06.

Grinding & Finishing Process

Grinding Wheel- (ii) Straight Wheel-
They are used on the periphery only and therefore
It is an expendable wheel that carries an abrasive produce a slightly concave surface on the part.
compound on it's periphery. (iii) Cylinder Wheel-
It is always rotates and mounted on spindle. They are used only in vertical or horizontal spindle
These wheels are used in grinding machines. grinder.
They may also be made from a solid steel or (iv) Dish Cup Wheel-
aluminium disc with particles bonded to the surface. It is used primarily in cutter grinding and jig
The grinding wheel selected depending on required grinding.
surface finish, metal removal rate, material, wheel Grinding Ratio-
speed etc.
The basic functions of a grinding wheel are- Volume of work material removed ( Vm )
G.R. =
(i) To remove material from a workpiece in an abrasive Volume of wheel wear out ( Vw )
action.
V ℓ×b×d
(ii) Each grain acts as a cutting tool. G.R= m =
V π
(iii) This is only self-sharpening cutting tool. w
4
( Di2 − Df2 ).w
Note–
Diamond wheel is not used to grind high speed steel. Where, w = Width of grinding wheel
Di = Initial diameter of grinding wheel
Classification of Grinding Processes-
Df = Final diameter of grinding wheel
Surface Grinding Used for grinding flat Note-
surfaces. Grinding ratio varies from 1.0 to 5.0 in very rough
Cylindrical Grinding This is used for grinding grinding.
external and internal Grinding ratio varies form 25to50 in finish grinding.
cylindrical surfaces. Specific energy of grinding ≈ 50 J/mm3
Center-less Grinding It is used for grinding of Specific energy of other processes ≈ 2 to 5 J/mm3
external and internal
surfaces. In this, Cutting Speed of Wheel-
machines are different It is an important parameter in various mechanical
from that of cylindrical process like grinding, drilling and cutting.
grinding. It is also known as surface speed/peripheral speed.
Form Grinding It is used for grinding of It is depends on the diameter of the wheel and the
grinding of gears, thread rotational speed of wheel.
grinding and grinding of Peripheral speed (V) = πDN mm/minute
splines etc. πDN
Abrasive cut off This is used for severing V= mm/sec.
60
metallic and non metallic πDN
materials. Cutting speed (V) = m/sec.
60 ×1000
Abrasive Belt Grinding It is used for grind flat,
Where, D = diameter of wheel (mm)
cylindrical or curved
shapes. N = Rotational speed of wheel
Creep Feed Grinding It is a method in which a Abrasive-
soft grinding wheel is It is very hard and very small particles which is used
used. In this large to remove the material from workpiece so it is also
amount of metal is called grains.
removed in a single pass. There are two types-
Various Wheels are Used in Grinding- (i) Natural abrasives-
(i) Cup Wheels- (a) Emery
These wheels are used (and dressed) on the side face (b) Corundum (85% to 95% Al2O3)
and have the advantage of producing a truly flat (c) Diamond
surface on the side of the tools. (d) Quartz
They are used in jig grinders to produce large flat (e) Garnet
surface or counter bores. (f) Sand stone
Grinding 106 YCT
(ii) Artificial/Synthetic abrasives- 3. Hardness (Grade)-
(a) Silicon carbide (SiC) (or) carborundum Hardness Wheel W/P
(b) Aluminium oxide (or) fuse corundum or fuse (Grade)
alumina. A-H Soft wheel Hard w/p
(c) Zirconia I-P Medium wheel Medium w/p
(d) Boron carbide Q-Z Hard wheel Soft w/p
(e) Tungsten carbide
In general, we use soft wheel for hard metals and
(f) Cubic Boron Nitride (CBN) hard wheels for soft metals.
(g) Cubic Boron Carbonitride (CBC) At higher grinding wheel speed the harder grade
ISO Designation of Grinding Wheel- wheel is needed.
A grinding wheel is said to be of soft grade if the
abrasive grains can be easily dislodged.
The hardness of a grinding wheel is determined by
the ability of the bond to retain the abrasives.
4. Structure of Grinding Wheel-
(0 - 7) - Close structure → Finish grinding
1. Type of Abrasive-
(8 - 16) - Open structure → Rough grinding
Abrasive Uses Structure is the distance between the two cutting
It is softer and tougher than SiC edges.
A → Al2O3 and used for steels and high A dense structure is required for finishing cut.
strength materials. Open Structure-
B → B 4C Poor finishing • Space is more in open structure.
