Grinding

Grinding
Grinding is a material removal process accomplished by abrasive particles that are contained in a bonded grinding wheel rotating at very high surface speeds. The rotating grinding wheel consists of many cutting teeth ( abrasive particles ) and the work is fed relative to the rotating grinding wheel to accomplish material removal.

INTRODUCTION TO GRINDING PROCESS

It is the only economical method of cutting hard material like hardened steel. It produces very smooth surface , suitable for bearing surface. Surface pressure is minimum in grinding. It is suitable for light work,which will spring away from the cutting tool in the other machining processes.

Internal Grinding

Centerless Grinding

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Surface Grinding

Centre less Grinding

Cylindrical Grinding

Grinding Process

CONSTRUCTION OF A GRINDING WHEEL

In order make the grinding wheel suitable for different work situations, the features such as abrasive, grain size, grade, structure and bonding materials can be varied. A grinding wheel consists of an abrasive that does the cutting, and a bond that holds the abrasive particles together

ABRASIVES
Natural abrasives Artificial abrasives

GRAIN SIZE
The number indicating the size of the grit represents the number of openings in the sieve used to size the grain. The larger the grit size number , the finer the grit.

GRADE
Grade indicates the strength of the bond and, therefore, the `hardness` of the wheel. In a hard wheel the bond is strong and it securely anchor the grit in place, and therefore, reduces the rate of wear. In a soft wheel, the bond is weak and the grit is easily detached resulting in a high rate of wear.

STRUCTURE
This indicates the amount of bond present between the individual abrasive grains, and the closeness of the individual grain to each other. An open structured wheel will cut more freely. That is, it will remove more metal. In a given time and produce less heat.

BOND
Vitrified bond (V) Silicate bond (S) Shellac bond (E) Rubber bond (R) Resinoid bond (B)

Vitrified
Essentially a Glass ,a vitrified bond is also called a ceramic bond. It is the most common and widely used bond. The raw materials used consist of feldspar ( crystalline mineral) and clay. They are mixed with the abrasives ,moistened and molded under pressure into the shape of grinding wheels.

 They are fired slowly, up to a temperature of aboutb1250Deg C to fuse the glass and develop structural strength. They are then cooled and finished. Vitrified bonded wheels are strong, stiff,porus and resistant to oils, acids and water.

Resinoid
They are made of thermosetting resins .They are also called organic wheels. They are cured after mixing with phenolic resins at 175 deg,c. They are more flexible than vitrified wheels,

Rubber
They are more flexible and manufactured by mixing with crude rubber ,sulphur and the abrasive grains together rolling into sheets and then heated and vulcanized. They are mainly used for cutting.

Grinding ratio
G = Volume of material removed / Volume of wheel wear G = 2 to 200

Grinding MRR = dwv d = depth of cut W= width of cut v = feed rate of the workpiece Power = u x MRR u = specific cutting energy

 Torque = Fc x D/2 x 2x wheel speed. POWER= Torque x rotational speed Rotational speed = 2 N

STANDARD SHAPES OF GRINDING WHEELS

Straight wheel Cylinder Tapered Recessed one side Straight cup Recessed both sides Flaring cup Dish Saucer Mounted wheels

SPECIFICATION OF GRINDING WHEELS

Standard wheel markings Diameter of the wheel Bore diameter of the wheel Thickness of the wheel Type of the wheel

SELECTION OF GRINDING WHEEL

For grinding a job the right grinding wheel is to be selected. The selection of a grinding wheel will depend on the following factors. Material to be ground Amount of stock to be removed Finish required Area of contact Wheel speed Work speed Personal factor Method of cooling

GRINDING WHEEL DRESSING &TRUING

Dressing refers to the removing of clogs and blunt abrasive grains from the surface of the grinding wheel. Dressing exposes the cutting edges which restore the correct cutting action of the wheel. Dressing is done on a glazed or loaded wheel to recondition it. Truing refers to the shaping of the wheel to make it run concentric with the axis. When a new grinding wheel is mounted, it must be trued before use to remove the run out.

GLAZING & LOADING

When the surface of a grinding wheel develops a smooth and shining appearance, it is said to be glazed. This indicate the abrasive particles on the wheel face are not sharp. These are worked down to bond level. When soft materials like aluminium, copper, lead, etc. are ground the metal particles get clogged between the abrasive particles. This condition is called loading.

