22ME430

Machining Processes

Grinding Machine

Dr.C. Paramasivam, Prof./Mech.

 Grinding Operation

 It is also know as abrasive machining.

 Grinding is a surface finishing operation where very thin
layer of material is removed in the form of fine dust metal
particles.
 Material removal thickness is varied from 0.25 to 0.5 mm
 Grinding can be defined as a material removal process by
the abrasive action between rotating abrasive wheel &
the work piece.

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The work piece is fed
against a constantly rotating
abrasive wheel so that, a
thin layer of material is
removed from the it.

Grinding action

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 It is used to produce a smooth
finish on flat surfaces.

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Advantages of grinding
1. Good dimensional accuracy

2. Good surface finish

3. Good form and positional accuracy

applicable to all materials.

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Applications of grinding

1. Stock/metal removal (abrasive milling) from

flat and cylindrical surfaces

2. Surface finishing

3. Slitting and parting

4. De-scaling, De-burring

5. Grinding and re-sharpening of tools and

cutters.

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Applications of grinding

Surface Finish

De-scaling Sharpening of tool

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General classification of Grinding Machine

 Grinding machine is a power operated machine tool

where, the work piece is fed against a constantly
rotating abrasive wheel which is also called as Grinding
wheel so that, a thin layer of material is removed from
the work piece.
 Grinding machines according to quality of surface
finish, may be classified as,

A. Rough grinding

B. Precision grinding

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A. Rough /non-precision grinders:
 To remove more stock than other grinding

Types:

1. Floor stand and Bench grinders

2. Portable and flexible shaft grinders

3. Swing frame grinders

4. Abrasive belt grinders

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Floor stand and bench grinders
 Used for snagging and off-hand grinding of various
materials and cutting tools in tool rooms, foundries and
general repair shops.

 It carries a horizontal spindle having grinding wheels

mounted on both ends.

 It can be suitably bolted on a bench/floor.

 The floor or pedestal grinder is nothing but a bench grinder

of the above type mounted on a steel stand or pedestal of
suitable height

 These grinder are also be used for polishing by replacing the

grinding wheel by polishing wheel 11
Floor stand and bench grinders

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tpmech@[Link] 13
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Floor stand grinders

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Bench grinders

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Abrasive belt grinders

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B. Precision grinders:
 To remove less stock from a raw material/part.
Types:
 According to the type surface generated or work
done they classified as:
1. Surface grinding machine
2. Cylindrical grinding machine
3. Internal grinding machine
4. Tool and cutter grinding machine

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1. Surface grinding machine

Principle: The work

piece is fed against a
constantly rotating
abrasive wheel so that a
thin layer of material is
removed from the it.

Work Piece Type: Flat,

Angular & Irregular
surfaces

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Types:

a) Horizontal spindle and

reciprocating table

b) Vertical spindle and reciprocating

table

c) Horizontal spindle and rotary

table

d) Vertical spindle and rotary table

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SURFACE GRINDING MACHINE

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Working:
 Wheel ->rotates
 Work piece -> reciprocates under the wheel
 Wheel or table -> feeds axially between passes to
produce a fine flat surface.
 amount of feed = 0.01 mm

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 Horizontal Grinding Machine
Vertical Grinding Machine

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

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Horizontal Grinding Machine Vertical Grinding Machine

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2. Cylindrical grinding machine

Principle:
• The work piece is held
between two centers & and
the rotating grinding wheel
is fed against it.

Work Piece Type:

• Cylindrical surfaces may be Principle of cylindrical
straight, curved or grinding
contoured.

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  This machine is used to produce external cylindrical
surface. The surfaces may be straight, tapered, steps or
profiled.

A: rotation of grinding wheel B: work table rotation C: reciprocation of worktable D: infeed

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Cylindrical grinding machine

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Cylindrical grinding machine

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3. Internal Grinding Machine

 Used for grinding internal surface of different holes,

cylindrical, tapered parts etc.

