PEDESTAL GRINDING

THE NYERI NATIONAL POLYTECHNIC

MECHANICAL ENGINEERING DEPARTMENT
PRODUCTION PROCESSES TECHNOLOGY
COURSE CODE:1501:205
MODULE 2 CMC 21M2
MECHANICAL ENG DPT.
Bsc.M.Eng:MR :KIUNA R
 PEDESTAL GRINDING
By the end of this unit, the learners
should be able to:
Types of grinding Processes
Grinding machines
Grinding wheel
Grinding faults
Grinding wheel mounting
Care and maintenance of grinding
wheel
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Types Of Grinding Processes
Tool & Cutter Grinding
Surface Grinding
Cylindrical Grinding
Centerless Grinding
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PARTS OF A GRINDING MACHINE:-
Base or Bed
Tables
Headstock
Tailstock
Wheel head
Cross feed
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#1. Base-
■ It is a cast-iron casting rests on the floor and supports the other parts which
are mounted on it.The base houses the table drive mechanism and on the top of
the base accurately machined guideways are provided at right angles to the
table to slide on it.
#2.Table-
■ There are two tables, a lower table, and the upper table. The lower table
provides transverse movement to the work by sliding over the guideways on the
bed, which can be moved by hand or power. The upper table pivoted at its
center over the sliding table and provided with headstock and tailstock and
these can be positioned at any position along the table to hold the workpiece.
The upper table can be swiveled and clamped for grinding straight or tapered
surface.
#3.Head Stock:
■ The headstock fixed over the bed and supports the workpiece by means of a
dead center and drives it by means of a dog or it may hold the workpiece in a
chuck and drives it.
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#4.Tailstock:
■ The tailstock can be adjusted and fixed in any required
position to accommodate different lengths of the
workpiece.
#5.Wheel Head:
■ It consists of a grinding wheel and its driving motor.
■ The wheel head is mounted on a slide at the rear end of
the base and moves perpendicularly to the table ways by
hand or power to feed the grinding wheel to the work.
#6.Crossfeed:
■ The grinding wheel can be fed to the work by engagement
of the cross feed control lever by hand or power.
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Grinding Machines
 Pedestal Grinder
 Hand Grinder{portable}
 Cylindrical Grinder
 Surface Grinder
 Centerless Grinders
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Grinding Machine Types:-
There are 9 types of Grinding Machines:-
 Surface Grinding Machine.
 Cylindrical Grinding Machine.
 Centerless Grinding Machine.
 Tool & Cutter Grinding Machine.
 Jig Grinding Machine.
 Gear Grinding Machine.
 Centre Grinding Machine.
 Die Grinding Machine.
 Angle Grinding Machine.
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#1. Surface Grinding–
■ A surface grinder consists of an abrasives wheel, chucks (a
workpiece holding device), & a rotary table.
■ The chuck is used to hold the materials while the wheel and work
are rotated for a smooth finish.
#2. Cylindrical Grinding–
■ A cylindrical grinder is used to shape the outside of the workpiece.
These machines accept workpieces in many types of shapes as long
as they can be rotated through the central axis.
■ In a cylindrical grinder, both the workpiece and the grinding wheel
are rotated simultaneously.
■ The outer diameter grinder, inner diameter grinder, and centerless
grinder are all types of cylindrical grinders.
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#3. Centerless Grinding–
■ A centerless grinder is the type of cylindrical grinder that uses two
rotary wheels to secure the workpiece. Unlike a concentric grinder,
a centerless grinder does not use a spindle.
■ The rotation speed of the wheels determines the rate at which the
material is removed.
#4. Tool & Cutter Grinding–
■ A tool and cutter grinder uses a CNC machine tool with five axes
and several grinding wheels.
■ These tools are used for accelerating and producing drilling,
endmills, and step tools such as milling cutters.
■ It is also widely used in the woodworking and metal cutting
industries to produce the necessary equipment.
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#5. Jig Grinding–
■ Jig grinder, as the name suggests, there are many uses, dies, and
fixtures when finishing jigs.
■ Its primary function is to drill holes for grinding bushes and pins.
■ It can also be used for the complex surface grinding to finish work
started on a mill.
#6. Gear Grinding–
■ Gear-grinders are usually employed as the final machining process
when manufacturing high-precision gears.
■ The primary function of this machine is to remove the remainings
few thousandths of an inch of materials left by other
manufacturing methods (such as gassing or hobbing).
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#7. Centre Grinding–
■ The center mill is usually employed as a machining process when all
types of high-precision shafts are constructed. The primary
functioned of this machine is to grinds the centers of a shaft very
accurately.
■ Precise round center holes on both edges ensure a position with high
repetition accuracy at live centers.
#8. Die Grinding–
■ The die grinder is a high-speed handheld rotary tool with a small
diameter grind.
■ They are typically driven by air (using compressed air) but can be
run directly with a small electric motor or through a flexible shaft.
#9. Angle Grinding–
■ Another handheld power tool, often used in construction and
construction work.
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Uses of a Bench/pedestal Grinder Machine
1. Grinding
■ Bench grinders are generally for removing quite a bit of material quickly
using grinding wheels. The grindstones typically come in different levels of
coarseness. As the grindstones are used, the front edge wears out, and it may be
clogged with the metal. As such, it is vital to dress your grindstone periodically
for better grinding efficiency.
■ Also, the grinding stones that are designed for hard materials such as steel
should not be used on softer materials like aluminum. This is because the metal
can get lodged in the wheel and explode later with the heat of grinding. This can
dislodge the grinding wheel and cause injuries or damage the machine.
■ While grinding, it is crucial to move the material back and forth to avoid heat
buildup. Also, using a coarse grit will help prevent the metal from overheating as
it will enable you to work quickly. In addition, you can dip the metal in a can of
water if it starts to heat up.
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Uses of a Bench/pedestal Grinder Machine
1. Grinding

