Grinding

Common Grinding Processes

Details of Surface grinding

Mechanics of Grinding

Uncut Chip thickness per grit

f t1 = mm ZN
Where Z = Number of active grains N = rpm of the wheel

Z = DCb '

Where D = Diameter of the wheel C = Surface density of active grains (mm-2)

rg = b ' / t1

b = Average grain width of cut (mm)

f t1 = DNCrg
Power

AfU c W= 60
Force per single grit
'

Where A cross sectional area of the job Uc = Specific energy

1000 fU c 60, 000W Fc= N= N DACN DCN

Chip Formation during surface grinding

D l 2
D D 2d Cos = ( d ) / = 1 D 2 2

Cos 1

2
2

l Dd
1 ' ( NDBC ) bmax t1max l = fdB 6

t1max

6f = NDrg C

d D

BfdU c W= W 60

60, 000W 1000 BfdU c Fc = = ND ND

Average force per grit

Components of Grinding Force

60, 000W F = N NDCB Dd

' c

Fc' =

369U o f 0.8 d 0.4 rg0.2 N N 0.8 D1.2C 0.8

Thermal aspects
Energy spent per unit surface area ground

Fc ND s Bf
Since

s dU c

and

U c = U o (t1av )

0.4

and

t1av

1 = t1max 2

d 0.9 D 0.3C 0.2 N 0.2 s f 0.2

Grain chip interface temperature

g = U c

vt1max k C

Residual stress in workpiece after surface grinding

Growth of power requirement of different wheel grades

Grinding Wheel Specification

Grinding Wheel Wear

Types of grinding operations

Honing Operation

Lapping

Abrasive Flow Machining (AFM)

Magnetic Abrasive Finishing (MAF)

Sintered ferromagnetic abrasive particle

Ferromagnetic abrasive particle in action Magnetic Abrasive Finishing

MAF

External Finishing by MAF

Internal Finishing by MAF

Ideal roughness in turning

Maximum height of unevenness f H max = tan + cot '

where side cutting edge angle

end cutting edge angle Maximum height of unevenness, when nose radius (r) is used

H max

f2 = 8r

Generation of Ideal roughness in slab milling

Verification of surface roughness with cutting Speed during turning mild steel bar

Economics of Machining Operation

Optimizing cutting parameters for Minimum cost

R = R1 + R2 + R3 + R4 + R5
R = Total Cost/ piece R1 = Material Cost/ piece R2 = Set up and idle time Cost/ piece R3 = Machining Cost/ piece R4 = Tool changing Cost/ piece R5 = Tool regrinding Cost/ piece 1= Cost/ min of labour and overheads 2= Cost of setting a tool for regrinding 3 = Cost/mm of tool ground ts = Set-up tme and idel time/ piece, min, tm = Machining time/piece, min, tct = Tool changing time, min

Set- up and idle time cost

R2 = 1ts
Machining cost

R3 = 1t3 = 1

LD
1000 fv

L = Length D =Diameter f = feed V = speed

Tool Changing cost

tm R4 = 1 tct T
k T = 1/ n 1/ m v f
T = Tool life

R4 = 1tct

LD
1000 fv

v1/ n 1 f 1/ m 1

Tool regrinding cost

= h f tan vs ,

hf = flank wear = Minimum length of tool to be reground

2 + 3 = 2 + 3h f tan s
tm R5 = (2 + 3 h f tan vs ) T
= (2 + 3 h f tan vs )

LD
1000k
A

Vs = Clearance angle

v1/ n 1 f 1/ m 1

If tool cost of new tool is A and the total length that can be reground is B mm , then cost per mm of the tool

3 =

1 + h

B ta n v s

Total cost per piece

R = R1 + 1ts + 1

LD
1000 fv

+ 1tct

LD
1000 fv

v1/ n 1 f 1/ m 1 + (2 + 3 h f tan vs )

LD
1000 fv

v1/ n 1 f 1/ m 1

Optimum speed for a given feed

R LD 2 1 LD 1/ n 2 1/ m 1 = 1 v + (1tct + 2 + 3h f tan vs ) 1 v f =0 v vopt 1000 f n 1000k v = vopt

or

vopt

nk 1 = 1/ m (1 n) f (1tct + 2 + 3 h f tan s )

Optimum speed for minimum cost

vopt

nk 1 = 1/ m (1 n) f (1tct + 4 )
mk 1 = 1/ n (1 m)v (1tct + 4 )
m

Optimum feed for minimum cost

f opt

f max = 8rH max lim

H maxlim= Limiting value of unevenness

Machining force

Fc = 1000U 0 wt10.6

Fc = k1 f 0.6
Power consumption Variation of machining cost with v and f

W = k1vf 0.6
Maximum available power in the machine then limiting cutting speed-feed

vf

0.6

Wlim = k1

Selection of optimum feed

Variation of various costs with cutting speed.

Optimum cutting parameters for maximum production

tm tt = ts + tm + tct min T
= ts +

LD

1000 fv 1000k

LD

v1/ n 1 f 1/ m 1tct min

For optimum speed to minimize t1

tt v

v = vopt

1 LD 1/ n 2 1/ m 1 = =0 v + 1 v f tct 1000 f n 1000k v = vopt

2

LD

vopt

nk = 1/ m (1 ) n f tct

Optimum cutting seed for maximum efficiency

Profit rate

SR pr = tt

S = Amount received per piece

R and tt can be expressed in terms of v as before, then

pr v

=0
v = vopt