Grinding Machine

Contents

1. Introduction
2. Principle of Grinding Machine
3. Types of grinding
4. Various elements of grinding wheel
5. Shapes and Coding of a Grinding Wheel
6. Wheel surface finishing
7. Classification of Grinding Machines
8. Grinding operations
9. Work holding devices
 1. Introduction
➢ Grinding is a metal cutting operation performed by
means of abrasive particles rigidly mounted on a
rotating wheel.
➢Each of the abrasive particles act as a single point
cutting tool and grinding wheel acts as a multipoint
cutting tool.
➢ The grinding operation is used to finish the
workpieces with extremely high quality of surface
finish and accuracy of shape and dimension.
➢Grinding is one of the widely accepted finishing
operations because it removes material in very small
size of chips 0.25 to 0.50 mm.
➢ It provides accuracy of the order of 0.000025 mm.
 2. Principle of Grinding Machines

✓ Work piece is fed against the rotating abrasive wheel.

✓ Due to action of rubbing or friction between the
abrasive particles and work piece material is
removed.
 3. 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.
 Major advantages and applications of grinding

Advantages :
➢ Dimensional accuracy
➢ Good surface finish
➢ Possesses highest hardness
➢ Applicable to both hardened and unhardened material
Applications :
✓ Surface finishing, and parting
✓ Descaling, Deburring
✓ Stock removal (abrasive milling)
✓ Finishing of flat as well as cylindrical surface
✓ Grinding of tools and cutters and resharpening of the same.
 4. Various elements or construction of a
Grinding Wheel
The various main elements of a grinding wheel are
abrasive; bonds and structure which are described below.
Abrasive:- Generally abrasive properties like hardness,
toughness and resistance to fracture uniformly abrasives
are classified into two principal groups:-
✓ Natural abrasives
✓ Artificial abrasive

✓ Natural abrasive:- There are a few examples of natural

abrasives which include sand stone (solid quartz), emery, &
diamond.
✓ Artificial abrasive:- Main artificial abrasive are silicon
carbide and aluminium oxide. Artificial abrasive are
preferred in manufacturing of grinding wheels because of
their uniformity and purity.

NATURAL ABRASIVE ARTIFICIAL ABRASIVE

 Abrasive material
Silicon carbide is used for grinding non-ferrous
materials and low tensile strength material and
denoted by ‘GC’
‘Green’ silicon carbide is used for very hard materials
with low tensile strength such as cemented carbides
and denoted by ‘C’
‘White’ aluminum oxide is used for very hard materials
and cutters and denoted by ‘AA’
‘Brown’ aluminum oxide is used for general purpose
grinding of tough materials and denoted by letter ‘A’
 Bond:- A bond is an adhesive material used to held
abrasive particles together relatively stable that constitute a
grinding wheel.
Different types of bonds are:-

(a) Vitrified bond

(b) Silicate bond
(c) Shellac bond
(d) Resinoid bond
(e) Rubber bond
(f) Oxychloride bond
(a) Vitrified bond:-
✓This bond consists of mixture of clay and water. Clay and
abrasives are thoroughly mixed with water to make a uniform
mixture.
✓This is the most widely used bond. It has high porosity and
strength which makes this type of wheel suitable for high rate of
stock removal
✓ This bond is denoted by symbol ‘V’ in specification.

(b) Silicate bond:-

✓ Silicate bonds are made by mixing abrasive particles with
silicate and soda or water glass.
✓These wheels are denoted by ‘S’ in specification.
(c) Shellac bond:-
✓ These are prepared by mixing abrasive with shellac than
moulded by rolling and pressing and then by heating up to
150` C for several hours.
✓This is used for heavy duty, large diameter wheels a fine
finish is required
✓ This bond is denoted by ‘E’ in specifications.

(d) Resinoid bond:-

✓ These bonds are prepared by mixing abrasives with
synthetic resins like backelite and redmanol and other
compounds & baked up to 200` C.
✓ A Resinoid bond is denoted by the letter ‘B’.
(e) Rubber bond:-

✓ Rubber bonded wheels are made by mixing abrasives

with pure rubber and sulphur.
✓A rubber wheel bonded wheel is denoted by the letter ‘R’.

(f) Oxychloride bond:-

✓ These bonds are processed by mixing abrasives with
oxides and chlorides of magnesium.
✓ An oxychloride bonded wheel is specified the letter ‘O’.
❑ STRUCTURE OF GRINDING WHEEL
 Coding:-
The Indian Standard Coding system of
grinding wheel is IS : 551-1954. It gives a general
indication of the hardness and abrasive size of any wheel as
compared with another.

