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eSs 2 GRINDING
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TYPES OF GRINDING MACHINES

rfa
hou
Q.1. What doyou mean by grinding ?
[Link] is amachining process of abradingthe work surface material
al an bymeans of a rotating abrasive wheel to provide high dimensional accuracy
y th and afine surface finish. Grinding
Wheel
rhea To grind means 'to abrade'or 'to wear away
by friction' or to sharpen'. In grinding, the
material is removed bymeans of a rotating abrasive
wheel. The wheel is made up of alarge number of Workpiece
cutting tools constituted by projected abrasive
particles in the grinding wheel. Fig. 2.1 Grinding
Q2. Explain in brief about the different tvpes of grinding.
Ans. Phere are three types of grinding
(i)/Abrasive Grinding - Abrasive grinding relates to the rapid
emoval ofrelatively larger amounts of stock, with the added capability of
Special workpiece shape formation.
ASCompared with precision grinding, abrasive grinding requires heavier
machines with increased power capac1ties.
nethod of(i)cutting
/Precision Grinding- Precision grinding is the principal production
materials that are too hardto cut by other conventional tools
or for
producing surfaces and parts to tolerances or finish requirements
Xacting than can be achieved by other manufacturing methods. more

(ii) Rough Grinding - Rough grinding is the most commonly used

nethod
r for
for removng excess material from castings, forgings and weldments
removi ng or snagging thin fins, sharp corners, burrs or other unwanted
rojections from various shapes of workpieces.
Rough grinding is accomplished by using aslow work speed and afast
averse.
 Machine Tools Grinding 63
62 Metal Cutting and

.3. Write in brief the cutting action in grinding. Monw is grindingdifferent from other machining operations ?
.5. applicationsin view of its capabilities.
Ans. As showninthefig. 2.2 agrinding whecl consists ofabrasive
particles act likeparticl Eyplainits
([Link], May 2018)
bonding material and voids. The projccting abrasive cutin Differences between Grinding and Other Machining Operations -
grinding wheel
tool tips and remove metal. Aproperly selected
Ans.

particles at cutting edge become dulled, and

abrasive
sharpening action. As cutting proceeds, theeventually Abrasive exhibits el (i) Grinding is mainly used as a fin1shing process and not a bulk
metal,removalprocess. Grinding
is mainly
is usually preceded by some other bulk metal
because of the high cost of labour., tools and
due to Particle This
these become cracked along the cleavage planes
process.
removal
resistance offered by workpiece material which resists grinding work.
powerrequired in ttaken to remove a certain amount of material through
the cutting action. Thus new cutting points are produced Wheel
Face of
(i) Time
which carry out further cutting action. This process Bonding grinding is much more
than that required for the same in other machining
continues till the abrasive grains get worn down to the Material operations.
level ofbond. Atthis point the bond allows the remainder and wear out more quickly than
of the worn grains to be torn from the wheel, exposing Fig. 2.2 Edge of
(ii) Grinding wheels are costlier
cutting tools.
new grains which were previously below the surface other types of
of the wheel and the new grains do further cutting action.
Abrasive Grain (iv) Very hard metals can be machined more easily and efficiently
the other operations.
Q.4. What are the advantages of grinding process over other cutin than Accuracy and surface finish obtained by grinding is much better
processes ? ([Link], Dec. 201 (v)
Or than obtained through other machining operations.
Enlist the advantages of grinding machine over other convention Applications of Grinding Grinding is mainly used for following
([Link]., Dec. 2013
machining processes. applications
Ans. Grinding is one of the extreme important process in productia (i)Grinding is basically employed as a finishing process for producing
work. It possesses following advantages over other cuting processes close dimensional and geometrical accuracies.
() of removing the material from th
Grinding is the only method (ii) It is also used to obtain better surtace finish.
workpiece surface after hardening. (i) It is sometimes used to machine those hard surfaces which are
(ii) Extremely smooth finish desirable at contact and bearing surfac
difficult to be machined by the other surfaces.
can be produced only by grinding operation due to large number of cuttin
edges on the grinding wheel. (iv) It is also used for sharpening the cutting tools.
(iü) No marks as a result of feeding are there, because the whe (v) lt is used for grinding threads in order to have close tolerances
has considerable width. and better finish.
(iv) Very accurate dimensions and smoother surface finish can
achieved in a very short time. Q.6. How are grinding machines classified ? (R. GPV., Dec. 2014)
(V) Complex profiles can be produced accurately with relative Ans. Grinding machines, according to the quality of surface finish produced
inexpensive truing templates. may be classified into following two types
(vi) Very little pressure is required in this process, thus permitting () Rough grinders (ii) Precision grinders.
use on very light work that would otherwise tend to spring away from the to (9 Rough Grinders - Rough grinders are those grinding machines
as
(vii) Abrasives, having very high hardness, are less sensitive to le whose main work is the removal of stockwithout any reference to the accuracy
compared to other tool materials and can withstand high temperatuothe results. Types of rouch erinders are
Thus, these can be worked at higher cutting speeds. given as follows
(vii)Grinding wheels have the self-sharpening properties due (a) Floor stand and bench grinders
releasing of dulled grains and exposing new sharp ones. (b) Portable and flexible shaft grinders
(ix) Grinding, unlike conventional machining need not cut throu (c) Swing frame grinders
the hard skin of forgings, etc. (d) Abrasive belt grinders.
64 Metal Cutting and Machine Tools

(i) Precision Grinders - These grinders are used to finish Grinding 65

to very accurate dimensions. According to the type of surface the pan s53) SwingFrame Grinders - Swing frame grinder has a horizontal
work done they may be classified as follows - generated frame
aboutt 2to 3 mlong suspended at its centre of gravity so as to move
(a) Cylindrical grinders within the area of operation. It is used for snagging particularly for
freely large for the operator to hold up to the wheel.
() Centre-type (Plain) castingsthat are too
(2) Centre-type (Universal) ) Cylindrical Centre-type Grinders - These grinders are intended
(3) Centreless. plain cylindrical parts. although they can also be used for grinding
for grindingcylinders, fillets and even cams and crankshafts.
(b) Internal grinders contoured
() Chucking - plainand universal (v) Centreless Grinders - Centreless grinders are used for grinding
(2) Planetary exterior cylindrical, tapered and formed surfaces on workpieces that are not
centres.
(3) Centreless. held and rotated on
/wi) Internal Grinders - These are used to finish straight., tapered,
(c) Surface grinders size, shape and finish.
() Reciprocating table - or formed holes to the correct
(A) Horizontalspindle (vi) Surface Grinders - These are used to finish plane or flat
curved, convex and
(B) Vertical spindle. surfaces. They are also capable of grinding irregular,
concave surfaces.
(2) Rotating table - mainly
(A) Horizontal spindle (viii) Tool and Cutter Grinders - Tool and cutter grinders are
recondition multiple tooth cutters like reamers, milling
used to sharpen and
(B)Vertical spindle. tools used in the shop. With
cutters, drills, taps, hobs and other types of cylindrical and internal
(d) Tool and cutter grinders light surface,
various attachments, they can also do details and sharpen
(1) Universal fixtures, dies and gauge
grinding to finish such items as jigs,
(2) Special. single point tools.
(e) Special grinding machines. discuss different types of
Q.8. What do you mean by grinding ? Briefly (R. GPV, June 2013)
Q.7. Discuss types ofgrinding machines. ([Link]., June 2016 grinding machines available forgrinding operation
Ans. Description of some important grinders are given as follows - Or
(i) Floor Stand and Bench Grinders Afloor stand grinder has Define grinding. Explain the types ofgrinding machines.
([Link]., Dec. 2010)
horizontal spindle with wheels usually at both ends and is mountedon a bas
or pedestal. There is provision for driving the wheel spindle by belt frot Ans. Refer Q.l and Q.7.
special grinding machines -
motor at the rear, at floor level. The wheels are mounted directly on the mote Q9. Write short notes on the following
shaft extensions, in which case the motor is on the top of the stand. Abend (i) Crankshaft grinders
grinder is mounted on a bench. Bench grinder is used for snagging and o (i) Piston grinders
hand grinding of tools. Polishing wheels may be run on these grinders. (ii) Cam grinders.
(ii) Portable and Flexible Shaft Grinders - Portable grinde Grinders-Crankshatt grinding is actually cylindrical
Ans. () Crankshaft adopted. These grnders
resembles a portable or electric hand drill with a grinding wheel mountedo 8nding where the principle of plungegrinding has been
craft engines, diesel engines,
the spindle. e used for crankshafts of automobile engines, air
Flexible shaft grinder has grinding wheel on the end of a long flexi compressors, etc. crankshaft rotates in a
fixed
shaft driven by a motor on a relatively stationary stand. It can be easily mo In the prOcess of crankshaft grinding, the cylinders of alength equalto
about and may be used to the advantage in removing small amount of slo position, as the grinding wheel fecds to produce requires very
from widely separated areas. or shorter than the width of wheel. The crankshaft grinding
slow speed.
 66 Metal Cutting and Machine Tools Grinding 67
Column
(ü) Piston Grinders - The grinding of pistons of high Column
internal combustion engines is basically cylindrical grinding
slightly from plain cylindrical grinding. Many such pistons are butitnotdevspe,
iale
Grinding
Wheel
Magnetie
-Wheel Head

