IPE 4821

MACHINE
TOOLS
Lecture 8:Grinding
Machine
Reference Books

ELEMENTS OF MACHINE MACHINING FUNDAMENTALS OF

TOOLS BY DR. M. TECHNOLOGY BY HELMI MACHINING AND
ANWARUL AZIM A. YOUSSEF MACHINE TOOLS BY
GEOFFREY BOOTHROYD
AND WINSTON A. KNIGHT
 Grinding
Grinding, or abrasive machining, is the process of
removing metal in the form of minute chips by the
action of irregularly shaped abrasive particles.
These particles may be in bonded wheels, coated
belts, or simply loose.

It is usually carried out with a grinding wheel made

of abrasive grains materials i.e. hard materials to
remove very fine quantities of material from a
workpiece.
 When used?

• Machining workpiece materials which are

too hard for other machining operations.
• High degree of surface smoothness and
accuracy.
 Grinding Machines

Grinding Machines are also regarded as machine tools. A distinguishing feature of

grinding machines is the rotating abrasive tool. Grinding machine is employed to obtain
high accuracy along with very high class of surface finish on the workpiece. However,
advent of new generation of grinding wheels and grinding machines, characterized by
their rigidity, power and speed enables one to go for high efficiency deep grinding (often
called as abrasive milling)
Conventional grinding machines can be broadly classified as:
1. Surface grinding machine
2. Cylindrical grinding machine
3. Centerless grinding machine
4. Internal grinding machine
5. Tool and cutter grinding machine
 Surface Grinding

• Surface grinding is used to shape i.e. generate flat surface.

• It is similar to milling machine operation.
Basically there are four different types of surface grinding machines
characterized by the movement of their tables and the orientation of grinding
wheel spindles as follows:

1. Horizontal spindle and reciprocating table

2. Vertical spindle and reciprocating table
3. Horizontal spindle and rotary table
4. Vertical spindle and rotary table
Surface Grinding
 Grinding Machines

The grinding machine consists of a power-driven grinding wheel

and a bed with a fixture to guide and hold the workpiece. The
wheel is made to spin at the desired speed, based on the wheel’s
diameter and manufacturer’s rating, usually by a formula. The
grinding head can be controlled to travel across a fixed workpiece,
or the workpiece can be moved whilst the grinding head stays in a
fixed position. Very fine control of the grinding head or table
position is feasible using a vernier calibrated hand wheel, or using
the features of numerical control (NC) or computer numerical
control (CNC).
 Grinding Machines

Grinding machines remove material from the workpiece by abrasion, which can generate
substantial amounts of heat. They therefore incorporate a coolant to cool the workpiece so
that it does not overheat and exceed its tolerance range. The coolant also benefits the
machinist, as the heat generated may cause burns in some cases.

In very high-precision grinding machines (such as most cylindrical and surface grinders),
the final grinding stages are usually set up to remove about 2/10000 millimeter (less than
1/100000 inch) of the workpiece surface per pass. This process generates such little heat
that the temperature rise is negligible even without a coolant

[Link]
grinding-machine/
 Types of Surface grinding machine

Surface grinding (a) traverse grinding (b) plunge grinding

A: rotation of grinding wheel B: reciprocation of worktable

C: transverse feed D: down feed

➢ Horizontal spindle and reciprocating table

A di s c typ e g rin din g w heel p er f or m s the g rin din g a ctio n with its p eri ph e ral s u r fa ce . B oth
trave r s e a n d p l u n g e g r i n d ing ca n b e ca r r i e d o u t i n th i s m a ch i n e
 Types of Surface grinding machine
Ver tical spi ndl e and recip rocati ng
table

The grinding operation is sim ilar to

that of f ace m illing on a ver tical
milling machine . I n this machine a
cup shaped wheel grinds the
workpiece over its f ull width using
end face of the wheel as shown in
f igure . This brings more grits in
action at the sam e tim e and
consequently a hig her m ateri al
Vertical spindle reciprocating rem oval rate m ay be at t ained than
table surface grinder for grinding with a peripheral
wheel.
 Types of Surface grinding machine

A: rotation of
grinding
wheel
B: table
rotation
C: table
reciprocation
D: down feed
of grinding
wheel

➢ Horizontal spindle and rotary table

I n pri n ci p l e t he o pe ra ti on i s s a m e a s th a t f o r fa ci ng on th e l a the . Thi s m a c h i n e ha s a l i mi ta ti o n i n
a c c omm o da ti on o f w or k pi e ce a n d th e re f o re d oe s n ot h ave wi de s pre a d u se . H owe ve r, b y swi ve l i ng the
w o r k t a b l e , c o n c a ve o r c o nve x o r t a p e re d s u r f a c e c a n b e p r o d u c e d o n i n d i vi du a l p a r t .
 Types of Surface grinding machine

A: rotation of grinding wheel B: work table

rotation C: down feed of grinding wheel

➢ Vertical spindle and rotary table

Th e m a ch i ne i s m o s tl y s u i ta b le f o r s m a l l w o r k p i eces i n l a r g e q u a n titie s . Th i s p r i m a rily p r od uctio n
ty p e m a ch i n e o f ten u s e s tw o o r m o r e g r i n d in g h e a d s th u s e n a b l ing b o th r o u g h i ng a n d f i n is hin g i n
o n e r o ta tion o f th e w o r k ta b l e .
 Cylindrical Grinding
• Cylindrical Grinding is used to shape the outside of an object, that is generating external cylindrical surface.
• It is similar to lathe operation.

