UNIT-V

ME305 MANUFACTURING PROCESS – II

GRINDING MACHINES
 GRINDING (Abrasive machining)

• Grinding is a surface finishing operation where very thin layer of

material is removed in the form of fine dust particles. (thickness
0.25-0.5mm)

• Grinding can be defined as a material removal process by the

abrasive action between rotating abrasive wheel & the work piece.

• Grinding machine is a power operated machine tool where, the

work piece is fed against a constantly rotating abrasive wheel which
is also called as Grinding wheel so that a thin layer of material is
removed from the work piece.
 PRINCIPLE OF GRINDING

• The work piece is fed against

a constantly rotating abrasive

wheel so that a thin layer of

material is removed from the

it.

FIG. GRINDING
 GRINDING PROCESS
 GRINDING WHEEL

Bonding Grinding
Abrasives
materials wheels
  GRINDING WHEEL

• A grinding wheel is a multitooth cutter made up of many hard particles known as

abrasives which have been crushed to leave sharped edges for machining.

• Every grinding wheel has two constituents:

i. Abrasive used for cutting.

ii. Bond that holds abrasive grains.

 BASIC FUNCTIONS OF A GRINDING WHEEL:-

1. Removal of stock

2. Generation of cylindrical, flat and curved surfaces

3. Production of highly finished surfaces

4. Cutting off operations

5. Production of sharp edges and points.

 CONSTRUCTION OF GRINDING WHEEL:-

Grinding wheel consists of-

i. Abrasives

ii. Bond

iii. Grit/grain size

iv. Grade

v. Structure of wheels
  ABRASIVES:-

• An abrasive is a hard and tough substance, having sharp edges. It cuts or wears
away materials softer than itself.
• Important properties of abrasives are penetration hardness, fracture resistance and
wear resistance.

 TYPES OF ABRASIVES:-

 Natural abrasives- they are obtained from nature. Natural abrasives are sand
stone, emergy/corundum, diamond and garnet.

 Artificial/synthetic abrasives- they are manufactured to have well defined and

controlled properties of hardness, roughness and type of structure. Artificial o
synthetic abrasives are silicon carbide(SiC), aluminium oxide(Al2O3)
 BOND:-

o The bond is an adhesive substance which cements or holds the abrasive grains
together to form a grinding wheel.
o Depending upon the application, bond imparts the qualities of hardness or
softness to the grinding wheel.
o The choice or selection of the bond depends upon the accuracy, the required
surface finish and the nature of grinding operation.
  Bonding materials & Process

• Vitrified Process: Abrasive+ Feld spar & clay, heated at higher temperatures in

kilns.75-80% of grinding wheels are made by this process.

• Silicate Process: Abrasive+ Silicate of soda. Baked @ 260°C for 20 to 80 Hrs.

• Elastic Process: Abrasives + Shellac. Baked @150°C for few hours.

• Vulcanite or Rubber Process: Abrasive+ Pure rubber+ Sulphur.

  GRIT/GRAIN SIZE:-

• Size of grain grit is determined by sorting or grading the material by passing

through screens with the no. of meshes per linear inch.

• The grain size influences stock removal rate and the generated surface finish.

• The selection of grain size is determined by-

i. Nature of grinding operation

ii. Material to be grinded

iii. Material removal rate

iv. Surface finish required

 GRIT/GRAIN SIZE:-

SR. NO. SIZE TYPE APPLICATIONS

1. 10,12,14,16,20,24 Coarse Rapid material removal

2. 30,36,46,54,60 Medium Stock removal and finish both

3. 80,100,120,150,180 Fine Less stock removal, high surface

finish
4. 220,240,280,320,400,500,600 Very fine Very high surface finish, grinding
hard materials
  GRADE OF THE WHEEL:-

 Structure of the grinding wheel represents to the grain spacing or the manner in

which the abrasive grains are distributed throughout the wheel.

 The entire volume is occupied by abrasive grains, bonding material and pores.