 Types:

a) Plain internal grinders

b) Universal internal grinders

c) Chucking internal grinders

d) Planetary internal grinders

e) Centreless internal grinders

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Plain Internal Grinders
 It carries an individual driven wheel-head mounted on a
cross-slide.
 The work head either carries a chuck or face-plate to
hold the work or latter can be mounted on a fixture
attached to the work head spindle
 The work can be swiveled to the grind tapered holes

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4. Tool and cutter Grinder

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Tool and cutter Grinder

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Work holding device

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 The Work holding devices and attachments
cover a wide range and include the following:

1. Work holding and supporting devices

2. Equipment for contour grinding

3. Attachments to improve grinding results

4. Measuring and sizing devices

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1. Work holding and supporting devices

 It includes

1. Steady rest for cylindrical grinders.

2. Chucks and fixtures for other grinders

3. Magnetic chucks used particularly for

surface grinders

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2. Equipment for contour grinding:

It include

 Wheel dressing and attachments using cams

 Templates for cam and shape grinding

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3. Attachments to improve grinding results:

It include

 Wheel reciprocating attachments for better

finish.

 Ultrasonic wheel cleaning devices

 Electrolytic attachments to aid in grinding

extremely hard materials

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4. Measuring and sizing devices:

 They range from simple measuring

devices to continuous reading gauges
which actually control the feeding of the
machine.

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Grinding wheel

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 Grinding wheel
 Grinding wheel consists of hard
abrasive grains (sharp crystal)
called grits, which perform the
cutting or material removal, held
together by a binding material or
bond.
 The wheel used for performing the
grinding operation is known as
grinding wheel.

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 A grinding wheel commonly identified by the type of the
abrasive material used.
1. Conventional wheels -> Al2O3 & SiC wheels
2. Super abrasive wheel -> Diamond and CBN.
• The types of wheel may be:
1. Single piece
2. Solid type
3. may be composed of several segments of abrasive
blocks joined together.

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• Diamond wheels are used to grind high hardness
non-ferrous materials.
• Diamond wheels are great for working with difficult
to grind materials such as: carbide tipped cutting
tools, gemstones.

• CBN wheels should be used on ferrous materials with

a harness above 40HRC.
• CBN wheel is made from cubic boron nitride. This
material is one of the hardest materials available,
second only to diamonds.

• The main feature of the material is of high abrasion

resistance and thermal conductivity that maintains
its sharp cutting edges.

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• The wheel may be
1. Straight Grinding Wheels
2. Large Diameter Grinding Wheels
3. Grinding Cup Wheel
4. Grinding Dish Wheel
5. Segmented Grinding Wheel
6. Cutting Face Grinding Wheel

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Grinding wheel Materials
Grinding wheel material

 It Consists of abrasives and bonding material

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Abrasive for Grinding wheel
Abrasive: it is that material of grinding wheel which does
the cutting action

Types

(a) Natural Abrasive

(b) Artificial abrasive

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(a) Natural Abrasive:
 The common natural abrasives are
 Iron Oxide, Sand stone etc.
 Emery (50-60%crystalline AL2O3+iron oxide)
 Corundum (75-90% crystalline aluminium+iron
oxide)
 Diamond.

Use
 Sand stone -> sharpening some wood-working tool.
 Diamond -> dressing the grinding wheel &
-> abrasive material for hard material

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(b) Artificial abrasive:
 These are manufactured under controlled conditions in
closed electric furnaces in order to avoid the introduction
of impurities and to achieve the necessary temperature
for chemical reactions to take place.
 Example:
 Silicon carbide(SiC),
 Aluminum oxide(Al2O3)
 Artificial diamond

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Bonding Material for Grinding wheel
 Bond is the substance that acts as a binder to hold the
abrasive grains together in the form of sharpening stones
or grinding wheels.
 Several types of bonding materials used for making
grinding wheels such as,
1. Vitrified bond
2. Silicate bond
3. Shellac bond
4. Resinoid bond
5. Rubber bond
6. Oxy-chloride bond
 These bonds may be used with either silicon carbide or
aluminum oxide.