Cylindrical Grinding Machines

Cylindrical grinding machine is a type of grinding machine used to shape the outside of an object. The cylindrical
grinder can work on a variety of shapes, however the object must have a central axis of rotation. This includes but is not
limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft. This machine is used to produce external
cylindrical surface. The surfaces may be straight, tapered, steps , contoured or profiled.

Cylindrical grinding operations resemble lathe-turning operations. They replace the lathe when the workpiece is
hardened or when extreme accuracy and superior finish are required. As the workpiece revolves, the grinding wheel,
rotating much faster in the opposite direction, is brought into contact with the part. The workpiece and table reciprocate
while in contact with the grinding wheel to remove material.
These machines accept workpieces in a variety of shapes as long as they can be rotated through a central axis. In a
cylindrical grinder, both the workpiece and grinding wheel are simultaneously rotated. Outside diameter grinders,
internal diameter grinders, and centerless grinders are all types of cylindrical grinders.
 Operation of cylindrical grinding
• The work (object) must be constantly rotating
• The grinding wheel must be constantly rotating
• The grinding wheel is fed towards and away
from the work
• Either the work or the grinding wheel is
traversed with respect to the other.

While the majority of cylindrical grinders employ

all four movements, there are grinders that only
employ three of the four action
The workpiece are held between the center with the
help of a spindle. The grinding wheel is rotated by
motor and the grinding wheel is attached to post
similar to tool post.
Here both grinding wheel and workpiece rotate and
they are in contact with each other.
 Plain Cylindrical grinding machine

➢ Plain center type cylindrical grinder

The workpiece is held between head stock and tailstock centers . A disc typ e grinding w he e l
per f orm s the grinding action with i ts peripheral s ur face . Both traverse and plunge grinding
can be carried out in this machine .

(a) Traverse grinding (b) Plunge grinding

A: Rotation of grinding wheel B: Work table rotation C: Reciprocation

of worktable D: Infeed
 Centerless grinding machines
Centerless grinding machines eliminate the
need to have center holes for the work or
to use workholding devices. Usually it does
not have a spindle.
Two rotary wheels are usually used to
secure the workpiece in place.
In centerless grinding, the workpiece rests
on a workrest blade and is backed up by a
second wheel, called the regulating wheel.
The rotation of the grinding wheel pushes
the workpiece down on the workrest blade
and against the regulating wheel. The
regulating wheel, usually made of a rubber-
bonded abrasive, controls the longitudinal
feed of the work when set at a slight angle.
By changing this angle and the speed of the
wheel, the workpiece feed rate can be
changed.
 Centerless grinding machines
When used and advantage
• Faster production as process is continuous
• No or less deflection
• Absence of end pressure makes it possible to grind brittle materials and easily distorted parts.
• Workpiece may be loaded automatically thus saving more time.
 Types of centerless grinding

1. Through feed: a circular workpiece is used as shown in figure.

2. In feed: Workpiece with an obstacle or stop is used.
3. End feed: a tapered workpiece with an end stop is used.

Throug h feed

End feed
In feed
 Internal grinding machine
Internal grinders are used to finish straight, tapered or formed holes accurately. The most popular internal grinder is
similar in operation to a boring operation in a lathe: The workpiece is held by a work holding device, usually a chuck or
collet, and revolved by a motorized headstock. A separate motor head in the same direction as the workpiece revolves
the grinding wheel. It can be fed in and out of the work and also adjusted for depth of cut.