slightly [Link]
Wheel Head
truly cylindrical butslightly elliptical, and sometimes -Table
Chuck

On a piston grinder, theretore. a mechanism is provided| to Rotary. Grinding

and synchronously movethe revolving piston alternately toward orr
the wheel. thus grinding an clliptical form. At the same time, the
autworkaway
omaticfromall, Table Wheel

progressively away from the wheel during its longitudinal movethu Saddle Base
Base

grinding the desired taper. movement, Fig. 2.4 Block Diagram of a

(iii) Cam Grinders- Acam grinder is a special form of cylindrica 2.3 Block Diagram ofa
Fig.
Horizontal Spindle Surface Vertical Spindle Surface
grinder which is used to generate cams. Grinder
Grinder
The headstock and tailstock are mounted on a base on the bed ways sn rotary
that they can oscillate about a centre below the work. The headstock containe (i) Vertical Spindle Surface Grinder - The verticalspindle machine
The principal elements of this
a shortened, hardened replica of the finished camshaft. This template rotatet table surface grindershown in fig. 2.4.
is for
magnetic chuck which can
be moved under or away from the wheel
with the work and runs against a fixed roller which causes the headstock to is mounted vertically on
are a grinding spindle
Oscillate. The work which is mounted between centres, rotates at very slow unloading and loading the work. The position, feeding only along its axis.
and rotated in a fixed
speed and oscillates continuously, moving toward or away from the wheel to the face ofa column
Discuss following surface grinding
generate the cam shape. Allmovements in the machine are automatic.
0.12. What is surface grinding ?
operations
SURFACE, CYLINDRICAL AND INTERNAL GRINDING, () Tapered surface grinding
CENTRELESS GRINDING (ii) Formed surface grinding
(üi) Threaded surface grinding.
Q.10. What is surfuce grinding, give its uses ? Ans. For surface grinding, refer Q.10.
Tapered surfaces are ground on
Ans. In surface grinding, heavy workpieces are clamped on the table by (i) Tapered Surface Grinding
means of pads, strap clamps and other such devices or they are held in fixtures. cylindrical grinding machines by swivelling -
the workpiece.
Small work is usually held by a magnetic chuck. The surface grinders are (a) The table to the taper angle of
(tig. 2.5)
available with horizontal spindle and vertical spindle and with either reciprocating (b) The wheel head to the same angle
table or rotary table. (c) The headstock with
Surface grinding machines are employed to finish plane or flat surfaces. the workpiece clamped in a chuck.
They are also capable of grinding irregular, curved, convex and concave surfaces. In the second method longitudinal
Q.I1. With neat sketches, explain following types aof surface grinding feed is obtained by the axial motion of
machines the flywheel.
(i) Horizontal spindle surface grinder Internal tapered surfaces are
(ii) Vertical spindle surface grinder. ground on centreless grinding
Ans. (i) Horizontal Spindle Surface Grinder - In this machines by swivelling housing and Grinding
the workpiece to the taper angle. Fig. 2.5 Taper
the workpiece reciprocates under the wheel, and the wheel ortype of grinding
the table feeds finished on cylindrical
axially between passes to produce a fine flat surface (Fig. 2.3). (ii) Formed Surfuce Grinding These are periphery
ground by either the
downfeed determines depth of cut and final height of the piece from theWheel
table
and surface grinding machines. The work may beworkpiece
or by the end face of the grinding wheel. The is reciprocated at a
to the wheel. wheel.
Constant speed below or onthe end face of the grinding
68 Metal Cutting and Machine Tools Grinding 69
(ii) Threaded Surface Grinding Threaded Diferentiate between external and internal cylindrical grinding.
specialthread grinding machines, with either single grinding is done o Q/s.
grinding of
or multiple rib wheele
external threads with a multiple rib wheel, the work is Ans. External Cylindrical Grinding -This type of grinding produces a
tapered surface on the workpiece. The workpiece must be rotated
between the centres and rotated at a definite speed. mounted straightor aX0s between centres as it passes lengthwise across the face of
Own
Q.13. Explain the principle of cylindrical grinding. about its grindingwheel.
Ans. The principle of cylindrical grinding, as shown in fig. 2.6 involv. arevolving Cylindrical Grinding - It is used to produce cylindrical and
Internal
holding the workpiece rigidly on centres, in a chuck or in a suitable workpieces are chucked and precisely rotated about their
lapered holes. The
against the same. If the work surface to be ground is longer than the faes
holding
fixture, rotating it about its axis and feeding a fast revolving grinding whe
Ownaxis, the
grinding wwheel or in the case of small bore holes,
against the direction of rotation of the
the cylindrical
workpiece.
width of the grinding wheel, the work is traversed past the wheel or the wheel wheel rotates Grinding
Wheel
past the work. Traversing of wheel or work is done either by hydraulic or Workpiece
mechanical power or by hand. Grinding
Feed is given to the work or the Wheel
E Grinding Wheel
wheel at the end of each
Wheel
traversing movement. In case Feed Workpiece
the width of wheel face is more
(b) Internal Cylindrical Grinding
or equal to the length of the Workpiece (a) External Cylindrical Grinding
work surface to be ground, the Fig. 2.7
wheel may be fed in with no cylindricalcentre-type grinding.
traversing movement of it or that Work Traverse .16. Discuss the main features of workpiece is usually held
Fig. 2.6 Principle of Cylindrical Grinding grinding the
of the work. Ans. In centre-type cylindrical dog and driver on the face plate. The
Cylindrical grinding produces a cylindrical or conical shape ona workpiece. between dead centres and rotated by a There are four
its own axis in a chuck.
Cylindrical grinding is used to produce - work may also be rotated about
grind1ng -
() Plain or stepped surfaces movements involved in a cylindrical centre-type
(i) The work must revolve
(ii) External cylinders
(iii)) Concave and convex radii (ii) The wheel must revolve
wheel, and
(iv) Tapers and undercuts. (11) The work must pass the
(iv) The wheel must pass the work. grinding
Q.14. Compare surface and cylindrical grinding. ([Link]., June 2014)
Ihese grinders are equipped with a mechanism which enables the Hand
Ans. The comparison between surface and cylindrical grinding is given the work for successive cuts.
Wheel to be fed in automaticallv towards
below
only for adjusting the wheel or starting the cut. Aprovision is
eed is employed longitudinal movement of the work or traversethe wheel,
[Link]. Surface Grinding Cylindrical Grinding so inade for varying the different conditions. The of
work to suit
erotatingspeed of thevice-versa. cause table
() Used to produce flat surfaces. Used to produce cylindrical and is controlled by dogs which
work past the wheel or
tapered surfaces. stroke. An important feature of soie
The workpiece is reciprocated at The workpiece is held in chucks wneel to reverse at the end of each wnen e
(ü) may be stopped automatically
Pes of grinders is that the operation Hydraulic
a constant speed below or on theand must be rotated about its own controls are more preferred on
end face of the grinding wheel. axis between the centres. workpiece has been finished to size.
Erinding machines because of the minimum vibrat1on. ?
(iii) The grinding wheel revolves andThe work is ground by either the andplunge grinding
workpiece is fed across it. periphery or by the end face of the Q.17. What do you understand by traversegrinding([Link], June 2010)
grinding wheel. How these twocan be differentiated ?
 70 Metal Cutting and Machine Tools Grinding 71
Ans. In cylindrical type grinding machines, two distinct types of from thetable.
The lower worktable can be traversed on its ways either
operations are done grindin and
orby power feed and has provisions for controlling the rate of traverse.
() Traverse grinding (ii) Plungegrinding. byhand worktable is equipped with scales and adjusting screws for setting
The upper produce slight tapers. Steep tapers can be produced by swivelling
In case of traverse grinding. the work is reciprocated as the
wheel fee thetableto
to producecylinders longer than the width of the wheel face. While in cas headstock on its base. The headstock is equipped with a self contained
plunge grinding. the work rotates in a fixed position as the wheel feeds i with provisions for variable work speeds. The headstock
driving mechanism either live or dead by engaging the work drive plate wi
produce cylinders of length equal to or shorter than the width of the whe centre may be
made
m
The plunge grinding (shown thespindle.
following additional features
in fig. 2.8) has one important A universalgrinding machine has the
advantage. By plunge grinding, (i) The headstock spindle used may be alive or dead, so that the
and revolved by chuck as well as ground between centres.
cylindrical shapes can be work can be held
produced as easily as straight (ii) The headstock can be swivelled at an angle in a horizontal plane.
cylinders in a single "plunge" of ii) The wheel head and slide can be swivelled and traversed at any
wheel simply by forming the grinding by the addition
angle. The wheel head can also be arranged for internal
periphery of the wheel. Plunge revolve small wheels at high speeds.
grinding requires very slow speed. Fig. 2.8 Plunge Grinding of an auxiliary wheel head to
grinding.
0.20. Explain the working of internal centreless ([Link],
Traverse speeds should be in proportion to the width of the wheel fac Dec. 2009)
and he finish desired.
Or
Q.18. Draw a neat sketch of chucktype internal cylindrical grinder and Explain the working principle of internal grinding. (RGPL, Dec. 2014)
xplain its operation. ([Link] V, June 201)
Ans. Chucking type internal cylindricalgrinders are used, when workpie: Ans. In rentreless internal grinding (fig. 2.10), the workpiece is supported
can be conveniently chucked and rotated. In this method, the workpiece hel between three rolls, a pressure roll, a supporting roll and a regulating roll.
in a chuck can rotate, while the grinding wheel besides These rolls support the workpiece and also rotate the same. All three rolls
rotation, also cal
reciprocate back and forth through the length of the hole (fig. 2.9). In ths rotate in the same direction, while the workpiece and the grinding wheel rotate
arrangement, work has no lateral and cross movement.. In another arrangemenl In the opposite direction. The grinding wheel remains in contact with the
of chucking type grinders, the work is slowlyrotated and Internal surface of the workpiece at the horizontal axis of the regulating roll.
forth, while the grinder is only rotated and has no traversed back and The pressure roll can be swung to a side to allow loading and unloading of the
this case, the work head is longitudinal movement. workpiece. The grinding wheel mounted on aslide can also have areciprocating
mounted on a motion.
longitudinal slide at the left end of the Workpiece
machine, so that the workpiece may be
4/Grinding Whedl Rressure b Grinding
raversed past the grinding
heel head is mounted on a
wheel, and the Wheel
-Reg
rioht end so that the wheelcross-slide
may be fed
at
ep' ofcut. Chucking type Path of
r ding holes in grinders are Swinging
he bore of gears and
small workpieces, euPPuriae.
the inner surfaces Roll