✓ Coding of a grinding wheel consists of six symbols as

described below.

W : Symbol for Manufacturer’s Abrasive Type (Prefix)

C : Name of Abrasive
30 : Grain Size
L : Grade
5 : Structure Type
R : Bond Type
17 : Manufacturer Symbol for Record (Suffix)
✓ The sequence of codes of a grinding should be followed
in the same sequence as described above Their brief
description is given below.
➢ Prefix:- Manufacturer’s Symbol.
➢ Abrasive:- Types of abrasive used in Grinding Wheel.
i.e. A= Aluminium Oxide
C= Silicon Carbide
➢ Grain Size:- It affects the metal removal rate & finishing
of surface. Coarse Medium Fine Very fine
10 30 80 220
12 36 100 240
14 46 120 280
16 54 150 320
➢ Grade:- Ability of bonding material to sustain abrasive.
Very soft A,B,C,D,E,F,G
Soft H,I,J,K
Medium L,M,N,O
Hard P,Q,R,S
Very hard T,U,V,W,X,Y,Z

➢ Structure:- Structure between bonding material &

abrasive grain inside the grinding wheel.

Dense ` Open
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
➢ Types of Bond:- It shows which type of bonding material
is used.
V= Vitrified Bond
B= Resinoid Bond
R= Rubber Bond
E= Shellac Bond
S= Silicate Bond

➢ Suffix:- Manufacturer’s own identification

 ❖ Example of Coding

51A 36L5V23

• 51 = Manufacture’s symbol
•A = Abrasive ( Aluminum Oxide)
• 36 = Grain size (Medium)
•L = Grade (Medium)
•5 = Structure ( Dense)
•V = Bond type (Vitrified Bond)
• 23 = Manufacture’s identification.
Standard Marking System for Aluminum-Oxide and Silicon-
Carbide Bonded Abrasives

Standard marking system for aluminum-oxide and

silicon-carbide bonded abrasives.
 5. Shapes and Coding of a Grinding Wheel
Shapes:-
There are different shapes of grinding wheel
which mention below.

➢ Straight Wheel:- These are generally used for cylindrical,

internal, centreless and surface grinding operations. These
wheels vary in size, diameter and width of the face.
Grinding Wheels

Common types of grinding

wheels made with
conventional abrasives.
Note that each wheel has a
specific grinding face;
grinding on other surfaces
is improper and unsafe.
➢ Cylindrical Wheel Ring:- It is used for surface grinding,
i.e. production of flat surfaces. Grinding takes place with
the help of face of the wheel.

➢ Cup Wheel:- It is used for grinding flat surfaces with the

help of face of grinding wheel.

➢Flaring Cup Wheel:- It is used in grinding of tools in tool

room.

➢ Saucer Wheel:- It is used for sharpening of circular or

band saw.
➢ Tapered Face Straight Wheels:- It is also a straight wheel
but its free is slightly tapered to facilitate the grinding of
threads an gear teeth.

➢Segmented Wheel:- These are normally on vertical

spindle, rotary type and reciprocating type surface grinders.

➢ Dish Wheel:- It is used for grinding of tools in tool room.

It is capable to grind very narrow places due to its thinners.
Bonded Abrasives Used in Abrasive-Machining
Processes
 6. Wheel Surface Finishing

Glazing:-

✓ This is the effect when the abrasive have become dull &
ground to the ground.
✓ It is a condition in which cutting edge take glass-like
appearance.
✓ This occurs due to high speed or the tool is very hard.
✓ To avoid glazing use softer wheel or decrease speed of
wheel.
 Loading:-

✓ When the material of the work piece is filled the gap

between the abrasive grain then it is called as loading.
✓ This material prevent the wheel from cutting freely.
✓ It may caused be grinding a soft material or by using a
heel of too hard and running it too slowly.
Truing:-

✓ It is a process of changing the shape of grinding wheel.

✓ It can be done on the new wheel or on the used tool.
✓ This is done to make tool true and equal distance from
the center.
1. LOADING 2. GLAZING
 Dressing of grinding wheel
• The dressing of a wheel in order to return the wheel to its
original shape.
• The removal of swarf, dull grains, and bonding material from
a grinding wheel is called DRESSING.
 Balancing Grinding Wheels

➢ If wheels become out of balance through wear and cannot be

balanced by truing or dressing, they should be removed from
the machine and discarded.

