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Elements of Mechanical Engineering

Milling and Grinding Machines

Milling and Grinding Machines


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Elements of Mechanical Engineering


Milling and Grinding Machines
Unit Overview Unit Objective List of Lectures: 1. Principle of Operation of Milling Machine and Types of Milling Machines 2. Working of Horizontal and Vertical Milling Machines

3. Milling Processes
4. Straddle Milling and Gang Milling; Milling Machine Specification 5. Principle of Working of Grinding Machines and Their Classification 6. Bonding Materials Used in Grinding Wheels; Types of Grinding Machines 7. Surface, Cylindrical and Center Less Grinding 8. Self Test
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Elements of Mechanical Engineering


Milling and Grinding Machines
Overview
This unit consists of seven lectures. In lecture 1 we learn the principle of operation of milling machine, and discuss about types of milling machines. In lecture 2 we discuss about the working of horizontal and vertical milling machines. In lecture 3 we learn some of the milling processes such as plane milling, end milling, slot milling, angular milling and form milling. In lecture 4 we learn about straddle milling and gang milling, discuss how a milling machine is specified. In lecture 5 we discuss about the principle of working and classification of grinding machines, discuss about abrasives used in grinding machines and their classification. In lecture 6 we discuss about bonding materials used in grinding wheels, we also discuss about the types of grinding machines. In lecture 7 we discuss about surface, cylindrical and center-less grinding.

Elements of Mechanical Engineering


Milling and Grinding Machines
Objective
At the end of this unit you should Understand the principle of milling and grinding machines. Be able to tell how milling machines and grinding machines are classified. Understand the different operations that are performed in milling and grinding machines. Understand the types of bonding materials used in grinding wheels.

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Principle of Operation of Milling Machine and Types of Milling Machines


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines Lecture Objective Lecture Introduction

List of Topics:
Types of Milling Machines Summary and Review Questions

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines Objective
We learn the principle of operation of milling machine, and discuss about types of milling machines.

Introduction
Milling is one of the most versatile machining processes or a metal cutting process for removing excess material from a work piece with a rotating multiple cutting tools. Each tooth removes a small amount of metal in each revolution; hence metal removal rate is high. Milling can be used to produce a very large variety of intricate shapes and size. A milling machine is a machine tool used to produce parts having flat as well as curved shapes of metal and other solid materials. Its basic form is that of a rotating cutter or end mill which rotates about the spindle axis (similar to a drill), and a movable table to which the work piece is affixed. That is to say the cutting tool generally remains stationary (except for its rotation) while the work piece moves to accomplish the cutting action. cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines Introduction
A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter (Milling cutter). The milling cutter is a multiple point tool, which has equally spaced peripheral teeth. The cutter rotates at a speed and because of the multiple cutting edges on the cutter it removes metal at a very fast rate. The machine can also hold one or more number of cutters at a time. This is why a milling machine finds wide application in production work. This is superior to other machines as regards accuracy and better surface finish.

Milling operation

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines Types of Milling Machines
Milling machines are generally classified into two types. This classification is done based on the orientation of the axis of rotation of the spindle or the cutter. The two types are: a) Horizontal Milling Machine b) Vertical Milling Machine In horizontal milling machine the spindle is horizontal and in the same plain as the table and in vertical milling machine the spindle is vertical to the table. Milling machines are classified based on the construction features a) Knee and column type milling machine 1. Plain or horizontal milling machine (horizontal spindle) 2. Universal milling machine (horizontal spindle with swivel table) 3. Omniversal milling machine (horizontal spindle with swivel table and swivel knee) 4. Vertical milling machine 5. Turret type milling machine 6. Ram type milling machine cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines Types of Milling Machines
b) Bed type 1. Horizontal spindle bed type milling machine 2. Vertical spindle bed type milling machine 3. Simplex duplex triplex model (based on number of milling spindles) c) Planar type 1. Fixed bridge milling machine 2. Moving bridge or Gantry type milling machine d) Special type 1. Profilers 2. Duplicators

3. Rotary Millers
4. Planetary Millers

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines Summary
We have discussed about the principle of milling, and the different types of milling machines.