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1. Vitrified bonding process:
 Vitrified wheels are made by bonding clay melted to a
glass like consistency with abrasive grains.
 The clay and abrasive grains are thoroughly mixed with
sufficient water to make uniform mixture.
 The fluid mixture is then poured in to the mould and
allowed to dry.
 After cooling, the material trimmed to more perfect size
and shape.
 It is then heated in a furnace to a temperature 1260 deg .
 It gives good strength and porosity to allow high stock
removal
 It is affected by heat, cool water or acids.
 Denoted by “V”

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2. Silicate bonding process:
 Silicate bonding wheels are made by mixing abrasive
grains with silica of soda or water glass.
 The mixture is packed in to moulds and allowed to dry.

 The mould shapes are baked in a furnace at a temp of 260

deg for several days.
 The silicate bonded wheels are water proof.

 Denoted by “S”

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3. Shellac bonding process:
 Shellac bond wheels are also known as elastic bonded
wheels.
 In this process, the abrasive and shellac are mixed in
heated containers and then rolled or pressed in heated
molds.
 Later the shapes are baked at a temp 150 deg.

 The elasticity in this is grater than in other two types and

it has considerable strength
 It is not for heavy duty.

 Used for finishing chilled iron, cast iron and steel rolls

 Denoted by “E”

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4. Resinoid bonding process:
 Resinoid wheels are produced by mixing abrasive grains
with synthetic resins and other compounds.
 The mixture placed in moulds and heated at about 200
deg.
 At this temp the resin sets to hold the abrasive grains in
wheel form.
 These wheels are used for purposes which require a
strong, high speed wheel.
 Denoted by “B”

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5. Rubber bonding process:
 Rubber wheels are produced by mixing abrasive grains
with pure rubber and Sulphur.
 The mixture rolled in to sheets and wheels are punched
out of these sheets on a punch press.
 These are less heat resistant and more dense then the
resinoid wheels
 Denoted by “R”

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6. Oxychloride bonding process:
 In this process consists of mixing abrasive grains with
oxide and chloride of magnesium.
 The mixing of bond and abrasive is performed in the
same way as for vitrified bond wheel.
 These wheels are used in making wheels and wheel
segments for disc grinding operation.
 Denoted by “O”

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 Standard Grinding wheel marking
system
 To maintain uniformity throughout the country in the
system of making grinding wheel, the Bureau of Indian
Standard has devised a standard system to be followed
by all manufacturer.
 According to the system, the various elements and
characteristics of grinding wheels are represented on all
the wheels in a definite sequence as follows:
1. Abrasive
2. Grain size
3. Grade
4. Structure
5. Bond
6. Manufacture’s record

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Example: A grinding wheel carrying the marking
125 x 25 x32 W A 46 L 4 V 17

125(mm)---wheel diameter
25(mm)--- Thickness of wheel
32 (mm)---Bore diameter
W---Manufacturer’s prefix to abrasive (Optional)
A--- Abrasive(Al2O3)
46 ----Grain size(medium)
L ---grade (medium)
4 --- Dense structure
V --- Vitrified bond
17----it is the suffix denoting the bond type of the manufacturer

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Selection of Grinding Wheel
1. Type of metal on which grinding is required
Abrasives
 Metal of low tensile strength – Silicon carbide

 Metal of high tensile strength- Aluminum oxide

Grain Size
 Low cut /Better surface finish – fine grain

 Rough cut/ deep cut- Coarse / Medium grain

Grade
 Soft metals- High grade

 Hard metals – Low grade

Structure
 Soft metals- open structure

 Hard metals – Dense structure

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 Bond
 High cut – vitrified bond

 High finish – shellac bond

 Parting – resinoid / Rubber

2. Amount of metal to be removed

 High cut – Rough / coarse – medium Grain

 Low cut – Fine grain/ Dense structure

3. Accuracy of size & finish

On grain size/bond
 Rough cut / low finish – coarse grain/ vitrified bond

 High finish – Resonoid / shellac / Rubber bond

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4. Area of contact
 Greater area – Soft Grade

 Smaller area – High grade / Soft grade

5. Types of machine
 Heavy Machine – Low vibration – Soft wheel

 Small machine – hard wheel

6. Speed of wheel
 200 m/s or lesser – vitrified bond

 Higher speed – resinoid bond

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Mounting the Grinding wheels

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Mounting the Grinding wheels
1. All wheels should be closely inspected just before mounting
to make sure that they have not been damaged in transit,
storage, or otherwise.
 The wheel must first be subjected to the ringing test. For

this purpose, the grinding wheel is put on an arbor while it

is subjected to slight hammer blows.
 A clear, ringing, vibrating sound must be heard.

