1 May 1, 2020

ME6402 – MANUFACTURING TECHNOLOGY - II

UNIT-4
ABRASIVE PROCESS AND BROACHING

Faculty Name: MR.I.SIRAJUDEEN, AP/MECHANICAL

2 May 1, 2020
 Contents:
 ABRASIVE PROCESS
 GRINDING WHEEL
 TYPES OF GRINDING PROCESS
 CYLINDRICAL GRINDING
 SURFACE GRINDING
 CENTRELESS GRINDERS
 HONING
 LAPPING
 SUPER FINISHING
 Polishing And buffing
 FORMING METHOD
 GEAR SHAPING
 GEAR HOBBING

3 May 1, 2020
 ABRASIVE PROCESS
Abrasive machining is a machining process where
material is removed from a workpiece using a
multitude of small abrasive particles. Common
examples include grinding, honing, and
polishing. Abrasive processes are usually
expensive, but capable of tighter tolerances and
better surface finish than other machining
process.

4 May 1, 2020
 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.
5 May 1, 2020
TYPES OF GRINDING PROCESS
Grinding is done on surfaces of almost all conceivable shapes and
materials of all kinds. Grinding may be classified broadly into two
groups .
Rough or non-precision grinding.
Precision grinding.

Rough grinding:
The common forms of rough grinding are snagging and off-hand
grinding where the work is held in the operator’ s hand. The work is
pressed hard against the wheel, or vice -versa. The accuracy and
surface finish obtained are of secondary importance.

Precision grinding:
This is concerned with producing good surface finish and high
degree of accuracy. The wheel or work both are guided in precise
paths.

6 May 1, 2020
 CYLINDRICAL GRINDERS

• Centre- type (Plain)

• Centre- type (Universel)
• Centre less

7 May 1, 2020
Cylindrical grinder
 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. This includes
but is not limited to such shapes as a cylinder, an ellipse
, a cam, or a crankshaft.[1]

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.
8 May 1, 2020
CYLINDRICAL GRINDING

9 May 1, 2020
SURFACE GRINDING
 Surface grinding produces flat surface.
 The work may be ground by either the
periphery or by the end face of the grinding
wheel.
 The work piece is reciprocated at a constant
speed below or on the end face of the
grinding wheel.

10 May 1, 2020
TYPES OF SURFACE GRINDERS
(a)Reciprocating table
(i) Horizontal spindle
(ii) Vertical spindle
(b) Rotating table
(i) Horizontal spindle
(ii) Vertical spindle

11 May 1, 2020
SURFACE GRINDERS
 Surface grinding machines are employed to finish
plane or flat surfaces. They are also capable of
grinding irregular, curved, convex, and concave
surfaces.
Conventional surface grinders may be divided into
two classes
 One class has reciprocating tables for work ground
along straight lines
 while the other covers the machines with rotating
work tables for
 The first two are most commonly used for repetitive
work by hand operation or with simple fixtures.
 The third type is widely used for production
operations where parallel surfaces are ground
simultaneously.

12 May 1, 2020
PLAIN CENTER TYPE GRINDER

13 May 1, 2020
HORIZONTAL SURFACE GRINDER

14 May 1, 2020
VERTICAL SURFACE GRINDER

15 May 1, 2020
CENTRELESS GRINDERS

 Centre less grinding is a method of grinding

exterior cylindrical, tapered, and formed
surfaces on work pieces that are not held and
rotated on centers.
 The principal elements of an external Centre less
grinder are the grinding wheel, regulating or back
up wheel, and the work rest. Both wheels are
rotated in the same direction.
 The work rest is located between the wheels. The
work is placed upon the work rest, and the latter,
together with the regulating wheel, is fed forward,
forcing the work against the grinding wheel.

16 May 1, 2020
 HONING
 Honing is an abrasive machining process that
produces a precision surface on a metal workpiece by
scrubbing an abrasive stone against it along a
controlled path. Honing is primarily used to improve
the geometric form of a surface, but may also improve
the surface texture.
 Typical applications are the finishing of cylinders for
internal combustion engines, air bearing spindles and
gears. Types of hone are many and various but all
consist of one or more abrasive stones that are held
under pressure against the surface they are working
on.
 In everyday use, a honing steel is used to hone knives,
especially kitchen knives, and is a fine process, there
contrasted with more abrasive sharpening.