Review Questions
1. What is a milling machine? 2. What is meant by multi-point cutting tool? 3. Explain how milling machines are classified.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Operation of Milling Machine and Types of Milling Machines

End of Lecture

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Working of Horizontal and Vertical Milling Machines


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Lecture Objective List of Topics:

Milling Processes
Up-Milling Down-Milling Comparison of Up Milling and Down Milling Processes Column and Knee Type Milling Machine Horizontal Milling Machine Vertical Milling Machine

Summary and Review Questions

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Objective
We discuss about the working of horizontal and vertical milling machines.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Milling Processes Up-Milling
It is know as a conventional milling. Metal is removed when the cutter moves upwards. The cutter rotates opposite direction of feed of work piece. At the beginning of the cutting process the chip thickness is at minimum as the process of cutting proceeds the thickness of the chip increases. Thickness of the chip would be maximum at the end of the cut. Similarly in case of stress, minimum at the initial stage, increases and reaches maximum at the end of the cut. The cutting force is directed upwards and this tends to lift the work from the table, therefore greater need for good clamping device.

Up-milling
Animation

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Down-Milling
This type of milling is also known as climb milling. The metal removed by the cutter is in the downward direction. The cutter and feed are in the same direction. In this type of milling the chip thickness is maximum at the beginning of the cut and decreases as the cutting process progress. Thickness of the chip is least at the end of the cut. The cutting force is maximum when the tooth begins its cut and it reduces to minimum when the tooth leaves the work piece. The cutting action of the teeth press the work piece downwards, this tends to seat the work firmly on the table. Hence, lesser clamping force is required for the work piece.

Animation

Down-milling 3 of 12

Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Comparison of Up-Milling and Down Milling Processes
Sl. UPMILLING The direction of rotation of the cutter and the work piece travel are in the opposite direction. DOWNMILLING The direction of rotation of the cutter and work piece travel are in the same direction.

No
1

The material removed by the milling cutter starts with a minimum thickness and ends with a
maximum thickness.

The material removed by the milling cutter starts with a maximum thickness and ends with a minimum
thickness.

The cutting force of the milling cutter acts upwards tends to lift the work piece from the
table, results in greater clamping force.

The cutting force of the milling cutter acts down wards, push the work piece in down direction results
in lesser clamping force.

4
5 6 7

The chips accumulate at the cutting zone and interfere with cutting tool.
It is difficult to pour the coolant directly at the cutting zone. In up milling greater speeds and feeds are not possible. In up milling good surface finish can be obtained.

Chips are disposed off easily and do not interfere with cutting tool.
The coolant can be poured directly at the cutting zone. In down milling greater speeds and feeds are possible. In down milling good surface finish can be obtained.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Column and Knee Type Milling Machine
Knee and column milling machines are designed for general-purpose work and can perform not only the straight milling of plane and curved surfaces but also gear and thread cutting drilling boring and slotting.

Horizontal milling machine Knee and column type

Knee and column type horizontal milling machine


Explain

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Horizontal Milling Machine Knee and Column type
The basic components of a knee and column type milling machines are 1. The base, which supports the other components. 2. The column, which contains the spindle and its driving mechanism. 3. The over arm, which provides support for arbor mounted cutters. 4. The knee, a separate section attached to the column and can move vertically over the column. 5. The saddle, which is supported by and moves horizontally on the knee. 6. The table, which supports the work piece and can move horizontally at right angles to the saddle movement. Base: The base of the machine is made of cast iron. The top and bottom surface are machined accurately and serves as a foundation member for all other parts of the machine. Base provides strength and rigidity to the machine. It may also contain a reservoir for cutting fluids. Column: The column is the supporting frame mounted vertically on the base. The column is hollow box shaped and incorporates all driving mechanisms, like the spindle, the bearings, the gearbox, the clutches, the shafts, the pumps, and the shifting mechanisms for transmitting power from the cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Horizontal Milling Machine Knee and Column type
electric motor to the spindle at a selected speed. The front vertical face of the column is accurately machined and contains a dovetail guide ways. The over arm is supported at the top of the column. Knee: The knee is a rigid cast iron casing, which slides up and down on the vertical face of the column over a dovetail guide ways. The guide ways are perpendicular to the front face of the

Knee and Column horizontal milling machine 7 of 12

cont'd ...

Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Horizontal Milling Machine Knee and Column type
column. The elevating screw is used to raise or lower the knee (Z direction) to accommodate the height of the work piece. On top face of the knee a horizontal dovetail guide ways are provided for saddle. Saddle: The saddle can slides on the face of the knee, this movement is know as cross feed. The saddle moves perpendicular to the face of the column (movement towards and away from the column). The cross feed is obtained by hand or by power. The top surface of the saddle is machined to high degree of accuracy and a dovetail guide ways are provided for the table to be mounted. The guide ways are parallel to the face of the column. Table: The table rests on the saddle and travels longitudinally. The longitudinal travel of the table is perpendicular to the axis of the spindle. The top and bottom of the table is machined for high degree of accuracy, T slots are provided on top face of the table, which supports for work holding devices like vice. The table movement is either by hand or power. Over arm: The over arm is mounted on the top face of the column. One end of the arbor is supported on vertical face of the column and the other end is supported by over arm, which also acts as bearing for the arbor.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Principal Parts of a Vertical Milling Machine

Vertical Milling machine


Explain

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Principal Parts of a Vertical Milling Machine
The basic components of a knee and column type Vertical milling machines are 1. The base, which supports the other components. 2. The column, which contains the spindle and its driving mechanism. 3. The knee, a separate section attached to the column and can move vertically over the column. 4. The saddle, which is supported by and moves horizontally on the knee. 5. The table, which supports the work piece and can move horizontally at right angles to the saddle movement. 6. The spindle head, this hold the spindle which is normal to the machining surface or the table. The base, column, knee, saddle and table of a vertical milling machine are very similar to that of the Horizontal Milling machine. The difference is the positioning of the spindle. The spindle axis is vertical or normal to the machining surface of the work piece. The over arm and the arbor are not present in vertical type. The milling cutter is directly mounted on to the spindle with spindle attachment. The spindle head or Machine head is supported by the column, which is mounted on the base of the milling machine. Spindle shaft one end is connected to a motor through a gearbox for, varying cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Principal Parts of a Vertical Milling Machine

Vertical milling machine


speed of the spindle. The other end of the spindle shaft is connected to the milling cutter. The spindle can move up and down relative to work piece. In some vertical milling machines the spindle head can swivel, allowing the milling cutter to machine angular surfaces.
Vertical milling machines are used for machining grooves, slots and flat surfaces. The usual tools that are mounted on to the spindle are end mill and face mill.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines Summary
We have discussed about the two types of milling- up milling, and down milling. We studied the column and knee type milling machine construction, and operation.

Review Questions
1. Explain up milling and down milling with the help of sketches. 2. What are the differences between up milling and down milling? 3. Explain with a neat sketch the working of column and knee type vertical milling machine. 4. Explain with a neat sketch the working of column and knee type horizontal milling machine.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Working of Horizontal and Vertical Milling Machines

End of Lecture

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Milling Processes


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Lecture Objective List of Topics:

Milling Operations
Slab or Plain Milling Face Milling Slotting Angular Milling Form Milling Summary and Review Questions

Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Objective
We learn some of the milling processes such as plane milling, end milling, slot milling, angular milling and form milling.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Milling Operations
The different types of milling operations that can be carried out on a milling machine are:

1. Slab or plain milling


2. Face milling 3. Straddle milling 4. Slotting 5. Angular milling 6. Gang milling 7. Form milling

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Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Slab or Plain milling
The slab milling is the operation of producing flat, horizontal surface parallel to the axis of rotation of a slab-milling cutter. Slab milling is done to remove the material from the upper surface of the work piece. The slab milling cutters is held in the arbor and it may have straight or helical teethes. Both cutters can be used to generate flat surfaces. The require depth of cut can be adjusted by raising the table or the knee and the feed is given by moving the saddle.

Slab or Plain milling

Helical teeth mill cutter

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Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Face Milling
Face milling is the operation of milling flat surface on the face of the work piece. The difference between the plain milling and the face milling is the axis of the milling cutter. The operation is performed by a face-milling cutter rotated about an axis perpendicular to the surface machined. The face-milling cutter is mounted on a vertical milling machine. The cutter is directly mounted on to the spindle head. The depth of cut is adjusted by raising or lowering the spindle head.