 The primary purpose of structure is to provide chip clearance and it may be open

medium or dense.

SR. NO. TYPE DESIGNATION APPLICATION

1. Dense 1,2,3,4 Cutting and snagging, hard and brittle
materials
2. Medium 5,6,7,8 90% grinding wheels

3. Open 9,10,11,12,13,14 Soft, tough, ductile materials e.g. ball

bearings, brass, bronze
  (WHEEL DESIGNING):

• It consists of 6 symbols representing following properties of grinding wheel:

i. Manufacturer’s symbol

ii. Type of abrasive

iii. Grain size

iv. Grade

v. Structure

vi. Type of bond

vii. Manufacture symbol (optional) for reference

 Example of a wheel specification:

51 A 36 L 5 V 40

51 Manufacturer’s symbol indicating type of abrasive

A Abrasive (aluminium oxide)

36 Grain size(medium)

L Grade(medium)

5 Structure(dense)

V Bond(vitrified)

40 Manufacture symbol (suffix) optional

FIG. COATED &MOUNTED ABRASIVE WHEELS
 Types of Grinding

 On the basis of quality of grinding, it is classified as rough grinding and

precision grinding.

 Rough Grinding

 Precision Grinding

 Rough Grinding:- It involves removal of stock without any reference to the

accuracy of results.

 Precision Grinding:- Precision grinding removes negligible amount of metal. It is

used to produce finished parts and accurate dimensions.
 CLASSIFICATION OF GRINDING MACHINES

Grinding machines are classified based on their construction & type of surface

produced.

1. Bench Grinding Machine

2. Surface Grinding Machine

3. Cylindrical Grinding Machine

4. Centerless Grinding Machine

5. Internal Grinding Machine

6. Special Purpose Grinding Machine

 1.Bench Grinding Machine

• Two wheels of different grain sizes for roughing and finishing operations and is
secured to a workbench.
2. SURFACE GRINDING MACHINE

Principle: The work piece is fed

against a constantly rotating
abrasive wheel so that a thin layer
of material is removed from the it.

Work Piece Type: Flat, Angular &

Irregular surfaces

FIG. PRINCIPLE OF SURFACE GRINDING

 Surface Grinding machine

FIG. SURFACE GRINDING MACHINE

  SURFACE GRINDING MACHINE

• This machine may be similar to a milling machine used mainly to grind flat
surface. However, some types of surface grinders are also capable of producing
contour surface with formed grinding wheel.

• Basically there are four different types of surface grinding machines

characterised by the movement of their tables and the orientation of grinding
wheel spindles as follows:

• Horizontal spindle and reciprocating table

• Vertical spindle and reciprocating table

• Horizontal spindle and rotary table

• Vertical spindle and rotary table

 Horizontal spindle and reciprocating table

c
 Vertical spindle and reciprocating table
 Horizontal spindle and rotary table  Vertical spindle and rotary table
 CYLINDRICAL GRINDING MACHINE

Principle:
The work piece is held between two
centers & and the rotating grinding wheel
is fed against it.

External Grinding machine

FIG. PRINCIPLE OF CYLINDRICAL
GRINDING
Work Piece Type: Cylindrical surfaces
may be straight, curved or contoured.
  CYLINDRICAL GRINDING MACHINE

• This machine is used to produce external cylindrical surface. The surfaces may

be straight, tapered, steps or profiled. Broadly there are three different types of

cylindrical grinding machine as follows:

1. Plain centre type cylindrical grinder

2. Universal cylindrical surface grinder

3. Centreless cylindrical surface grinder

 Cylindrical Grinding Machine

FIG. CYLINDRICAL GRINDING MACHINE

 Plain centre type cylindrical grinder
 Universal cylindrical surface grinder

• Universal cylindrical grinder is similar to a plain cylindrical one except that it

is more versatile. In addition to small worktable swivel, this machine
provides large swivel of head stock, wheel head slide and wheel head mount
on the wheel head slide.
  Special application of cylindrical grinder

• Principle of cylindrical grinding is being used for thread grinding with

specially formed wheel that matches the thread profile. A single ribbed wheel
or a multi ribbed wheel can be used as shown in Fig. below.
  CENTERLESS GRINDING MACHINE

Principle: The work piece is placed on work rest

blade between two wheels namely grinding &
regulating wheel, which are rotating in clockwise &
work piece rotates counter clockwise. Grinding
wheel remove material from W/P surface &
regulating wheel regulates the W/P.