vaii bear1ng rings.

0.19. How a universal Fig. 2.9 Chucking Grinder
Ans. Auniversal
grinder differs from plain cylindrical grinder! Workpiece
in the sense that the cylindrical grinder differs from a
l
ncylindrical grind
sWivelled on itsplain
wheel head can be
base and can befed W Fig. 2.10 lnternal Centreless Grinding
 Grinding 73
72 Metal Cutting and Machine Tools the depth of cut. This method is
given a radial infeed to increase
Q.21. Explain the steps to be followed in finishing an external wheelis usedto grind holes in large, irregular shaped and heavy workpieces
faarimarily
hy cylindrical grinder. inconvenient to clamp in a chuck.
([Link], Dec. 201
Ans. The steps to finish an external surtace by cylindrical
whichare
(ii) Centreless Internal Grinders -Refer Q.20.
follows - grinding
(i) The workpiece is mounted between the two centres. One of tha
are a
Q23. Write short note on Cylindrical and internal grinding.
(R. GP. V., June 2013)
entres is in the headstock and the other in the tailstock. O.20.
Ans. Refer Q.13 and
(ii)The headstock is rigidly attached to the worktable and with suitable sketch.
Swiveled, while tailstock can slide along the worktable to accommodat
cannot k 0.24. Discuss the creep feed grinding ([Link].V., June 2015)
workpieces of different lengths. grinding in which a soft
(ii) The headstock should rotate opposite to the wheel rotation. Ans. Creep feed grind1ng is a special type of
used. In this method, the grinding wheel revolves in position,
that the sparking is directed towards the table. grinding wheel is The principle of operation is
while thework is fed past the revolving wheel.
(iv) The feed is obtained by traversing the worktable on the
either by hand or automatically. In case of automatic feeding, enough bedwaw shown in fig. 2.12.
dwel The work is fed very Diamond Coated
time should be provided to allow the wheel clear before the table Dressing Roll
reciprocates slowly so that the cn
(v) SlowBy feed the grinding wheel into the workpiece until it spark: depth of material to
be
Grinding Downward
(vi) Grind the diameter until the surface is removed is removed in a Wheel
completely ground. Compensating
(vii)Stop the machine and check, if any adjustment is required. single pass. To reduce the Movement