 If a grinding wheel contains fine cracks then wheel makes

discordant sound.
2. The abrasive wheels should have an easy fit on their
spindles or locating spigots. They should not be forced on.

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4. There must be a flange on each side of the wheel. The
mounting flanges must be large enough to hold the wheel
properly, at least the flange diameter must be equal to the
half of the grinding wheel diameter.
 Both the flanges should be of the same diameter, other-
wise the wheel is under a bending stress which is liable to
cause fracture.
5. The sides of the wheel and the flanges which clamp them
should be flat and bear evenly all round.
6. Washers of compressible materials such as card board,
leather, rubber, etc. not over 1.5 mm thick should be fitted
between the wheel and its flanges.
 The diameter of washers may be normally equal to the
diameter of the flanges.

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7. The inner fixed flange should be keyed or otherwise fastened
to the spindle, whereas the outer flange should have an easy
sliding fit on the spindle so that it can adjust itself slightly to
give a uniform bearing on the wheel and the compressible
washers.
8. The nut should be tightened to hold the wheel firmly. Undue
tightness is unnecessary and undesirable as excessive
clamping strain is liable to damage the wheel.
9. The wheel guard should be placed and tightened before the
machine is started for work.

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Mounting the Grinding wheels

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Glazing and Loading in wheels

tpmech@[Link] 73
Glazing
 When the surface of a
grinding wheel develops a
smooth and shining
appearance, it is said to be
glazed.

 This indicates the abrasive

particles on the wheel face
are not sharp.

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Loading
 When soft materials like
aluminum, copper, lead,
etc. are ground the metal
particles get clogged
between the abrasive
particles. This condition is
called loading.

 The effects of a glazed or a

loaded grinding wheel are
almost the same.

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Dressing and Truing grinding wheels

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Dressing
 Dressing removes loading and breaks away the glazed
surface. so that sharp abrasive particles are again
presented to the work.
 This is done with various type of dressers. A common
type of wheel dresser, known as the star-dresser.

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Truing
 Truing is the act of regenerating the required
geometry on the grinding wheel, whether the geometry
is a special form or flat profile.
 Therefore, truing produces the macro-geometry of the
grinding wheel.
 This is done to make the wheel true and concentric with
the bore, or to change the face contour for form grinding.
 In turning a wheel with a diamond, the feed rate must
not exceed 0.02 mm/rev, otherwise grooves may be
cut into the wheel.

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Balancing grinding wheels

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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
Finish also undue strains on
the machine.

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 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

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Process Parameters

tpmech@[Link] 83
Process Parameters
1. Cutting Speed
 It is the relative speed of the wheel (Vw) and the work
piece.
V= m/min

Where D= diameter of the grinding wheel in mm.

N=speed of wheel in rpm
2. Feed
 The feed is the relative longitudinal movement of the work
piece per revolution.
 It is expressed in mm/rev.

3. Depth of cut
 Depth of cut ‘d’ is the thickness of the material removed in
one pass. It is expressed in mm.

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4. Machining Time:
 It is defined as the time required to machine a component
from workpiece.

Machining time, t= LiK/Sinp (minute)

Where L= Length of longitudinal travel in mm.

i = the number of pass
np=Speed of the work spindle in rpm
Si = Longitudinal Feed in mm/rev.
K = Coefficient depends on specified grade of
accuracy and class of surface finish
For rough grinding K = 1 to 1.2
For finish grinding K = 1.3 to 1.7

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