Face milling 4 of 8

Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Slotting
The process of producing keyways grooves and slots of varying shapes and sizes is known as slotting. The side milling cutter is mounted on to the arbor of a horizontal milling machine when slotting had to be done on Horizontal milling machine. TSlots and dovetail slots are carried out on a veridical milling machine.

Simple slotting of key way using side milling cutter

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Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Angular Milling
The angular milling is a process of generation of angular surface on a work piece. The angular groove may be single or double angle depends on the shape of groove required. One simple example of angular milling is a v-block.

Angular milling 6 of 8

Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Form Milling
It is a process of producing a required profile on the work piece. This process is carried out on horizontal milling machine. The number of parallel and angular relationships that can be machined by horizontal (peripheral) milling is limited almost solely by cutter design. Form cutters are expensive, but it is the only way of obtaining complex profiles.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes Summary
We have discussed about different milling operations such as plain milling, face milling, slotting, angular milling, and form milling.

Review Questions
1. What are the different operations that can be performed on a milling machine? 2. Explain with neat sketches the working of a) Plain milling b) Face milling c) Slotting d) Angular milling e) Form milling

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Elements of Mechanical Engineering


Milling and Grinding Machines
Milling Processes

End of Lecture

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Straddle Milling and Gang Milling; Milling Machine Specification


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Straddle Milling and Gang Milling; Milling Machine Specification Lecture Objective List of Topics:

Gang Milling
Straddle Milling Summary and Review Questions

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Elements of Mechanical Engineering


Milling and Grinding Machines
Straddle Milling and Gang Milling; Milling Machine Specification Objective
We learn about straddle milling and gang milling, discuss how a milling machine is specified.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Straddle Milling and Gang Milling; Milling Machine Specification Gang Milling
It is a process of milling a work piece with two or more cutter mounted on the same arbor. There are no space collars provided. The size of the cutter can be same or different depending up on the profile of the end product required. Gang milling is commonly used to produce several different steps simultaneously in a work piece or to produce sections of the same thickness from bars or extrusions.

Gang Milling

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Elements of Mechanical Engineering


Milling and Grinding Machines
Straddle Milling and Gang Milling; Milling Machine Specification Straddle Milling
The straddle milling is the operation of generating two flat vertical surfaces on either sides of work piece at the same time. The side milling cutters are mounted on the arbor of the horizontal milling machine. The space between the two side mills depends of the width of the vertical surface and the distance is obtained by the spacing collars.

Straddle Milling

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Elements of Mechanical Engineering


Milling and Grinding Machines
Straddle Milling and Gang Milling; Milling Machine Specification Summary
We have discussed gang milling and straddle milling. We have see how a milling machine is specified.

Review Questions
1. Explain with a neat sketch how gang-milling operation is performed on a milling machine. 2. Explain with a neat sketch how straddle-milling operation is performed on a milling machine. 3. Explain how a milling machine is specified.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Straddle Milling and Gang Milling; Milling Machine Specification

End of Lecture

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Principle of Working of Grinding Machines and Their Classification


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Working of Grinding Machines and Their Classification Lecture Objective Lecture Introduction

List of Topics:
Reasons for Grinding Grinding Wheel Abrasives Summary and Review Questions

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Working of Grinding Machines and Their Classification Objective
We discuss about the principle of working and classification of grinding machines, discuss about abrasives used in grinding machines and their classification.

Introduction
Grinding is a metal removal process or a finishing process, where metal is removed due to abrasive action of rotating grinding wheel. By grinding, good surface finish is obtained on the work piece. Always grinding is used as a finishing process. The amount of material removed by grinding process varies from microns to millimeters.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Working of Grinding Machines and Their Classification Reasons for Grinding
1. The material is too hard to be machined economically.

2. Tolerances required preclude machining. Grinding can produce flatness tolerances of less than 0.0025 mm (0.0001 in) on a 127 x 127 mm (5 x 5 in) steel surface if the surface is adequately supported.

