeds. The cutting edges dull after a series of operations been performed. Change in shape due to localized high stress points. Due to the presence of lubricant the tool tends to smoothen along with the work piece. Both horizontal and vertical components of grinding increases linearly with wear flat area.

There are two types of Wearing in Grinding wheels:

1. 2.

Attritious wear Fracture wear

Attritious wear
It results in the dulling of the tips of abrasive grain by rubbing against the work piece surface. The Attritious wear, although contributes insignificantly to the total, is the most important form of wear. Dulling of grains occurs due to Attritious wear

Fracture wear
It is the removal of abrasive particle from the wheel either by fracturing within the grain or fracturing within the bond. Most common type of wear.

The rate at which fracture wear occurs is directly related to the grinding forces.

Dressing and Truing

Truing is the process of making a grinding wheel round and concentric with the grinding wheel spindle axis. Truing is also the process of forming a specific shape on the face of the wheel. Dressing is the process of conditioning the surface of a trued wheel to expose the grain for efficient grinding action.

 A properly trued and dressed wheel grinds with a minimum of grinding power, has no burn or chatter, and produces good quality parts. The technology in the rotary diamond dressing field has improved to such an extent that tolerances in the millionths of an inch are being consistently met. This method of dressing is not only the fastest but also the most accurate way to shape grinding wheels in high volume production of precision parts.

MAXIMUM CHIP THICKNESS

Maximum chip thickness

Maximum chip thickness is the most important parameter for achieving a productive and reliable milling process. Effective cutting will only take place when this is maintained at a value correctly matched to the milling cutter in use.

A thin chip with a hex value that is too low, is the most common cause of poor performance resulting in low productivity. This can negatively affect tool life and chip formation.
A value that is too high will overload the cutting edge, which can lead to breakage.

Surface Grinding Machine

Surface grinding is the most common of the grinding operations. It is a finishing process that uses a rotating abrasive wheel to smooth the flat surface of metallic or non-metallic materials to give them a more refined look or to attain a desired surface for a functional purpose.

Cylindrical Grinding
The cylindrical grinder is a type of grinding machine used to shape the outside of an object. The cylindrical grinder can work on a variety of shapes, however the object must have a central axis of rotation. but is not limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft.

Cylindrical grinding is defined as having four essential actions: The work (object) must be constantly rotating The grinding wheel must be constantly rotating The grinding wheel is fed towards and away from the work Either the work or the grinding wheel is traversed with the respect to the other.

Centre-less Grinding
Centerless grinding is a form of grinding where there is no collet or pair of centers holding the object in place. Instead, there is a regulating wheel positioned on the opposite side of the object to the grinding wheel. A work rest keeps the object at the appropriate height but has no bearing on its rotary speed. Centerless grinding is much easier to combine with automatic loading procedures than centered grinding; throughfeed grinding, where the regulating wheel is held at a slight angle to the part so that there is a force feeding the part through the grinder, is particularly efficient

Fig: A Schematic Diagram of Centre-less Grinding