GRINDING SPEED

TYPE OF GRINDING Rough grinding wheel with vitrified bond Rough grinding wheels with resinoid bond Surface grinding wheels with vitrified bond Internal grinding wheels with vitrified bond Centreless grinding wheels with vitrified bond Cylindrical grinding wheels with vitrified bond Cutting off wheels with resinoid bond

WHEEL SPEED m/sec. 25 45 20-25 20-35 30-80 30-35 45-80

Hand grinding of tools

Automatic grinding of tools Hand grinding of carbide tools

20-25
25-35 18-25

WORK SPEED
CLASS OF WORK Soft steel Hardened steel Cast iron ROUGH GRIND m/min. 10-20 25-30 35-55 FINISH GRIND m/min. 20-25 30-40 45-65

Aluminium and fine brass

50-65

50-65

DEPTH OF CUT

It is the thickness of the material removed in surface grinding for one cut. Depth of cut in grinding depend on the: Cutting load Power of the machine Finish required

SURFACE GRINDING MACHINE

It is precision grinding machine to produce flat surface on a workpiece. It is a more economical and more practical method of accurately finishing flat surface than filling and scraping.

PRECISION SURFACE GRINDER

SPECIFICATION OF A SURFACE GRINDER

Maximum dia. of the wheel that can be held on the spindle. Maximum size of the job that can be ground.(length*width*height)(150*150*400). The type of drive of the work table:hydraulic/electrical.

TYPES OF SURFACE GRINDERS

Horizonal spindle reciprocating table Horizontal spindle rotary table Vertical spindle reciprocating table Vertical spindle rotary table

HORIZONTAL TYPE GRINDER

Base Saddle Table Wheel head

WORK HOLDING DEVICES

The work holding devices used in grinding are: Magnetic chuck Vice Angle plates `V`blocks clamps

MAGNETIC CHUCK
Magnetic chucks are of two types Electromagnetic chuck Permanent magnetic chuck The magnetic power of the electro magnetic chuck can be varied according to the size of the work. But not so in the case of a permanent magnetic chuck.

TILTING TYPE VICE

A tilting vice is used to hold the workpiece while grinding angular surfaces. If required the tilting base can be removed and it can be mounted on the magnetic chuck as a plain vice.

SURFACE GRINDING OPERATIONS

Grinding flat surface Grinding vertical surface Grinding slot Grinding angular surface Grinding a radius Cutting off

CYLINDRICAL GRINDERS

Cylindrical grinders are used to grind the external of internal surface of a cylindrical workpiece. By cylindrical grinding the diameter of a workpiece can be maintained to a close tolerance (up to 0.0025 mm), and a high quality surface finish can be obtained (up to N4).

TYPES OF CYLINDRICAL GRINDERS

External cylindrical grinders Internal cylindrical grinders Universal cylindrical grinders Centreless grinders

GRINDING ALLOWANCE

Machine parts are processed in different machine such as lathes, shaping machines, etc. in such a way that their final dimension have some stock left, which is finished during the grinding operation. The amount of this stock left is called the `grinding` allowance.

IMPORTANT FACTORE OF GRINDING ALLOWANCE

Hardness of material to be ground Whether the part has to be heat treated Case depth of case hardened workpiece Grint and grade of grinding wheel Whether grinding is done wet or dry grinding

Grinding wheel specification

Diamond wheel on steels and CBN on carbides?

A diamond wheel is specifically used for carbides, plastics and other synthetic materials. It will not grind steel well at all. CBN wheels should only be used on steels. There is a hybrid grit available that will grind both; However, it is a compromise in wheel life and grindability. But in cases where you must grind both materials at the same time, it can be a real time saver.

Grinding wheel specification system

Grinding wheel selection

Abrasive : Generally, Aluminium Oxide abrasives are well suited for steels and ferrous metals, while Silicon Carbide abrasives are ideal for grinding cast iron, non-ferrous metals and non-metallic materials.

Grinding wheel selection

Grit Size : A relatively fine grit-size works best on hard and brittle material. A coarser grit capable of taking heavier cuts can be used advantageously on soft and ductile materials that are readily penetratable.

 On hard materials the increased number of cutting points, on the face of a moderately fine grit wheel (Fig. 1) will remove stock faster than the fewer cutting points presented by a coarser wheel (Fig. 2). The larger abrasive grains in a coarser grit wheel can not penetrate as deeply into the hard work-piece without burning it.

The second factor in selecting the correct wheel is the amount of stock to be removed and the finish required. These affect the choice of grit size and bond.

Grit-size : As a rule, coarser grit is selected for fast-cutting action and fine grit where a high finish is required.