Grinding Operation

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Working of Grinding Machines and Their Classification Grinding Wheel
The grinding wheel is a multi point cutting tool. Grinding wheel is made of very small abrasive particles, and these are held together by a bonding material. The abrasive particles are very hard and projects out on the surface of the wheel. When the grinding wheel is rotated at higher speeds and the work is fed against the grinding wheel, due to abrasive action metal is removed from the work piece. During grinding the abrasive particles becomes blunt and automatically gets dislodged from the wheel and new abrasive particles are exposed to the surface.

Grinding Wheel

Abrasives
The abrasives which are used for manufacturing grinding wheels are of two types, they are Natural and synthetic abrasive particles. 1. Natural abrasive particles are sand stone, quartz, corundum and diamond. 2. Synthetic abrasive particles are silicon carbide, cubic boron nitride and aluminum oxide.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Working of Grinding Machines and Their Classification Summary
We have discussed the principle of grinding. We have discussed about the abrasives used in grinding wheels.

Review Questions
1. What is grinding? What are the advantages of grinding?

2. Explain the different materials used as abrasives on a grinding wheel.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Principle of Working of Grinding Machines and Their Classification

End of Lecture

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Bonding Materials Used in Grinding Wheels; Types of Grinding Machines


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Lecture Objective List of Topics: Bonding Materials Classification of Grinding Machines Summary and Review Questions

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Objective
We discuss about bonding materials used in grinding wheels, we also discuss about the types of grinding machines.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Bonding Materials
Bond is an adhesive substance used to hold the abrasive grits together to form a grinding wheel. Selection of bonding material to form a wheel depends on several parameters like working temperature, material to be machined and strength. The following are the different bonding materials used for manufacturing grinding wheel. 1. Vitrified bond (V) 2. Silicate bond (S)

3. Resinoid bond (B)


4. Rubber bond (R) 5. Shellac bond (E) 6. Oxychloride bond (O)

cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Bonding Materials
Grit: The grit size refers to the size of the abrasive particles. The grit or grain size is denoted by a number. To obtain smooth surface on the work piece fine-grained wheels are used. For rough grinding, coarse-grained grinding wheels are used. Coarse Medium Fine Very fine 10 30 80 200 Grit or grain size 12 14 16 36 46 54 100 120 150 240 280 320 20 60 180 400 24 500 600

The above table shows the grit or grain size number. Greater the grit number smaller the grit size. Grade: The grade of the grinding wheel indicates the bond strength. This is the bonding strength, which holds the grits intact. The grade of the wheel is represented by alphabets. A indicates the softest grinding wheel and Z indicates the hardest grinding wheel. Soft Medium Hard A I Q B J R C K S D L T E M U F N V G O W H P X

Z cont'd ...

The above table indicates the grades of grinding wheel.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Bonding Materials
Structure; The structure of the wheel indicates the space between the grits. The wheel with close grit spacing is known as open structure is suitable for grinding hard materials, and the wheel with wide space between the grit is known as dense structure, suitable for grinding soft materials. Numbers ranging from 1 to 15 specifies the structure of the wheel. Dense Open 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 And above

Glazing: After continuous use of grinding wheel, the cutting edges wear off and get a glass appearance on the surface of the wheel. This is known as glazing. Loading: During grinding, material is removed from the work piece. This material fills the gap between the grits results in inefficient in cutting. This is known as loading. Dressing: Both glazing and loading will decrease the material removal rate from the work piece. Dressing is a process to remove both glazed and loaded wheel and make it useful for cutting operation. cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Bonding Materials
A wheel dresser is used to dress the grinding wheel. After dressing new grits (Abrasive particles) are exposed to the surface, which will remove more material from the work piece. Truing: Truing is an operation to correct any irregularities in the grinding wheel. During grinding, wheel geometry (shape and size) should be maintained. A diamond tool is used for truing the wheel. Balancing: The grinding wheel speed varies from 2000 to 10,000 rpm. If the wheel is not properly balanced lead to unbalanced centrifugal force, and these unbalanced forces will breaks the wheel at higher speeds. Heavy paint and lead is applied on the (side or on the flange) grinding wheel to maintain uniform weight through out the body of the grinding wheel.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Classification of Grinding Machines
Grinding machines are classified as follows 1. Rough grinders 2. Precision grinders a) Cylindrical grinders b) Internal grinders c) Surface grinders d) Tool and cutter grinders e) Special grinders

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Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines Summary
We have discussed about the bonding materials used on grinding wheels. We looked into the classification of grinding machines.