C → SiC Non-ferrous, non-metallic • It is used for ductile material.
materials, hard and dense metals Close Structure-
and good finish. • Space is less in close structure.
Ex.- Brass, Copper, Grey cast iron, • It is used for brittle and hard material.
Aluminium. 5. Type of Bond-
D → Diamond Used in die steels and tungsten V Vitrified bond (glass material which produces
carbide. strong wheel is generally used)
Note- S Silicate bond (It is softest bond and low heat
Loose abrasives are used in surface grinding, generation)
honing, lapping etc. B Resinoid bond (Thermosetting materials
Abrasive used for grinding ceramics and tungsten which are flexible than vitrified bond)
carbide is boron carbide. E Shellac bond
The abrasive particle for grinding steel fittings is R Rubber bond (Most flexible bond material
silicon carbide. used for very thin grinding wheel)
2. Grain size (or) grit size- M Metal bond
10 - 24 → Roughening (coarse grain) The performance of grinding wheel depends upon
30 - 60 → Medium grain the-
80 - 180 → Finishing (fine grain) • Type of abrasive material
220 - 600 → Super finishing (very fine grains) • Grain size
The term used to indicate the size of the abrasive • Wheel grade
grain in a grinding wheel is grit. • Wheel structure
Grit or grain size is denoted by the number of • Bonding material
meshes per inch.
Center Less Grinding-
In grinding, to get good surface finish, the grain size
of the abrasive to be used is fine.
Coarse grits are used for soft and ductile materials
when fast grinding is required.
Fine grits are used for hard and brittle materials
when good surface finish is required.
Grinding wheel with large grain size is used for the
machining of soft ductile materials.
Size of Metal Grains-
• Fine grain – 0.063 mm to 0.2 mm
• Medium grain – 0.2 mm to 0.63 mm
• Coarse grain – 0.63 mm to 2 mm Feed, f = πDN sin θ (mm/minute)
Grinding 107 YCT
Where, (iv) Grinding of curved workpiece can be done only to a
D = Diameter of control wheel (in mm) limited extent.
N = Rotational speed of wheel (RPM) (v) It is not necessary in tube grinding because the outer
θ = Angle of control wheel from horizontal diameter and inner diameter are concentric.
surface Grinding Wheel Maintenance and Balancing-
Regulating wheel is given an inclination at an angle 1. Balancing-
(2° to 10°) vertically so that one component of force New grinding wheel, when used, should be properly
provides in feed and the other component provide balanced.
through feed. Balancing of a grinding wheel also depends upon the
In centre less grinding, the workpiece rests on work machine spindle as well as the condition of
rest. tightening.
Balancing of grinding wheels is done to obtain good
This machine is used to grind long and slender surface finish, prevent vibration, avoid undue wear
cylindrical rods. in machine parts.
There are three processes in center-less grinding- 2. Truing-
Through feed The workpiece is supported Truing is the process of changing the actual shape of
and revolved, grinding wheel during the grinding. Therefore truing
simultaneously axial is done to bring it back to its original geometry.
movement is given by In this process required tool material is diamond.
regulating wheel and guides 3. Loading-
so as to pass between the If wheel is loading to reduce the MRR.
wheels. If rough grinding is performed using dense structure
• It is used for grinding on wheel then chips will be clogged within the
long shaft. abrasives.
Infeed Both regulating and grinding Blocking the inter spaces between cutting grains is
wheels are more in width known as loading of grinding wheel.
than the work length to be Other Reasons of Loading-
ground. Axis of regulating If w/p is too soft.
wheel is inclined a little, If grinding wheel has low rpm.
about half a degree from the If cutting fluid is not properly supplied.
horizontal. 4. Glazing-
A grinding wheel gets glazed due to wear of abrasive
grain.
End Feed The workpiece is fed If we select hard grinding wheel for hard workpiece,
longitudinally from the sides glazing/blunt will takes place.
of the wheels. During machining of hard workpiece, the force
• As it advances between the induced are higher and wheel wear is also high and
revolving wheels its surface abrasive particles will become blunt very fast within
is ground till its further end 2 - 3 min. once abrasive particle will become blunt it
touches the end stop. is started rubbing on to the workpiece and producing
rubbing force.
This rubbing force is not sufficient to pull out the
blunted abrasive particles if grinding wheel is too
Advantage of Center less Grinding- hard.