➢ C hu c ki n g type i n te r na l
g r i n de r

T he w o r kpi e ce is u sua l l y
m o unte d in a c hu c k . A
s ma l l g ri ndi ng w he e l
p e r f orm s the ne ce s sa r y
g ri ndi ng wi t h i t s pe ri p he ra l
s ur f a c e . B oth tra n sve r se
a nd pl u ng e g ri n di ng ca n b e
c a r r i e d o u t i n t h i s m a c h i ne
 Internal grinding machine

➢ planetary internal grinder

Plane tar y int ernal grinder is used where the workpiece is of irregular shape and can not be
rotate d conveniently as shown in f igure . I n this machine the workpiece does not rot ate .
Instead, the grinding wheel orbits the axis of the hole in the workpiece .
 Internal grinding machine

➢ Centerless internal
grinder
This m achine is used f or
grinding cylindrical and
tapered holes in cylindrical
par ts (e.g. cylindrical li ners,
various bushings etc.). T he
workpiece is rotated between
suppor ting roll, pressure roll
and reg ulating wheel and is
ground by th e grinding w heel
as illustrated in f igure..
 Tool and cutter grinder machine

To o l g r i n d i n g m ay be d i vi d e d into two
subgroups:

(1) tool manufacturing and

( 2 ) t o o l r e sh a r p e n i n g . Th e r e a r e m a ny
types of tool and cutter grinding machine
t o m e e t t h e se r e q u i r e m en t s .

I t m ay h a ve u p t o 5 a xe s a n d m u l t i p l e
grinding wheels.

➢ Simple single point tools are occasionally sharpened by hand on bench or pedestal grinder.
However, tools and cutters with complex geometry like milling cutter, drills, reamers and
hobs require sophisticated grinding machine commonly known as universal tool and cutter
grinder.
➢ Present trend is to use tool and cutter grinder equipped with CNC to grind tool angles,
concentricity, cutting edges and dimensional size with high precision.
 Grinding Wheels
Grinding wheels are composed of thousands of small abrasive grains i.e. grits held together by a bonding material. Each abrasive grain
is a cutting edge. As the grain passes over the work piece it cuts a small chip, leaving a smooth, accurate surface.
Types of Abrasive Grain
Two types of abrasives are used in grinding wheels: natural and manufactured i.e. artificial.
• Natural abrasives: The most commonly used natural abrasives are impure form of aluminum oxide called emery and corundum,
natural diamond.
• Except for diamonds, manufactured abrasives have almost entirely replaced natural abrasive materials. Even natural diamonds have
been replaced in some instances by synthetic diamonds.
• The manufactured abrasives most commonly used in grinding wheels are aluminum oxide, silicon carbide, cubic boron nitride, and
synthetic diamond.

The abrasive aggregate is selected according to the hardness of the material being cut.
• Aluminum oxide (A)
• Silicon carbide (S)
• Ceramic (C)
• Diamond (D, MD, SD)
• Cubic boron nitride (CBN)
Grinding wheels with diamond or CBN grains are called super abrasives.
Grinding wheels with aluminum oxide (corundum), silicon carbide, or ceramic grains are called conventional abrasives.
 Grain size
• A low grain size number indicates large grit, and a high number indicates a small grain.
• From 10 (coarsest) to 600 (finest), determines the average physical size of the abrasive grains in the wheel. A larger
grain will cut freely, allowing fast cutting but poor surface finish. Ultra-fine grain sizes are for precision finish work.
generally grain size of grinding wheel are 10-24(coarse),30-60(medium),80-200(fine) and 220-600(very fine).

Grade of Wheel
The grade of a grinding wheel is a measure of the strength of the bonding material holding the individual grains in the
wheel. It is used to indicate the relative hardness of a grinding wheel. Grade or hardness refers to the amount of bonding
material used in the wheel, not to the hardness of the abrasive.
The range used to indicate grade is A to Z, with A representing maximum softness and Z maximum hardness. The
selection of the proper grade of wheel is very important. Wheels that are too soft tend to release grains too rapidly and
wheel wear is great. Wheels that are too hard do not release the abrasive grains fast enough and the dull grains remain
bonded to the wheel causing a condition known as "glazing."
From A (soft) to Z (hard), determines how tightly the bond holds the abrasive. A to H for softer structure, I to P for
moderately hard structure and Q to Z for hard structure. Grade affects almost all considerations of grinding, such as
wheel speed, coolant flow, maximum and minimum feed rates, and grinding depth.
 Grain spacing or density

The structure of a grinding wheel refers to the relative spacing of the abrasive grains; it is the wheel's
density. There are fewer abrasive grains in an open-structure wheel than in a closed-structure wheel. A
number from 1 to 17 designates the structure of a wheel. The higher the number, the more open the structure
will be; and the lower the number, the more dense the structure will be.

Spacing or structure, from 1 (densest) to 17 (least dense). Density is the ratio of bond and abrasive to air
space. A less-dense wheel will cut freely, and has a large effect on surface finish. It is also able to take a
deeper or wider cut with less coolant, as the chip clearance on the wheel is greater.

Bond material in wheel

Abrasive grains are held together in a grinding wheel by a bonding material. The bonding material does not
cut during grinding operation. Its main function is to hold the grains together with varying degrees of
strength. Standard grinding wheel bonds are silicate, rubber and metal.
 Video Links

• SURFACE GRINDING MACHINE with ANIMATION

[Link]

• Centerless grinding real life operation

[Link]
THANK YOU