Review Questions
1. What is a bonding material? Why it is required? 2. What are the bonding materials generally used in a grinding wheel? 3. Explain the following terms related to bonding materials a) Grit b) Grade c) Structure

d) Glazing

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Elements of Mechanical Engineering


Milling and Grinding Machines
Bonding Materials Used in Grinding Wheels; Types of Grinding Machines

End of Lecture

Elements of Mechanical Engineering


Milling and Grinding Machines

Lecture: Surface, Cylindrical and Center Less Grinding


START

Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Lecture Objective List of Topics:

Cylindrical Grinding
Surface Grinding Center Less Grinding Summary and Review Questions

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Objective
We discuss about surface, cylindrical and center-less grinding.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Cylindrical Grinding
In cylindrical grinding the work piece is held between the centers, and it is rotated at slow speed. The cross feed (depth of cut) is given by moving the wheel head perpendicular to the work piece. The table can be reciprocated by rotating the hand wheel or by auto feed. Both the work piece and grinding wheel will rotate in opposite direction at different speeds.

The figure shows a cylindrical grinding machine. The main parts are bed, table headstock, tailstock and wheel. cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Cylindrical Grinding Machine
Bed: The bed is the main part and supports all other parts. The bed houses the table traversing mechanism. The guide ways are provided on the top of the bed. Table: The machine consists of two tables, upper and lower table. The lower table reciprocates on the guide ways of the bed. Adjustable trip dogs are located on the upper table, which helps to vary the length of reciprocation.

cont'd ...

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Cylindrical Grinding Machine

Cylindrical grinding machine


Head Stock and Tailstock: The headstock and tailstock are mounted on the upper table. The work piece is held between the centers. The headstock is rigidly fixed on the table and the tailstock can be moved to different positions to held various length work pieces. The work piece is held at headstock, which rotates the work piece at different speeds. Wheel head: The grinding wheel is connected to wheel head. The wheel head is connected to a electric motor, which rotates the grinding wheel at higher rated speeds. The wheel head (grinding wheel) is moved perpendicular to the work piece.

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Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Surface Grinding

Surface grinding
Explain

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Surface Grinding
Surface grinding machine is used mainly to machine flat surfaces. The wheel head can be moved up and down to vary the depth of cut. The work piece is held on a magnetic table. The longitudinal feed is done by rotating the hand wheel or by auto feed mechanism; and the cross feed is provided by rotating the cross feed hand wheel. These grinding machines are also used to machine tapered, irregular and circular work pieces.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Center Less Grinding
The center less grinding process is as shown in figure. The grinding wheel, a regulating wheel and work rest blade supports the work piece. Both grinding wheel and regulating wheel rotates in the same direction. The regulating wheel is smaller in diameter compare to grinding wheel and is made of rubber. The regulating wheel is held at an angle of with respect to grinding wheel. Example: To grind piston pin or piston, center less grinder is used. Top face of the piston is flat and lower side is hollow, the material used for construction of piston is aluminum alloy. The piston has to finished to a high degree of accuracy (Microns) and surface finish hence center less grinder is the only process which satisfies our requirements.

Center less grinding 7 of 10

cont'd ...

Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Center Less Grinding

Center less grinding


cont'd ...

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Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Advantages of Center Less Grinding
1. The work is supported along its full length. So a work piece having small diameter and larger length can be machined with out any deflection of the work piece. 2. Suitable for mass production. 3. Less skilled operator is required to machine any complex component. 4. No work holding devices are used.

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding Summary
We have discussed about surface, cylindrical and center less grinding machine parts, and operations.

Review Questions
1. With a neat sketch explain surface grinding. 2. With a neat sketch explain cylindrical grinding. 3. With a neat sketch explain center less grinding. 4. What are the advantages of center less grinding?

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Elements of Mechanical Engineering


Milling and Grinding Machines
Surface, Cylindrical and Center Less Grinding

End of Lecture

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