(vii) If more machining is required, then adjust the infeed accordingly heat generated, ample
amount of coolant is
(ix) Stop the machine, making sure the wheel has cleared the
supplied under pressure.
workpiece. The most commonly used
(x) Remnove the workpiece and check its diameter to coolant is sulfurised oil. As
Coolant
Depth of Cut
ensure it is
within acceptable tolerances. grinding wheel is made of
0.22. Discuss in brief important types of internal a soft material, it requires
grinders. continuous dressing during
Ans. Internal grinders are used to finish straight, tapered or formed holes
to the correct size and finish. Internal grinders can the process. For that
be mainly classified into purpose, a diamond coated
following types
() Chucking (ii) Planetary (ii)Centreless. dressing roll is mounted Fig. 2.12 Creep Feed Grinding
above the grinding wheel.
continuous dressing.
(i) Chucking Internal Grinders - Refer
Q.18. 8nding wheel is likely to go undersize due to this maintain the same
lost size and
(i) Planetary Internal Grinders - In Therefore, in order to compensate for the
mechanism is used to continuously
workpiece remains stationary, planetary grinding tn Pu or cut throughout the process. a
which is mounted on a slide. The press the grinding wheel downwards.
wheel spindle is so arranged that grindng.
besides rotating on its axis it can
Planetar)
Rotation 25. Explain the surface, eylindrical and internal
([Link]., June 2010)
be made to run eccentrically,
Ans. Surface Grinding Refer Q.10.
thus making it possible to grind
large holes of varying diameter Infeed
Infeed CylindricalGrinding Refer Q.13.
(fig. 2.1). After completion of Motion of Workpiece Internal Grinding- Refer Q.20.
cach planetary circle, the grinding g 2.I Planetary Type Internal Grinding
 74 Metal Cutting and Machine Tools Grinding 75
Q.26. With the help of neat sketch, explain the centreless ori What is centreless grinding ? Write down its advantages and
0.27.
process. Also write its applications. ([Link]., May 2018)
Or
([Link]., Dec. 20 limitations.
Or
grinding with its advantages and limitations.
Explain the working principle of centreless grinding. Discussthe centreless ([Link], June 2015)
Or
([Link]., June 2014 Or

Explain the principle of centreless grinding. What are its uses ? of centreless grinder.
Describe the operation, advantages and limitations([Link]., Dec. 2010)
([Link], June 201) Or
Ans. In contrast to cylindrical grinding, where the workpiece is helk advantages and limitations.
between the centres, in centreless grinding, the workpiece is not held in centre Explain centreless grinding process. State its ([Link]., June 2016)
instead two wheels and a work rest support the workpiece, as shown in fi
- Refer ).26.
2.13. Two wheels also help feed the workpiece. Out of the two wheels, the Ans. Centreless Grinding are the advantages of
larger wheel is the grinding wheel, and the smaller one is the pressure o Advantages of Centreless Grinding - Following
regulating wheel. During operation, the pressure exerted by the grinding whel centreless grinding over the cylindrical centre-type grinding grinding
on the workpiece forces it against the work rest and regulating wheel. The (i) The rate of production is much more in centreless
regulating wheel is of rubber bonded abrasive, having the frictiond than cylindrical grinding.
whole lengthensuring
characteristics to rotate the work at its own rotational speed. (ii) The work is supported rigidly along the
better stability.
long jobs as the work is
(ii). This process is very suitable for of deflection can be
hence chances
Grinding Work supported along the whole length and
Wheel Regulating avoided.
can be eliminated and
Wheel
centering
(iv) Due to floating conditions, the
hence no time is wasted in job setting.
less stock will be needed.
(V) As the centering is eliminated thus
(vi) Cost of production is very less. economical
is less and hence
Work Rest (VIi) The wear and tear of the machine
Fig. 2.13 External Centreless Grinding tomaintain.
operation of the machine.
The axial movement of the work past the grinding wheel is (Vi) A low level of skill is needed in the
tilting the regulating wheel at a slight angle from horizontal. obtained
by adopted for production work.
An angular (IX) The process is continuous and supported between
adjustment of 0° to 8 or I0° is provided in the machine for this purpose. (X) No axial thrust is present on work as
it is
The actual feed (S) can be calculated by the
formula centres. Thus, long thinpieces are not likely to be distorted
internal grinding.
S = [Link] a (XI) It can be used for both external and
where S =Feed in mm per minute for sizes can be made, resulting in a h1gher
(A) Direct adjustment
n =Revolutions per minute
d =Diameter of regulating wheel in
accuracy.
mm Limitations of Centreless Grinding
easily handled.
a- Angle of inclination of regulating
wheel. (i) Workpiece having several diameters is not
Centreless grinding is performed on workpieces which do not or cano () Work with tlats and kevwavs cannot be ground. diameter
the outside
have centres such as pistons, valves, rings, tubes, balls,
wrist pins, dr1lls, (i)) In hollow work, there IS no assurance that
rods, bushings, shafts, balls and rollers for will be
bearings, etc. concentric with inside diameter.
methods
lowing
threecentreless
grinding.
(VI) (v) (iv) [Link]. given grinding ? grinding? centreless grinding.
centreless centreless
grinding. 76
Ans. (1) (1)
(i)High
Q.33. Ans. Ans. Q.31. Ans. Q.30. Ans. 0.29. Ans. Metal
deflectionalong long stability. follows as- 0.32. Refer
Q.27.
0.28.
Centreless Discuss This the setting.
The centering
hence maintain.
Due to ine The Cost Comparison Refer Refer grinding How Reter Cutting
jobs
process whole work is
wear Compare What How What is
the no to less Centreless
Grinding
ofrate
as floating production are Q.26
"Through-feed',
doeswhole
the length is time can
supported and and of are Q.6 are Q.6, and
grinding is the andgrinding Q.26 Describe grinding ? andcentrelessMachine
not work very
length
is be hence production. tear between between
ensuring eliminated conditions,
wasted
advantages Q.26.
occur. of is and
suitable
is rigidly economical the very
Q.27.
on and
supported centreless
different better
in centreless
machines Q.2 7.
machines
the grinding Tools
thus along| job and mach less.
'In-feed' for the
of
operation,
short This grindinggrinding ([Link]., centreless classified Statethe ?
types Work maintain.
More is The Cost
more Low classified
and length process time wear of advantages
of is rate
Cylindrical
Grinding
'End-feed' supported production
and and and and grinding
jobs is of Dec. ?advantages
jobs. is wasted hence production cylindrical ([Link]
cylindrical ([Link].,
Dec.
2010 ([Link].,June
20I What ([Link].,
tear ?
may suitable 2006, What
at of over and do
be in
expensIve the is V.,
methods the job high. June is limitation, you
Dec.
done only ends. setting machine|
grinding grinding. centre-tye meant June of
201)
mean centrelen
tor 2013)
to is h i <0