Centerless: Means work piece is not held between

centers.
Work Piece Type: Curved or Cylindrical surfaces
FIG. PRINCIPLE OF
of long slender rods which cannot be ground on CENTERLESS GRINDING

cylindrical grinding.
 Centre less Grinding
 External centreless grinder

• This grinding machine is a production machine in which out side diameter

of the workpiece is ground. The workpiece is not held between centres but
by a work support blade. It is rotated by means of a regulating wheel and
ground by the grinding wheel.
  Internal grinding machine

• This machine is used to produce internal cylindrical surface. The

surface may be straight, tapered, grooved or profiled.

• Broadly there are three different types of internal grinding

machine as follows:

 Chucking type internal grinder

 Planetary internal grinder

 Centreless internal grinder

  Chucking type internal grinder

• The workpiece is usually mounted in a chuck. A magnetic face plate can also be
used. A small grinding wheel performs the necessary grinding with its peripheral
surface. Both transverse and plunge grinding can be carried out in this machine.
 Planetary internal grinder

• Planetary internal grinder is used where the workpiece is of irregular shape

and can not be rotated conveniently as shown in Fig. below. In this machine
the workpiece does not rotate. Instead, the grinding wheel orbits the axis of
the hole in the workpiece.
  Centreless internal grinder

• This machine is used for grinding cylindrical and tapered holes in cylindrical
parts (e.g. cylindrical liners, various bushings etc). The workpiece is rotated
between supporting roll, pressure roll and regulating wheel and is ground by
the grinding wheel.
Wheel Surface Finishing

Truing

• Truing is the act of regenerating the required geometry on the grinding wheel,
whether the geometry is a special form or flat profile. Therefore, truing
produces the macro-geometry of the grinding wheel.

• Truing is also required on a new conventional wheel to ensure concentricity

with specific mounting system. In practice the effective macro-geometry of a
grinding wheel is of vital importance and accuracy of the finished work piece
is directly related to effective wheel geometry.
 Manufacturing Technology

Dressing
• Dressing is the conditioning of the wheel surface which ensures that grit cutting
edges are exposed from the bond and thus able to penetrate into the work piece
material. Also, in dressing attempts are made to splinter the abrasive grains to
make them sharp and free cutting and also to remove any residue left by
material being ground.
• Dressing therefore produces micro-geometry. The structure of micro-geometry of
grinding wheel determine its cutting ability with a wheel of given composition.
Dressing can substantially influence the condition of the grinding tool.
• Truing and dressing are commonly combined into one operation for conventional
abrasive grinding wheels, but are usually two distinctly separate operation for
super abrasive wheel.
Finishing Operation
• To ensure reliable performance and prolonged service life of modern machinery,
its components require to be manufactured not only with high dimensional and
geometrical accuracy but also with high surface finish.
• The surface finish has a vital role in influencing functional characteristics like
wear resistance, fatigue strength, corrosion resistance and power loss due to
friction.
• The finishing operations are assigned as the last operations in the single part
production cycle usually after the conventional or abrasive machining
operations, but also after net shape processes such as powder metallurgy, cold
flash less forging, etc.
 Finishing Operations

• Finishing Operations

– Lapping

– Buffing

– Honing

– Super finishing

– Wire brushing

– Polishing
 Lapping

Lapping

• In lapping, instead of a bonded abrasive tool, oil-based fluid suspension of very

small free abrasive grains (aluminum oxide and silicon carbide, with typical grit
sizes between 300 and 600) called a lapping compound is applied between the
work piece and the lapping tool.