➢ Wheels should be tested for balance occasionally and re-

balanced if necessary-Wheels that are out of balance not only
produce poor work but may put undue strains on the machine.

➢ Small wheels may be balanced by milling a short recess on the

inside of the flanges and filling with lead.
➢ Large wheels should be placed on a balancing stand and
balanced by moving weights around a recessed flange.
➢ Now-a-days, grinding wheel mounts are provided with devices
to enable balancing to be done whilst the wheel is running and
between grinding operations
 Specification of grinding wheel

A grinding wheel is specified by the

- Standard wheel markings
- Diameter of the wheel
- Bore diameter of the wheel
- Thickness of the wheel
- Type(shape) of the wheel
 7. Classification Of Grinding Machine

Grinding Machines are classified as,

a. Bench grinding machine

b. Surface grinding machine
c. Cylindrical grinding machine
d. Center less grinding machine
e. Internal grinding machine
f. Special purpose grinding machine
 a. Bench grinding machine
✓ These types of grinding machine is used to hand grind
cutting tools and perform rough grinding.
✓ It may be used for sharpening cutting tool such as lathe
tools or drill bits.
Rough Grinder
 b. Surface grinding machine

✓ It is machine basically used to grind flat surface.

✓ Job is mounted to a table which moves longitudinally
as well as in transverse direction.
✓ Manual feed or power feed.
✓ Work piece can clamped in two ways
– Manual clamps.
– Magnetic chuck.
✓ Internal pump and piping arrangement for coolant.
✓ Protective guard for safety.
Horizontal-Spindle Surface Grinder

Schematic illustration of a horizontal-spindle surface grinder

❑ Surface Grinding Machine
Horizontal spindle and reciprocating table
Vertical spindle and reciprocating table
Horizontal spindle and rotary table
Vertical spindle and rotary table
 Various Surface-Grinding Operations

Schematic illustrations of various surface-grinding operations. (a) Traverse grinding

with a horizontal-spindle surface grinder. (b) Plunge grinding with a horizontal-
spindle surface grinder. (c) A vertical-spindle rotary-table grinder (also known as the
Blanchard type.)
 c. Cylindrical grinding machine

✓ It is a process of grinding curved surfaces.

✓ Surface may be straight or tapered.
✓ Work piece is mounted on two centers, one is
tailstock centre and the other is headstock centre.
✓ Head stock center may or may not revolve.
Plain Cylindrical Grinder
 Cylindrical grinding
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:
• Outside diameter grinding
• Inside diameter grinding
• Plunge grinding
• Infeed grinding
• Centerless grinding
• Plain and universal type grinding
❑ WORKING PRINCIPLE
❑ CYLINDRICAL GRINDING MACHINE
 Work pieces and Operations Used in Grinding

The types of work pieces and operations typical of grinding: (a) cylindrical surfaces, (b)
conical surfaces. (c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or
slotting with thin wheels, and (g) internal grinding.
 Cylindrical-Grinding Operations

Examples of various cylindrical-grinding operations. (a) Traverse grinding, (b)

plunge grinding, and (c) profile grinding. Source
Plunge Grinding on Cylindrical Grinder

Plunge grinding of a work piece on a cylindrical grinder with

the wheel dressed to a stepped shape.
 d. Centre less grinding machine
✓ It is used to grind curved surface work piece which
are long and slender.
✓ Work piece rests on a work-rest blade and is backed
by a second wheel called as regulating wheel.
✓ Grinding wheel pushes the work piece down the
work-rest blade against the regulating wheel.
❑ WORKING PRINCIPLE
❑ CENTERLESS GRINDING MACHINE
Centerless Grinding Operations

Schematic illustration of
center less grinding
operations: (a) through-
feed grinding, (b) plunge
grinding, (c) internal
grinding, and (d) a
computer numerical-
control cylindrical-
grinding machine.
Source: Courtesy of
Cincinnati Milacron, Inc.
Advantages of centreless (centerless) Grinding
Machines
➢ It is not necessary to prepare the work piece for fixing in
the grinding machine (faults cause by fixing are
eliminated)
➢ Loading/Unloading of the work piece is simple and easy
to automate.
➢ When using continues through feed grinding there is no
time loss for changing the work piece.
➢ Long work pieces can be handled with rather small
machines.
➢ Very high grinding wheel rotation speed can be achieved.
 e. Internal grinding machine

✓ In this type the grinding is done in the internal side of

work piece.
✓ In this operation the work piece may rotate or may
not be rotate.
✓ It can be done on different internal surface like
straight, tapered, grooved, or profile.
 Internal Grinding Operations

Schematic illustrations of internal grinding operations: (a) traverse

grinding, (b) plunge grinding, and (c) profile grinding.
 f. Some special grinding

✓ It uses the principle of cylindrical grinding.