powders
ushing mounted POjeeing
oasive reaches
lengthwise
ground
ISformed taper, This surfaces.
regulating formeduseful in,workpiecewheel form orThis diameter grinding
grindingwork-rest
to shoullforng,dercompl
uss uallyetely
Ans. Q.3GRINDING
N 4. method is The
toeither feed
Ans. 235. CI to issimilar
dsTVe When aS stop.
endthe grinding,
oflayer (ii) orwith
tained on grains Agrinding as taper.
between a End-feed
Method
(iii) wheel.
grind thblade. e madrawn
y the
t
through
Abrasives What someblocks theabrasive
abrasives What AND wheel the other
it is In-feed
to of guides
Through-feed-This
advances Thegrinding used shoulders, This work Then be plungeworkpiece metslender
do wheel are is
WHEELS, placed back the al forms the
by you form built mixed particles wheelDRESSINGa the or at
include is which grinding wheels work both to methodagainst it
regulating
is Method removed space
toboth
mean of [Link] until
wheel
produce moved on grinding
so
by shafts
interfere i
with have isa is that between
tine machine into act and fed are or and the the 0. 02 ends.
natural by The
a
multi-tooth
SPECIFICATIONS,
alike wheel it is - by or
crushed
abrasive suitable
solidwheel been WITHOUT grinding tothe bars. This the is
adapted cutting Griding
Wheel Griding
Wheel 0.3 with the
or ? simplest
wheel. may crushedcutter Fig. mm. thgrinding
e
method
ynthetic
substances ? to bond, tool Fig.
2.15 passage
aconsist
The
which tips to
ECCENTRICITY
made 2.14
Stop
wheel
one method.
is
wheel
particular
materials. in abrasive of and leave up WHEEL End-feed Workpiece In-feed
Workpiece thin
e
the
ofused
and
the (R. one acts sharp of when The
form GPtypewheelpiece remove like
many Grinding reduces
pasS [Link] work
Grinding of of .,
Dec. work. is metal. or a edges. hard TRUING Grinding there
It
Grinding