• The lapping tool is called a lap, which is made of soft materials like copper,
lead or wood. To accomplish the process, the lap is pressed against the work
and moved back and forth over the surface.

• Lapping is sometimes performed by hand, but lapping machines accomplish the

process with greater consistency and efficiency.
 Lapping

• Lapping is regarded as the oldest method of obtaining a fine finish. Lapping is

basically an abrasive process in which loose abrasives function as cutting points
finding momentary support from the laps. Material removal in lapping usually
ranges from .003 to .03 mm but many reach 0.08 to 0.1mm in certain cases.
• Lapping processes are used to produce dimensionally accurate specimens to
high tolerances (generally less than 2.5 µm uniformity).

• Lapping is used to produce optical lenses, metallic bearing surfaces, gages, and
other parts requiring very good finishes and extreme accuracy.
 Characteristics of lapping process:

• Use of loose abrasive between lap and the work piece

• Usually lap and work piece are not positively driven but are guided in contact

with each other

• Relative motion between the lap and the work should change continuously so

that path of the abrasive grains of the lap is not repeated on the work piece.
 Lapping

Schematics of lapping process showing the lap and the cutting action of suspended abrasive
particles.
Figure (a) Schematic illustration of the lapping process. (b) Production lapping on flat surfaces.(c)
Production lapping on cylindrical surfaces.
 Manufacturing Technology

• Abrasives of lapping  Lubricating materials of

– Al2O3 and SiC, grain size 5~100μm lapping
– Cr2O3, grain size 1~2 μm  Machine oil
 Rape oil
– B4C3, grain size 5-60 μm
 grease
– Diamond, grain size 0.5~5 V
• Technical parameters affecting lapping processes are
– unit pressure
– the grain size of abrasive
– concentration of abrasive in the vehicle
– lapping speed
 Polishing And Buffing

Polishing
• Polishing is a finishing operation to improve the surface finish by means of a polishing
wheel made of fabrics or leather and rotating at high speed. The abrasive grains are glued
to the outside periphery of the polishing wheel. Polishing operations are often
accomplished manually.
Buffing
• Buffing is a finishing operation similar to polishing, in which abrasive grains are not
glued to the wheel but are contained in a buffing compound that is pressed into the
outside surface of the buffing wheel while it rotates. As in polishing, the abrasive particles
must be periodically replenished.
• As in polishing, buffing is usually done manually, although machines have been designed
to perform the process automatically.

• Buffing wheels are made of discs of linen, cotton, broad cloth and canvas
  Honing

• Honing is a finishing process performed by a honing tool, which

contains a set of three to a dozen and more bonded abrasive sticks.
• The sticks are equally spaced about the periphery of the honing tool.
• They are held against the work surface with controlled light pressure,
usually exercised by small springs.
• The honing tool is given a complex rotational and oscillatory axial
motion, which combine to produce a cross hatched lay pattern of very
low surface roughness

Honing tool
Honing
 Honing

• Stone

– Al2O3 or SiC bonded abrasives

• The critical process parameters are:

– Rotation speed

– Oscillation speed

– Length and position of the stroke

– Honing stick pressure

• Parameters that affect material removal rate (MRR) and surface roughness (R) are:

– Unit pressure, p

– Peripheral honing speed, Vc

– Honing time, T
 Super finishing

Super finishing

• Super finishing is a micro finishing process that produces a controlled surface

condition on parts which is not obtainable by any other method. The operation
which is also called ‘micro stoning’ consist of scrubbing a stone against a
surface to produce a fine quality metal finish.

• The process consists of removing chatter marks and fragmented or smear metal
from the surface of dimensionally finished parts. As much as 0.03 to 0.05 mm
of stock can be efficiently removed with some production applications, the
process becomes most economical if the metal removal is limited to 0.005 mm
Super finishing

Figure Schematic illustrations of the super finishing process for a cylindrical part. (a)
Cylindrical mircohoning, (b) Centerless microhoning.