(i) There is no need for having and maintaining centers Now, the abrasive particles simply rubbing onto the
and centers holes. w/p without doing any machining, called Glaze (or)
(ii) Work pieces can be loaded and unloaded form the blunt wheel grinding.
machine rapidly. Grinding is almost continuous for Glazing in grinding wheels can be decreased by
through feed grinding. using a softer wheel or by decreasing the wheel
(iii) Backing up the work piece by the regulating wheel speed.
and work rest blade practically eliminates any 5. Dressing-
deflection of the work piece. This permits maximum Dressing is the process of improving the cutting
material removal rates. action of the grinding wheel.
(iv) Work pieces may often be loaded into the machine If the grains of a grinding wheel become dulled, then
by the automatic feeding devices. it needs to be dressed.
(v) Less grinding allowance may be required, because To remove this glazing, Dressing of grinding wheel
the out-of-roundness is corrected across the diameter has to be done.
rather than the radius. "Dressing of grinding wheel is a turning operation
Limitations of Centre-less Grinding- used for removing a layer of material from surface of
(i) This process is useful only for large volume grinding wheel using diamond cutting tool"
production. If soft wheel is used for hard workpiece, self
(ii) This process is not suitable for large workpiece sizes. sharpening of gear/grinding wheel will take place
(iii) The workpiece must be curved and not flat, such as a hence no dressing is required.
keyway. The grinding wheel is dressed by artificial diamond.
Grinding 108 YCT
Tool life in grinding- It is an operation of sizing and finishing a small
It is time period between two successive wheel diameter hole.
dressing. It is used to produce geometrically true surfaces.
Bench grinder- It is an operation used for finishing flat, cylindrical
It is simple grinding machine. or curved surfaces.
It's working principle is based on the fundamental The lap is usually made of cast iron, copper, leather
concept of abrasion. or cloth.
It has a coarse and fine grinding wheels at both ends. The abrasive particles either are embedded in the lap
It is used to removing material, smoothing surfaces or may be carried in a slurry.
and sharpening tools etc. The tools used in lapping operation are generally
Grinding Coolant: called lapping shoes, quills or laps.
Grinding coolant, also known as grinding fluid or Running in of mating gears can be done by lapping,
grinding oil is a liquids solution that is used in the as on hypoid gears for rear axles.
grinding process to cool and lubricate the workpiece 4. Polishing-
and grinding wheel. It is a process that produces a smooth, lustrous
Coolant helps to reduce the risk of overheating and surface finish.
to remove small chips of material that are generated Two basic mechanism are involved in this
during the grinding process. polishing process-
It also helps to extend the life of the grinding wheel (i) Fine scale abrasive removal.
and to improve the surface finish of the workpiece. (ii) Softening and shearing of surface layer by frictional
Types of grinding coolants – heating during polishing.
(i) Water based coolants. The wheels used in this polishing process are called
(ii) Oil based coolants. bobs/mops. These bobs are usually made of leather,
(iii) Synshetic coolants. canvas, cotton cloth.
(iv) Semi synthetic coolants. 5. Buffing-
Finishing Operations- It is used to shine the polished surface after
1. Honing- polishing.
It is used to obtain a very smooth and reflective
surface like a mirror.
Buffing operations are classified into the
following two categories-
(i) Cutting down operation
(ii) Colouring operation
Cutting down operation is the first operation of
buffing which micro irregularities are finished from
the work surface, whereas colouring operation is the
last operation of buffing which is used to produce a
It is an operation that is used primarily to improve
the surface finish of holes produced by processes perfect shiny surface.
such as boring, drilling and internal grinding. Buffing operation is generally done on non ferrous
The honing tool consists of a set of aluminium oxide metals like aluminium, copper, brass, zinc, steel,
or silicon carbide bonded abrasives sticks, usually chromium, nickel etc.
called stones. 6. Tumbling-
The process of finishing round holes with the help of It is widely used to remove oxide layer, burrs and
bonded abrasive stone is called honing. sharp edges from casts, forges and stamped products
Diamond abrasive is used in honing process for etc.
tungsten and ceramics. During tumbling operation, the products are filled
It is a wet cutting operation because during the inside a rotating drum or barrel.
operation, coolant (generally paraffins) is used. This drum is filled with suitable materials like
It is also done on external cylindrical or flat surfaces sawdust, wood peeling, sand-coal is rotating at a
and to remove sharp edges on cutting tool and slow speed for 8 to 10 hours.
inserts. Again the products are taken out and thoroughly
2. Super Finishing- washed and dried.
In this process, the pressure applied is very light and Products are oiled to avoid rust.
the motion of the honing stone has a short stroke. 7. Electroplating-
The motion of the stone is controlled so that the
grains do not travel along the same path on the
surface of the workpiece.