■ Bench grinders are generally for removing quite a bit of material quickly using grindstone wheels. The
grindstones typically come in different levels of coarseness. As the grindstones are used, the front
edge wears out, and it may be clogged with the metal. As such, it is vital to dress your grindstone
periodically for better grinding efficiency.
■ Also, the grinding stones that are designed for hard materials such as steel should not be used on
softer materials like aluminum. This is because the metal can get lodged in the wheel and explode
later with the heat of grinding. This can dislodge the grinding wheel and cause injuries or damage the
machine.
■ While grinding, it is crucial to move the material back and forth to avoid heat buildup. Also, using a
coarse grit will help prevent the metal from overheating as it will enable you to work quickly. In
addition, you can dip the metal in a can of water if it starts to heat up.
2. Sharpening Metal Objects
■ Another primary function of a bench grinder is to sharpen metal objects. All you need is to set the
right speed, preferably a slower speed, to enable you to work with more precision. It is useful when it
comes to sharpening lawnmowers, chisel, saw blades, and cutting tools like knives and other
household metals.
■ Another reason why you should run the grinder at a slower speed is that it helps to reduce the
chances of overheating the edge of the tool. Many cutting tools are made of steel, and it usually is
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3. Cutting
■ A bench grinder is widely used for cutting hard items as well as
wooden objects. The process involves holding the piece firmly onto the
tool rest while rotating it towards the grinder surface gently. After
the grinder makes contact with the spot you want to cut, you will be
required to keep turning the material until it splits into two. Turning
the piece will cutting will ensure a clean cut while also preventing the
chances of catching fire, especially when dealing with wood. The
material is then dipped in water to temper the hot ends and to
achieve the desired smoothness.
4. Buffing
■ Buffing is a standard process carried out on metal products to ensure
that they retain their texture and that they don't get blunt. This is
done by ensuring regular cleaning using a buffing wheel on the bench
grinder. The motor is lined with a cloth that scrubs off the dirt as the
wheel rotates. When buffing, you'll be required to dip the metal piece
in water to cool it off as you continue to buff.
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5. Removing Rust
■ Metals parts tend to rust quickly, particularly if they are exposed to humid conditions. The
good news is that you can use a bench grinder to remove the rust, which can then be then
followed by sharpening. To avoid damaging the tool or the material you are working on,
always set the motor at a low speed. This will also allow you to eliminate all the rust. This is
particularly useful for preparing small areas for welding and other fittings. You can then
increase the speed if you would like to perform other functions.
6. Shaping Objects
■ When it comes to shaping metal or other objects, you'll be required to place the piece you
want to carve right on top of the wheel. This should be done gradually in a back and forth
motion, especially if you intend to grind off some parts off. A bench grinder will make it
easy for you to smoothen up the surface of your workpiece more than other shaping tools
would.
■ The object to be shaped should be held firmly against the grinding wheel and work slowly to
enable a varying degree of shaping or finishing. It will also ensure that the material is not
dislodged while being shaped. When shaping metal, ensure to dip it in the coolant frequently
to keep it cool.
7. Polishing
■ Polishing helps you to achieve a fine finish on your metal and wood pieces. The material to be
polished should be firmly held and moved toward the wheel while ensuring that you
maintain a firm grip throughout the process to ensure that the polish is evenly applied. You
should, however, be careful when polishing wood material as it can catch fire easil
 PEDESTAL GRINDING
 A grinding wheel is a wheel composed of an abrasive compound
and used for various grinding (abrasive cutting) and abrasive
machining operations. Such wheels are used in grinding machines.
 The wheels are generally made from a composite
material consisting of coarse-particle aggregate pressed and
bonded together by a cementing matrix (called the bond in
grinding wheel terminology) 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. Today most
grinding wheels are artificial composites made with artificial
aggregates, but the history of grinding wheels began with natural
composite stones, such as those used for millstones.
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Abrasive Material
 The abrasive aggregate is selected primarily according to the
hardness of the material being cut. Chemical compatibility is also a
concern. For example because carbon alloys with iron, silicon carbide
is not suitable for use with iron-based metals like steel.
 Aluminum oxide (A)
 Silicon carbide (S)
 Ceramic (C)
 Diamond (D, MD, SD)
 Cubic boron nitride (CBN)
 Grinding wheels with diamond or CBN grains are called
superabrasives. Grinding wheels with aluminum oxide (corundum),
silicon carbide, or ceramic grains are called conventional abrasives.
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Grain size
 From 10 (coarsest) to 600 (finest), determines the average 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.
generally grain size of grinding wheel are 10-24(coarse),30-60(medium),80-
200(fine) and 220-600(very fine).
Wheel grade
 From A (soft) to Z (hard), determines how tightly the bond holds the abrasive. A
to H for softer structure, I to P for moderately hard structure and Q to Z for
hard structure. Grade affects almost all considerations of grinding, such as wheel
speed, coolant flow, maximum and minimum feed rates, and grinding depth.
Grain spacing
 Spacing or structure, from 1 (densest) to 17 (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.
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Wheel bond
Bond name Bond symbol Bond description

Resin-based; made from plants or petroleum

Resinoid B
distillates

Shellac E Shellac-based

Metal M Made from various alloys

Oxychloride O Made from an oxohalide

Made by Electro / Electroless bonding of metal

Plated P
to hold abrasive

Rubber R Made from natural rubber or synthetic rubber

Silicate S Silicate-based

Glass-based; made