grains Regulating Regulating is e passed is

segmentsmatrix particles
usually
Wheel Wheel
useful arwheel,
wheels 20l6) The
These no 77
and Or
 Tools
78 Metal Cutting and Machine Grinding 79
are made of fine grains of abrasive materials held together by aabonding materia Boron nitride grinding wheels are used to grind hardened and difficult to grind
Each individual and irregularly shaped grain acts as a single point cutting too steels. These havelong life and high grinding ratios. Temperature encountered
are characterized by grain
size and shape, grinding is much less and hence much better finish and quality of surface.
Abrasive materials
toughness, resistance to fracture and friability. When fracture takes place, hardnes, in
Q.37. What is the role of abrasives in a grinding wheel ? Name afew
formnew sharp edges. ([Link]., Dec. 201 7)
grain break apart in chunks to
Q.36. What are the various ypes of abrasives used for, grinding wheel
commonabrasives.
).36.
Ans. Refer Q.35 and
([Link]., June 2015 o 38. Describe the different types of bonds used in
grinding wheels
Or applications. ([Link]., Dec. 2017)
used in grinding. along with their
State briefabout types ofabrasives ([Link], June 2016
together enabling
Ans. Abond is a materialthat holds the abrasive grains wheel. The most
in a desired shape in the form of
Ans. Abrasives used for grinding w
wheels can be classified into following the mixture to be kept wheels along with their code letters
commonly used type of bonds in grinding
two types are as follows
(i) Natural abrasives (ii) Artificial abrasives. (ii) Silicate bond, S
(i) Vitrified bond, V
(i) Natural Abrasives They are obtained directly from mines (iii) Shellac bond, E
(iv) Rubber bond, R
They are produced by uncontrolled forces of nature. The following are th (v) Bakelite or resinoid bond, B (vi) Oxychloride bond, O.
generally found and used natural abrasives - silicated, rubber and bakelite bonds are denoted by the
(a) Sandstone or solid quartz
Of these, vitrified, elasticity (E) in order
property, i.e.
process and shellac bond is denoted by its
(b) Emery (50-60% crystalline Al,O, + iron oxide) silicate bond.
(c) Corundum (75-95% crystalline Al,0, + iron oxide) toavoid confusion with
(d) Diamonds These bonds are discussed below -
like substance
(e) Garnet. () Vitrified Bond-Vitrifymeans to change into a glass
clay, feldspar or flint mixed
Almost all of the natural abrasives, except diamond, are now considered by heat and fusion. Vitrified wheels are made by uniform.
the mixture
with the abrasive grains. The water is also added to make
obsolete. The sandstone is used only for sharpening some wood-working The wet mixture is the poured into moulds and allowed to dry.
The wheel is
tools. Emery and corundum are the materials which were formerly used widely wheel. The
but have now been replaced almost completely by the artificial abrasies then shaped on a machine operating on the principle ofa potter's
about 1200°C.
wheels are then heated or burnt in a kiln at a temperature of
Diamond, however, stillretains its place even in modern grinding processes When the burning proceeds, the clay vitrifies, i.e. fuses and forms a glass like
ishardlargely used for dressing the grinding wheels and as an abrasive for grinding
materials. substance that surrounds and connects the abrasive grains. The high temperature
employed in this process tends to anneal the abrasive to some extent.
(ii) Artijicial Abrasives They are manufactured under conto About 75% of the grinding wheels are vitrified bonded. The reason for
conditions in closed electric furnaces in order to avoid the
impurities and to achieve necessary
introducuou this is the fact these wheels have good strength as well as porosity to allow
take place. The main artificial or temperature
for the chemical reacttoD high stock removal with cool cutting. These wheels are not affected by oils.
manufactured abrasives are - acids, water, heat or cold. The disadvantage of these wheels is that there are
(a) Silicon carbide (SiC) (b) Aluminium oxide greater chances of distortion or cracking due to high temperature of fusion.
(c) Boron carbide (Al,03) and the wheel is brittle.
(d) Boron nitride.
Silicon carbide abrasives are available in variety of colours. Aspecial (it) Silicate Bond- Silicate wheels are made bymixing sodum vi
variety of bluish green is very suitable for grinding tip tools. The trade names WiLn the abrasive, pressing in moulds, drying, then baking at 26
of it are 'carborandum', 'crystolon' and 'electron' etc. The trade names of
days,
fused aluminium oxide are special
form is white Al,0, which 'when
Aloxite', 'Alooks
pure. like and
lundum brilliant white crystal.
'Borolon'. Its Itis SIlicate wheels have a milder actionand cut with less harta acUipicu
lo vitrified wheels. In siieate bonds abrasive particles fall o apicy did
most suitable for tool islow.
ttus
steels where heat
generation due to grinding
 80 Metal Cutting and Machine Tools Grinding 81
hardly any grain becomes blunt. This reduces friction and selection mainly depends upon the following factors
Grinding wheel
during grinding. This quality makes them suitable for grindingheat
knives, etc. as their heat treatment will not be affected even
tools, bla
after
generation (i) Constant factors
() Constant Factors
(ii) Variable factors.
These include
However, silicate bonded wheels have less mechanical strength. grinding, (a) Material to be ground
compared to vitrified bonded wheels and wear out rapidly. That is why sili (b) Amount and rate of stock to be
removed
bond is the least used bond today.
(c)Area of contact (d) Type of grinding machine.
(ii) Shellac Bond- The shellac bonded wheel is made by mivie. (i)Variable Factors These include
shellac and the grit in a heated mixer, than moulding and baking at about 1S0 (b) Work speed
for few hours. Shellac bonded wheels are also known as elastic bonded wheal (a) Wheel speed
as their elasticity is greater than the other types. (c) Condition of machine (d) Personal factor.
Shellac bonded wheels are not intended for heavy duty [Link] variable factors considered for selection
are used only for a few special applications such as veryapplications.
They Q.40. ([Link]., Dec. 2008, 2009)
high finishes on of grinding wheels.
wheel
paper mill rolls, hardened steel cams and aluminium piston, and in very thin Aee Variousfactors need to be considered for selection of grinding
sections such as knife, scissors and cutlery. are discussed below
(iv) Rubber Bond- Rubber bonded wheels are (i) Constant Factors
prepared by
abrasive grains with pure rubber and sulphur. The mixture is rolled into mixing
and wheels are punched out of the sheets on a punch press. The wheels are
sheet (a) Materialto be Ground- This influences the selection of
then vulcanized. (1) Abrasive (2) Grain size (3) Grade (4) Structure.
Rubber bonds are strong and tough enough to make extremely thin wheel, (1)Abrasive Aluminium oxide (Al,0;) is used for tough
high speed
with a high factor of safety. This makes them these wheels
ideal for materials having high tensile strength such as mild steel, aloy steel,
off purposes when a coolant is used. Rubber bonded wheels are used cutting iron, etc. Silicon carbide (SiC)
for very annealed malleable iron, tough bronze, wrought
hard materials like grey cast iron castings, chilled iron,
fine finishing and polishing of metals such as ball bearing
races, and is used for brittle and
for cut substances. SiC is
off wheels where burr and burn must be avoided. tungsten carbide, hard steels, porcelain and other ceramic
also used for low tensile strength materials such as non-ferrous metals, bronze,
(v) Bakelite or Resinoid Bond- Resinoid bonded
by mixing abrasive grains with synthetic resins such as wheels are produced brass, copper, aluminium and plastic materials.
The mixture is placed in moulds and heated to a
Bakelite and Redmanol. (2) Grain Size - Grain size is determined by the mesh
temperature about 200°C. number by which it is retained when passed through a series of meshes in a
Resinoid bonded wheels are less brittle, tougher and more flexible than the
vitrified bonded wheels. They can be run up to 2900 m/min. Vibrating sieve. Coarse grain size is used for softer materials and fine grains
the second most frequently used bond next to the Resinoid bond is are used for harder materials. Coarser grain is used for high rate of stock
are useful for precision grinding cams and rolls
vitrified bond. These wheels removal and fine grain is used where work surface finish is important.
requiring high finish. (3) Grade Grade refers to the strength of the bond. Hard
(vi) Oxychloride Bond Oxychloride bonded
mixing abrasive grains with oxide and wheels are made by wheel is used for soft materials and soft wheel for hard materials.
chloride of magnesium. The mixing IS between the
performed in the same way as for vitrified bonded wheel. (4) Structure - This represents the void
grinding,
Oxychloride bond ensures a cool abrasives. Dense structured wheels are used for finish and form
making wheels and wheel segments for cutting action. This bond is used for
use in disc grinding
sincethey retain their shape well. Medium dense structured wheels are used
Q.39. Enlist the points to be considered in operations. Cnng hardened steel parts, for sharpening cutting tools, for cylindrical,
selecting a grinding whee entreless andinternal grinding and for surface grinding with the periphery or
materials
([Link]. Dec. 2016) :Open structure wheels are used for grindingsoft and ductile
and
Ans. The proper selection of grinding surlace grinding with the face of acup, eylinder or segmental wheel.
good results (i.e., obtaining better finish andwheels is very important for gets
at the same time having more Amount and Rate of Stock to be Removed It intluences
of the wheel). i (1) grain size, (b)
(2) grade and (3) structure.
82 Metal Cutting and Machine Too/s Grinding 83
Coarse grain is used for fast cutting and fine grain for fine finish. general, coarse grained wheels are used for fast removal of materials.
structure is used for rapid removal and dense structure for fine n:. 4 FineIngrained wheelsareused where finish is an important consideration. Coarse
regards grade, soft grade is used for fast removal. grained wheel may
be used for soft. ductile materials but generally a fine
(c) Area of Contact It influences the selection of_A Braorained wheel should be used to grind hard and brittle materials.
grain size for an abrasive is denoted by a number representing
size, (2) grade and (3) structure. The grit or inch of the screen through which the grains of
meshes per
Fine grain and dense spacing are used when area of contact is Smalla the number of passed for grading. The standard numbers representing
coarse grain and open spacing are used where alarge area of contact isInvol cushed abrasives areare gIven in table 2 1
A softer wheel is used when arc of contact is large and vice-versa. different grain sizes
Table 2.1 Standard Grain Sizes for Grinding Wheels
(d) Type of Grinding Machine - Type of grinding
determines to an extent the grade of the wheel. Heavy rigidly machin Grit Designation
Ifconstructed 10 12 14 16 20 24
machines require softer grade of wheel than the light machines. Coarse
are likely to occur during grinding. harder wheels are used. vibration Medium
Fine
30
80
36
100
46
120 150
54 60
180
(ü) Variable Factors - Very Fine 220 240 280 320 400 500 600
(a) Wheel Speed - It influences the selection of grade and
tenacity
bond. The higher the wheel speed relative to work speed, the softer the whe Grade - The term grade as applied to a grinding wheel refers to the
abrasive grains in
should be. Vitrified bond is usually specified for speeds upto 2000 [Link] or hardness with which the bond holds the cutting points or
hardness of abrasive grains. The grade shall be
and for speeds above 2000 s.m.p.m., rubber, shellac or resinoid bonds are usel place. does not refer to the 'A' denoting
(b) Work Speed - The higher the work speed relative to the indicated in allbonds and processes by a letter of the English alphabet,
to the resistance
the softest and Z' the hardest grade. The term 'soft' or 'hard' refer
wheel speed the harder the wheel should be. which the abrasive
abond offers to disruption of the abrasives. A wheel from
(c) Condition of the Grinding Machine - It influences th: grains can easily be dislodged is called soft, whereas, one which holds the grains
grade of wheel to be selected. Spindle loose in their bearings, and insecure oa hard. The grades are denoted in table 2.2.
more securely is called
shacky foundations would necessitate the use of harder wheels than would be
the case if the machines were in better operating condition. Table 2.2 Different Grades of Grinding Wheels
Soft A BC DE F G H
(d) PersonalFactors The skill of the workman also affects Medium J K L MN 0 P
the selection of the wheel. An unskilled worker cannot handle soft wheels and V W X Y Z
Hard R S TU
is likely to break them. Thus, unskilled worker should be allowed to work only
by the
in those conditions which require a hard wheel. The selection of a particular grade of wheel is largely governed used
work, its composition, size and hardness etc. Softer wheels are
Q.41. Explain the terms - Grit, grade and structure ofgrinding whees Haure of
size of
or grinding harder materials and vice-versa. Similarly, smaller the
Or also
wOrk, harder should be the wheel and vice-versa. The machine condition
Diferentiate between grains, grade and structure of a grinding w Pays an Important role in this selection. Where vibrations are
likely to occur,
([Link].. June 2012)
harder wheels are employed.
Ans. Grit - The term grit or grain denotes the approximate Size ofthe
grinding Sructure - Structure refers to the spacing between the abras1ve grains,
abrasive particles and gives an idea of fineness of the words the density of the wheel. Abrasive grains are not packed
coarseness or
wheel. Agrinding wheel may have the abrasive particles of same size or different .oher
distributedthrough the bond. The relative spacing
sizes. The former is known as a 'compound i n the wheel but are and denoted by the number of cutt1ng edges per
wheel'. The choice of grains size'straight wheel' anand
or grit depends latter
uponthe many factors, viZ Ired to as the structure
face as well as by number andsize of void spaces
between
quality of finish required, amount of stock material to be removed and physical eaof wheel it
grains. The primary Purpose provide chip clearance and
of structure is to
properties of the materials to be ground. may be open or dense.
 84 Metal Cutting and
Machine Tools Grinding 85