✓ Mainly it used for threaded profile.
✓ Specially formed wheel is use
✓ A single ribbed or multy ribbed wheel can be
used as shown in fig.
 Thread Grinding

Thread grinding by (a) traverse and (b) plunge grinding .

 Grinding-
Wheel Dressing

(a) Forms of grinding-wheel dressing. (b) Shaping the grinding face of a wheel by
dressing it with computer control. Note that the diamond dressing tool is normal to the
surface at point of contact with the wheel
 Tool and cutter grinder
➢ A tool and cutter grinder is used to sharpen milling
cutters and tool bits.
➢ It is an extremely versatile machine used to perform a
variety of grinding operations: surface, cylindrical
etc.
WORK HOLDING DEVICES:
Different work pieces have to be held by suitable means on the machine for the
necessary work to be done conveniently.
i. For cylindrical grinders
a. Chucks:
A three jaw self centering chuck or a four jaw independent jaw chuck can be
used on the head stock of a cylindrical grinder for holding the work for
convenience. They will be smaller in size than a lathe chuck.

Four jaw indipendent chuck. Three jaw Universal chuck.

b. Centers:
They are also smaller in size to lathe centers and are used to hold work in
between centers using the drive plate.

c. Steady Rest:
It is the same as the rest of a lathe but smaller in size, used to support long work
pieces in grinding to avoid hanging when held in between centers.

Work

Hinge

Machine bed

Steady rest
d. Fixtures:
They are specially made devices to hold work piece, when other devices
cannot be used. They are mainly used for mass production works.
ii. For surface grinders:
a. Magnetic chucks:
It is built in to the machine table. The work pieces can directly be kept on the
table, with magnet switched on. The magnet field needs to be cut to remove the
work piece. Non magnetic material needs to be clamped in other devices.
b. Vices:
Too small work pieces that cannot be kept on the magnetic bed and need to be
secured firmly can be easily clamped in vice. Also right angle grinding or any angle
grinding can be done in vice by pre-setting it to the required angle. Accurate setting of
angles and grinding of angles can be done on Sine vices, which can be clamped on to the
table of machine.

c. Transfer blocks:
They are magnetic pieces that can be kept on the machine table, with the work
mounted on it. When the table magnet is on, it transfers the magnetic field to these
blocks, which in turn, clamps the work tight. It is required to grind the top surface of
inserts or punches which are already assembled on its holders. The holder is made to
rest on these blocks, for the required surface to be ground. It is done for work pieces
which need to be ground in assembly.
d. V Blocks:
To grind flats or angles on round work pieces, or to grind corners of rectangular or
square pieces, it can be used. Magnetic v blocks are also available which can hold the
work with its magnetic field, and hence no other clamping is required.

e. Angle plates:
They are L shaped precise blocks which have slots machined in them to clamp any
shape of work piece. Right angle of plates or blocks can easily be ground on this.
ANGLE PLATE MOUNTED
ANGLE PLATE ON A MAGNETIC CHUCK

f. Fixtures:
They are specially made devices to hold work piece, when other devices cannot be
used. They are mainly used for mass production works.
Machining time calculation- Surface grinding
 Problem 1
A flat surface of a work piece is to be ground, work piece width is
110mm and length is 280mm. Machining allowance per side
=0.35mm. Traverse velocity of table is 16m/min. Downward feed
of the grinding wheel (depth of cut) per pass is 0.015mm per
reverse of the grinding wheel. Cross feed of grinding wheel =
32mm/table stroke. Determine the total machining time.
Solution
 Problem 2
• An internal cylindrical grinding operation is
used to finish an internal bore from an initial
diameter of 250.00 mm to a final diameter of
252.5 mm. The bore is 125 mm long. A
grinding wheel with an initial diameter of
150.00 mm and a width of 20.00 mm is used.
After the operation, the diameter of the
grinding wheel has been reduced to 149.75
mm. Determine the grinding ratio in this
operation.
 Solution
• GR = (volume of work material
removed)/(volume of wheel removed)
• Volume of work material removed =
(π/4)(125)(252.52 – 250.02) = 123,332 mm3
• Volume of wheel removed = (π/4)(20)(1502 –
149.752) = 1177 mm3
• GR = 123,332/1177 = 104.8