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Shaping & Grinding and Realated Operations
Shaping & Grinding and Realated Operations
These process require skilled operators and for the most part
have been replaced by other processes
Horizontal-push cut
Plain (Production work)
Universal (Tool room work)
Horizontal-draw cut
Vertical
Slotter
Key seater
The tool post and the tool slide can be angled as seen below. This allows
the shaper to be used for different types of work
The tool post has been The top slide is slowly feed
The tool post is not angled so
turned at an angle so that into the material so that a
that the tool can be used to
side of the material can ‘rack’ can be machined for a
level a surface.
be machined rack and pinion gear system.
Figure: Schematic of
planers. (a) Double-
housing planer with
multiple tool heads
and a large
reciprocating table; (b)
single-housing or
open-sided planer.
The grinding process consists of removing material from the workpiece by the
use of a rotating wheel that has a surface composed of abrasive grains. Grinding
is considered to be the most accurate of the existing machining processes.
Grinding processes are used when high accuracies, close dimensional tolerances,
and a fine surface finishes are required. Grinding processes also allow for high
production rates. This allows for a lowered cost of production. Hard materials can
also be machined.
Grinding may be classified as non-precision or precision, according to purpose
and procedure.
Non-precision grinding: The common forms are called, snagging and off-
hand grinding. Both are done primarily to remove stock that can not be taken
off as conveniently by other methods. The work is pressed hard against the
wheel or vice versa. The accuracy and surface finish are of secondary
importance.
Precision grinding: Precision grinding is concerned with producing good
surface finishes and accurate dimensions. Three types of precision grinding
exists
External cylindrical grinding
Internal cylindrical grinding
Surface grinding
Department of Industrial & Production Engineering 26/14
Grinding Operations
Figure: Examples
of various cylindrical
grinding operations.
(a) Traverse
grinding, (b) plunge
grinding, and (c)
profile grinding.
Figure: (a) Schematic illustration of the creep-feed grinding process. Note the large wheel depth of cut.
(b) A shaped groove produced on a flat surface in one pass by creep-feed grinding. Groove depth can be
on the order of a few mm. (c) An example of creep-feed grinding with a shaped wheel.
4v d
Undeformed chip thickness, t =
VCr D
v d
Grain force ∝
VC D
1/ 2
VC
Temperature rise ∝ D d
1/ 4 3/ 4
v
D=Grinding wheel diameter Volume of material removed
Grinding ratio, G =
d= Wheel depth of cut Volume of wheel wear
V= Tangential velocity
v= Workpiece velocity C=0.1 per mm2 to 10 per mm2
t=Undeform thickness (grain depth of cut) r= 10 to 20 for most grinding operation