The structure of a grinding whecl depends on the use a suitable 'prefix' preceding the
hardness of addition, a manufacturer can
grinding [Link], In brand of the abrasive used and a
to be ground, the finish required and the nature fthe
of notationto indicate his own trade
heavy cuts require an open abrasive the notations to indicate the manufacturer's own
tough and ductile materials and the end of all
hard and brittle materials and finishing cuts require a dense
used is deonted by numbers as
strstuctructure,ure. where 'suffix'atrepresentation
symbolic
for that particular type of wheel. The use of 'prefix'
however, optional.
The structure commonly
given below and 'suffix' is, the above information, in order to specify a grinding wheel
table 2.3
Apartfrom
diameter and width or thickness and the diameter of
completely, the sizze i.e.,mentioned.
Table 2.3
to be
Dense 2 3 4 6 7
bore also required carrying the markings
Open 9 10 1| 12 13 14 15 or higher Thus agrinding wheel conform the following specifications
950 x 25 x 32 x WA 46 LA V17 will
0.42. Explain the grain number and grade of grinding wheel. Wheel diameter= 250 mm
([Link] V., June 2010 Thickness of wheel = 25 mm
Ans. Refer ).41. Bore diameter = 32 mm
W =Manufacturer's prefix to abrasive. It is optional.
Q.43. How cylindrical grinders are specified ? Here it denotes white.
Ans. The size of a cylindrical grinder is designated by the diameter a A = Abrasive (Al,0,)
length of the largest workpiece that the machine can accommodate betwe
46 = It is grain size (medium).
centres. It is a common practice to give the height of centres above the table, i L= Itis again a medium grade.
addition to the above. Some manufacturers designated these machine sizes b
4= Represents a dense structure
numbers and their catalogues have to be consulted for knowing these details. V= Stands for vitrified bond
Q.44. Discuss specification of surface and internal grinders. 17= It is the suffix denoting the type symbol of the
Ans. The size of a surface grinder is specified by the length and breadt manufacturer.
of its tableand the maximum distance between the table and wheel. A rotar is specified ? State
Q.46. Define grinding. How a grinding wheel([Link].,
table surface grinder is specified by the diameter of the rotary table or ot the June 2014)
chuck, if used. Size of a centre type internal grinder is specified by advantages of grinding.
maximum travel of the grinding wheeland the maximum diameter of workpie: Ans. Refer Q.l, Q45 and Q.4.
bore that can be ground. In addition, power (or capacity), wheel ([Link]., June 2015)
diamee. Q.47. Discuss the wheel balancing.
maximum length of workpiece that can be ground, ranges of speeds and heavier than the other, the wheel
feeds, type of drive, etc. are also required to be Ans. When some portion of the wheel is
mentioned. IS Said to be unbalanced. The unbalance at high rotative speed can cause
0.45. Discuss the specification of grinding wheel. (R. GPV, surface. Unbalance may also cause the wheel to break,
May 20 Waviness in the work
Or and may damage the machine or Flange
How grinding wheels are specified ?
State in brief. Injure the operator. Thus, wheel
([Link], June 2010 balancing is essential before use.
Ans. The methods of
differs slightlyit
different countries. In order specifying
to maintain auniformity wheel
grinding throughout the country,I For balancing, the wheel is
the system of marking Institution has mounted at the centre of a Mandrel
grinding wheels, the
devised astandard system to be followed by all Indian Standard Its detailsat
manufacturers. perfectly straight and round Grinding
given in IS: 551-1954. to this system, the various elementsanu
spindle, the assembly is then Wheel

characteristics of grindingAccording
wheels are represented on all the wheels ina definit rested on level knife-edge ways.
Level Knife-edge
sequence as follows The test should be carried out after
() Abrasive (ii) Grain size or urning up the wheel face and Grinding Wheel
(iv) Structure (v) Bond. grit (ii) Grade mounting it on its spindle. Fig. 2.16 Balancing of
 Tools
88 Metal Cutting and Machine

Q.s1. Describe the dressing [Link] requirement in Grinding 89

Ans. Refer Q.47 and Q.50.

([Link].V., Maygrinding2,01 Thisis
doneto
avoid the
wheel.
concentration of the flange pressure ncar the central

Q.52. Define the grinding ? What is dressing and truingp ? holeofthe should be firmly secured to the spindle by
(vi) The inner flange

Ans. Refer Q.l and Q.50. ([Link].V., June 2016 keying,

screwing or
shrink fitting.
spindle.
while the outer flange should have asliding
fit on the Ivii) To balance any unevenness of the wheel and to obtain a tighter
Q.53. Discuss mounting of grinding wheel and wheel truing. materials such as cardboard, leather,
made of compressible
Ans. Mounting of Grinding Wheel - The grinding wheels
([Link].V., Dec. 2014 joint, washers provided between the wheel and its tlanges.
rubber, etc. are
at very high cutting speeds, therefore utmost care must be takensusually
of the outer
o
while operate li) Another washer is placed against the outer surface
proper seat for the nut. The nut is then tightened to hold the
themto ensure adequate safety and avoid chances of their failure mounting flange toprovide result in undue
operation. Following points should be considered while during the
mountingthe grinding wbeel firmly. ExceSsive tightening
damage the
is undesirable as
wheel.
it will
wheel - strain,which may starting
i) The wheel should be closely inspected betore mountingto ensut () Finally a wheel guard is placed and tightencd before
that it is sound and free from all defects. A ringing test is used to check th the machine.
soundness of the wheel. The wheel is put on an arbor and subjected to lohi Q.50.
hammer blows. Aclear, ringing, vibrating sound is an indicative of the whel Truing of Grinding Wheel - Refer
grinding wheel ? Sate
soundness. This test is applicable to vitrifiedand silicate whecls. .54. Why truing and dressing are necessary in
wheel.
(ii) The grinding wheel should easily fit on their spindles. They should afew methods of dressing a grinding June 2008, Dec. 2010)
([Link].,
not be forced on.
(ii) The hole of grinding wheels is generally lined with lead. These Ans. Truing and Dressing Refer Q.50.
lead liner bushes should neither be loose nor they extend beyond the sides of devices
the grinding wheel. Methods of Dressing The following are the common methods or
Grinding used for dressing of grinding wheel
(iv) A flange should be Wheel (i) Wheel dressers
provided on each side of the wheel Inner Flange
Outer (ii) Abrasive sticks
as shown in fig. 2.19. Both the Flange
flanges should be of equal diameter Lead Liner
(ii) Abrasive wheels
Washer
and must be large enough to hold Bush (iv) Dianmond
Lock
the wheel -Spindle (v) Crush dressing fixtures.
properly. The flange Nuts
diameter should be at least half of () Wheel Dressers They form a very common group of grnding
dresser.
star
the grinding wheel. Wheel dressers. They are made in four common types, namely
(v) The sides of the IoCKed dresser, corrugated disc type and cylinder dresser. The star dresser
grinding wheel and the flanges -Key COnsists of a number of pointed discs mounted on a pin and fed to the wheel
which clamp them should be flat Surtace by being held in a handle. Star dresser is commonly used for dressing
and bear evenly all round. ougn grinding wheels, Locked dreSser carries a set of cut or cast diseS,
on suitable
gZig-zag or serrated edges, mounted on a pin and supported
(vi) Both the flanges angs. It is suitable for dressing the wheels used in rough cylindrical grinding.
must be relieved at the centre, cast discs and is used for
so
that they contact the grinding wheel
Washers
Corrugated disc type dresser carries corrugated of solid steel
dressing relatively smoother wheels. Cylinder dresser consists which are to
only at their (flange's) outer part. Fig. 2. 19 Mounting of Grinding Wheel cylinders, helical grooves, and used for dressing wheels
be used for carrying
grinding cast iron jobs or in cylindrical grinding.
 90 Metal Cutting and Machine Tools Grinding 91
(ii) Abrasive Sticks - They are made in two about theterms speed. feed and depth ofcut used in, grinding
varieties, i.e. 0.56. State ([Link]., Dec. 2015)
round or square
The former is mounted on a magazine and used for shaping the t0olroom hafvaiworce%
section. The latter is used in hand dressing in