Examples of external super finishing of a round
parts.
3. Lapping-
In lapping, brass & copper are used for charging
lapping because it can be easily charged and cut
more quickly.
Grinding 109 YCT
 The process in which a layer of one metal is coated Wire Wheels and Brushes
with another metal by using electricity is called Wire wheel and brushes they are used for cutting,
Electroplating. . brushing, deburring, polishing and fineshing
In this method, plating on the object is used as the surface.
cathode and the metal to be coated is used as anode. Were wheels are required to clean weld and other
When electric current is passed through an materials from the surface.
electrolyte, the coating metal from the positive input Powder Coating
dissolves and accumulates at the negative input, this
Powder coating is a dry finishing process using
coating of the object continues.
finely ground particles of pigment and resin that are
It is mainly used to improve corrosion resistance.
generally electro statically charged and sprayed into
It also gives a shiny appearance to metals.
electrically grounded parts.
Electroplating is done by the process of electrolysis,
Powder coating is a surface finishing process that
which is based on the chemical electric effect.
has many application including automotive,
8. Galvanizing-
furniture, industrial, electrical.
The process of deposit a layer of zinc on iron to
prevent rusting is called galvanizing. Organic Coating
This process is generally used on iron sheets. An organic coating is a protective layer made from
9. Tinning- carbon based polymeric chain that come from
The process of deposit a layer of tin on iron is called natural or synthetic materials from corrosion and
tinning. oxidation.
This method is very similar to galvanizing. Oil Pants
10. Parkerizing process- Oil pants are nothing but normal pants, usually
This method of protecting the steel surface from containing a base and vehicle.
corrosion. Oil paints are white lead, zinc white lithopone, red
Wear resistance of the steel surface is also increase lead and titanium oxide.
by using phosphate coating. General vehicles used in oil paints are linseed oil,
This process is generally used on fire vessels and tug oil, etc.
automobile parts. Along with the base and vehicle, driers and colour
11. Anodizing- pigments are also used.
It is an electrochemical process of forming a thick The driers used may be litharge, red lead, zinc,
oxide layer of aluminium. sulphate, manganese sulphate etc.
In this method, the metal surface is transform to a Oil paints are very economical and they can be
durable, corrosion resistant, anionic oxide finish applied in an easy manner.
surface.
They are generally applied in three coats of varying
For ideally, Aluminium is suitable for anodizing.
composition.
12. Metal spraying-
So this type of paint can be applied to walls doors,
This is a metal coating method.
windows metal structures etc. But the main
In this method, the molten metal is sprayed on the
disadvantage of oil paint is that is they unsuitable for
main metal.
humid weather conditions.
13. Sherardizing-
Lacquer Based Enamels
The sherardizing process is a method of coating iron
with zinc to protect it from corrosion. Lacquer based enamel is type of colored enamel that
This method is applied on object which made of steel can be used for wood repair.
and iron. Licquer is thinner than other finishes. So it's usually
In this method, the object is sealed in an air tight box applied with a sprayer.
in contact with zinc dust and heated at a temperature Bituminous Paint
of 350 °C to 400 °C of about one hour. Bituminous paints is a type of bituminous coating
As a result, a strong layer of zinc deposited on the product that provides weather proofing and
object. corrosion resistance to the elements.
Hot Dipping- Rubber Base Coating
In hot dipping, the workpiece (usually steel or iron) is Rubber base coating is applied to seal tools,
dipped into a bath of molten metal, such as (a) Zinc, for flooring, and various other surface.
galvanized steel sheet and plumbing supplies; (b) Tin, for
tinplate and tin cans for food containers; (c) Aluminium The rubber coating is liquified having consistency of
(aluminizing); and (d) Terne, an alloy of lead with 10 to glue.
20% tin. Hot-dipped coatings on discrete parts provide Applying rubber coating to surfaces needs to be
long-term corrosion resistance to galvanized pipes, done evenly and quickly so that all the sides of the
plumbing supplies and many other products. surface might dry at the same time.
Grinding 110 YCT