17 May 1, 2020
 HONING TOOLS

18 May 1, 2020
 LAPPING
 Lapping is a machining operation, in which two
surfaces are rubbed together with an abrasive
between them, by hand movement or by way of a
machine.
 This can take two forms. The first type of lapping
(traditionally called grinding), typically involves
rubbing a brittle material such as glass against a
surface such as iron or glass itself (also known as the
"lap" or grinding tool) with an abrasive such as
aluminum oxide, jeweller's rouge, optician's rouge,
emery, silicon carbide, diamond, etc., in between
them. This produces microscopic conchoidal fractures
as the abrasive rolls about between the two surfaces
and removes material from both.
19 May 1, 2020
 LAPPING PLATES

20 May 1, 2020
 SUPER FINISHING
 Super finishing, also known as
micromachining and short-stroke honing,
is a metalworking process that improves
surface finish and work piece geometry. This
is achieved by removing just the thin
amorphous surface layer left by the last
process with an abrasive stone; this layer is
usually about 1 μm in magnitude. Super
finishing, unlike polishing which produces a
mirror finish, creates a cross-hatch pattern on
the work piece.

21 May 1, 2020
 Polishing And buffing
 Polishing and buffing are finishing processes
for smoothing a work piece's surface using an
abrasive and a work wheel. Technically
polishing refers to processes that use an
abrasive that is glued to the work wheel, while
buffing uses a loose abrasive applied to the
work wheel. Polishing is a more aggressive
process while buffing is less harsh, which
leads to a smoother, brighter finish. A
common misconception is that a polished
surface has a mirror bright finish, however
most mirror bright finishes are actually buffed.
22 May 1, 2020
 Gear Cutting Equipment

 Metal Lathe
 Horizontal Mill
 Horizontal Cutoff Saw
 Indexing Head
 Drill Bit
 Gear Involute Cutter
 Gear Blank & Mandrel

23 May 1, 2020
 Gear Cutting Equipment
Horizontal Mill Saw Cutoff Band Saw

24 May 1, 2020
 Gear Cutting Equipment

Metal Lathe

Drill

Gear Tooth
Gage
Gear
Blank
Gear Cutter
Mandrel

25 May 1, 2020
 FORMING METHOD

 In form machining, a form cutter is used. The formed cutter may

be single point cutting tool or a multipoint milling cutter. The
cutting edges of the formed cutter has been finished to the
shape of the space between the gear teeth being cut. Forming
method is used for Very small number of gears.
 Gears produced by forming are less accurate. Forming process
is simple and cheaper. This method is takes more time. Gears
are produced by forming method in milling, machine, shaper,
planer, and broaching machine.

FORMING OF GEARS IN MILLING

MACHINE:
Spur gears, helical gears and straight bevel gears are cut on a
milling machine. Here a disc like form cutter is used. A dividing
head is used for holding and indexing the gear blank. Indexing
is the operation of dividing the periphery of the (gear blank) in
to any number of equal divisions.

26 May 1, 2020
FORMING OF GEARS IN MILLING MACHINE

27 May 1, 2020
 GEAR SHAPING

 In gear shaping, a pinion type cutter is used.

 The cutter teeth are ground with a top rake and clearance.
 The cutter is mounted on a vertical spindle.
 The axes of the cutter and blank are parallel.
 The cutter and the blank are made to rotate together as two
gears which are in mesh.
 The surface speeds of the cutter and the blank are the same.
 The cutter reciprocates in a vertical direction along the width of
the blank.

28 May 1, 2020
 GEAR SHAPING

29 May 1, 2020
Shaping External Gear

Shaping Internal Gear

30 May 1, 2020
 Gear hobbing

31 May 1, 2020
GEAR HOBBING
 Hobbing is a process of generating a gear by
means of a rotating cutter called hob.
 The hob has helical threads.
 Grooves are cut in the threads parallel to the
axis.
 This will provide the cutting edges.
 Proper rake and clearance angles are ground
on these cutting edges.
 The rotating hob acts like a continuously
moving rack as it cuts.

32 May 1, 2020