truing and dressing thin wheels or rough dressing before applyingwheel

operations.
Speed - In grinding, the cutting speed, refers to the
Ans. Cutting the grinding wheel. It is expressed in m/s. Mathe-
a peripheral speed of
dresser. diamong matically.
(ii) Abrasive Hheel Dresser - I is a silicon carbide grain whel wheel,
with vitrified bond and is mounted on a holder. It can be obtained Cutting speed of grinding
in dif eren nDgw Ngw
designs to operate by hand or by machine. It is vastly used for ms
wheels used on cyl1ndrical and centreless grinders for grinding dressi ng tlhe
articles gw 1000 x60
crankshafts. camshafts and pistons, etc.
where Dgw =
Diameter of the grinding wheel in mm
grinding wheel in r.p.m.
(iv) Diamonds - They form an unparalleied device for truing xd Ngw =Speed of the
dressing the wheels to be used for precision work.
Feed- In cylindrical grinding, the term feed (f) denotes the axial movement
Thediamond or group of diamonds is mounted in a holder. The diamoni expressed as mm/revolution of the
ofthe workpiece in its one revolution. It is
should be kept pointed. since only the point can be used for cutting. This i workpiece. Mathematically,
done by slanting the holder down at al15degree angle and using a new surface f =C.b
each time the wheel is dressed.
where =aconstant, which depends upon the type of grinding, viz.
(v) Crush Dressing It is also known as crush forming. It is a = 0.6-0.9 for rough grinding
method of truing the grinding wheel and producing a desired contour on its
periphery. in this method a roll, made of a hard metal, like high speed steel, is = 0.4-0.6 for finish grinding.
be
machined to the desired shape. held in suitable brackets and pressed into the Using the value of feed, the work travel or table travel will
siowly revolving ginding wheel. With the result, a reverse contour of the rol
Is formed on the periphery of the wheel. Wheels carrying vitrified bond are Ws
1000 x 60
most suitable for crush dressing. Silicate bonded wheels are also sometimes
used but are not favoured much. Shellac. rubber and resin bonded wheels are where N = Sp ed of the workpiece in r.p.m.
not suitable for crush dressing because of the fact that they are
very strone Depth of Cat - Depth of cut (d) refers to the thickness of the metal
and tough anddo not break easily to acquire the desired shape, when subjecieu Temoved by the grinding wheel in one pass or one longitudinal raverse.
to cornpressive loads of the crushing Mathematically,
rolls.
2.55. Explain the following te rms connected to d=
D, - D,mm
(i) Wheel balancing grinding wheets 2
Where D, = Diameter of workpiece before grinding
(ü) Wheel loading (loaded
(üi) Wheel dressing
wheels) D, = Diameter of workpiece after grinding
The 0.005 mmto 0.04 mm depending
upon depth
(iv) Wheel truing by of cut in grinding varies from
turning. the ype of grinding, woik material, bond, etc.
([Link], June 201)
Ans. (i) Wheel Balancing NUMERICAL PROBLEMS
Refer ) 47.
(ü) Wheel Loading -
Refer ).48.
(ü) Wheel Dressing - Refer
().50. Prob. I. Agrinding wheel has the efollowing inscription on to io -
(iy) Wheel Truing - Refer 51A 36 Q9V6 ([Link]., June 201l)
().50. What are the of ubove codes ?
meanings
 0.018 mm,force
0.018 the m/min. mm 92
second
Power Amount Sol peripheral
Prob.4. Sol Prob.3. Wheel Sol. which
x = Prob.2. SoL Metal
10
Given,
84for This Given, 6 V 36 Meanings
A 51
Cutting
applied N, a
widthsurface speed is
of m, wheel Calculate
problemCalculate the Calculate
to
metal w
speed be
cutof= N= V= of
D and
by = F, 15= grinded.
Manufacturer's
= Structure
type(open)
Vitrified
bond (medium)
Grade
(medium)
Grain
size oxide
Aluminium
abrasive
= grinding
speed of the 100 Manufacturer's Machine of
grinding removed 14 84
the canm/min.14 TDN the Tools
P=F, V mm
150 I1000 shaft mm, the
= = = =vm N, 14 =power be [Link].p.m. X
47.75 -= 1000 100x Wmin code
84 4.536 0.18 Assumewheel
= Voperation
mm. 20 solved which
× wheel, x per
0.014 m/s, V
20 (d = required N = 51
x xsecond,
x 20 speedprivate symbol
10% 0.018 w) m.
m/s, work workpiece
in the is 15
peripheral A
1680 using a m/min. to 36Q9
m³/s x similar be of
y speed per marking to
N-m/s 103 the grinded a
=
0.18 following shaft indicate V6
= speed
45.36 x = mmway
0,014 0. to are
1680
= m/s. (R. 18 of diameter as
of
50 will with
([Link],2016)
discussed Dec. Dec. ofidentify
([Link],
201S) exact as
mm/s m/s, metal be the a
J/s GP.,
d data follows
= depth diameter
given workpiece type
0.018 removed wheel.
JuneTangental
in mm
and by of -
mn2012) of Prob.2. abrasive
cu per Ans.
as lhof
1s 8
lherefore with 600 work,100mm 10
3mnProb.6.
As Solmachining m
. Calculate Total Time At Speed m/min, SoL
approachreguired. steel
in-feed [Link],
5 length.
cuts.
T=time
an
Given,
diameter sieProf
ob.5. Power
required of V,
in-feed Assume
mm Speed the = distance 10 required
and Using
Time grinding
required 20 L
rate of L= The mm
required for rate m/s, 100 = of a 20 a
grinding
will m/min.
table of
600grinding down plate one table horizontal x per
the of wheel 12 5
f= be mm, =
grinding,
for
pass
n
= 5 N,= A
mm,
= speed
mm
mm 250
mm³
0.05 for mm/pass, thickness mm
0.5
3allowance b=
allowance one 125+2501000
10× 2x 2A
+
B f L 20
V in 125 B= m
P of
is 250IX x
60x
r.p.m. mm, and is
of toaxis 45.36 metal
6 0.5 2 xpass 100 60x 250 1680
mm/cut 20
x isf=5 mm, in-feed wheeland10
10 be
mm, time = number 1000 surface
is removed
has
of Number x 20 1000 given m/min ground.
used.
1 J/mm
37.04
n surfuceforminute minutes
=0.05 -1528
r.p.m.
to = 0.5
of
mm/pass. D, rate
be 3,
F,= mm
by, = Calculate grinder,
passes 250 of A per
ground has of mnm/pa[s. 5 grinding second
([Link],
m/min. 2016)
2Dec. mm,([Link].
grinding
tofor passes a
required the flat
down be t, speed
required = .,
grinding surfuce
wheel
ground 20June Grinding93
in to mm, of
cuts,
3
Ans.
grind 2015) 20 with of Ans.
V,
a =
m/s, time 250 C65
94 Metal Cuttingand Machine Tools
Now machiningtimne for surface grinding will be given as,
Lxb
Xnxk
T=
F, x1000xf
where k = Sparking out factor which can be taken as 1.4
grinding. assuming fimis
Substituting values in equation (i), we get
600x 0.5
T= x3×1.4
2x1000x1/6
=3.78 minutes
Ans,