Bond : Vitrified bonded wheels are generally used for fast-cutting action and commercial finish. Resinoid, Rubber and Shellac bonded wheels produce the highest finish.

Grade : The severity of the grinding operation also influences the .grade.. Hard grades provide durable wheels for rough grinding such as snagging, while medium and soft grade wheels are generally used for less severe precision grinding operations

 STRUCTURE : Wheel structure refers to the relative spacing of the abrasives in the wheel. In addition to the abrasives and bond the grinding wheel contain air gaps or pores. Pg + Pb +Pp = 1 Pg = Proportion of grains. Pb = Proportion of bond Pp = Proportion of pores

Common Grinding wheels

Structure of grinding wheel

GRINDING FLUID

GRINDING FORCE

 P =Ft ( Vs Vw)+FVfn.+ FaVfa Ft= Tangential force Fn= Normal Force Fa = Axial Force Vs = Wheel Speed Vw= Work Speed Vfn= Normal feed Vfa = Axial feed

Surface Grinding machine

Cylindrical Grinding Machine

Centre less Grinding machine

Advantages of Centerless Grinding

Due to shorter loading times, actual grinding time is decreased compared with other methods of grinding. Once the centerless grinder has been properly set-up for a particular run, no further adjustment or additional set-ups are needed as opposed to centertype (cylindrical) grinding. This alone offers substantial savings. The workpiece is under constant, rigid support while in the grinding mode, making it feasible to take heavier cuts and grind fine pins, rods and wires.

 When grinding easily distorted workpieces, the centerless grinder is most advantageous because of its lack of axial thrust. Automatic feeding offers continuous production of large quantities of smaller size workpieces. Centerless machines are designed for simplicity which in itself cuts down on machine maintenance

Methods of Centerless Grinding

Depending on the shape and condition of the work piece to be ground, the machine setup of the grinding wheel, the regulating wheel, work support blade and feeding mechanism will vary. The four basic methods of centerless grinding in use are through feed, infeed, end feed and infeed through feed combination.

Through feed grinding

Throughfeed grinding is used to grind straight, cylindrical workpieces which have no interfering projections. This method is a continuous production operation. To provide continuous, automatic throughfeed, the axis of the regulating wheel is tilted relative to the axis of the grinding wheel. The feed rate is controlled by the speed, angle and diameter of the regulating wheel. The parts are guided into and out of the machine in a straight line. If this line is not perfectly straight, taper and/or concavity conditions can result on the workpiece.

Infeed Grinding
Infeed (Plunge) Grinding is used to grind workpieces which have projections or shoulders, multiple diameters or other irregular shapes which preclude the use of throughfeed grinding. The wheels are opened to allow for the part to be loaded (from above if multidiameters). Most often the part is fed along with the blade and regulating wheel to a set finish position against a stationary grinding wheel.

 The grinding wheel must have sufficient width to cover the entire surface being ground. In many cases, the desired shape is cut into the face of the wheel either by single point diamond trueing or by diamond roll crush trueing. Diamond roll trueing is used on intricate shapes which are difficult to form with a single point diamond

Endfeed Grinding
Endfeed Grinding is used principally on tapered work. The grinding wheel, regulating wheel and work support blade are set at a fixed relationship to each other. All three are shaped to meet the desired taper of the part to be ground. The work is fed from the front of the machine and is ground until it reaches an end stop.

Infeed-Throughfeed Combination Grinding

Infeed-throughfeed combination is for parts which are more conveniently ground in one pass, but have too large an amount of stock for the conventional throughfeed method. It is also for grinding the smaller diameter of two diameter parts, where the portion to be ground exceeds the width of the grinding wheel.

Work Support Blades

The blade is an essential and important component in centerless grinding. The workpiece is held in contact with the grinding and regulating wheels by an adjustable blade made of various materials. The selection of the proper blade will affect the roundness and quality of the surface finish obtainable.

 Four types of support blades in general use are: aluminum bronze, chilled iron, high speed steel and tungsten carbide. For the majority of centerless grinding operations, the 30 angular top support blade is used.

 It should be noted however, that as the diameter of the workpiece to be ground increases, the angle of the blade decreases. The length of the blade is determined by the width of the wheels and thickness should be slightly less than the diameter of the workpiece.

 Work ground below the centerline may come out of round as well as work ground too high above the centerline. Long lengths generally have to run lower than short pieces due to the possibility of warpage or whip in the rods. Shims are used to adjust the height of the blade.