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Chapter
4
Grinding
Syllabus:
Statistical Analysis
Summer 2004 20
Winter 2004 20
Summer 2005 20
Production Processes 4-2 Grinding
4.1 Introduction :
Grinding and finishing operations are used for the final finish and super finish. There are
various types of grinding. The most common one is surface grinding. This process is
accompanied by a certain amount of metal removal. This process can give a surface finish in
the range of 0.75 to 1.25 µ m.
(iv) Complex profiles can be produced accurately with relatively inexpensive turning
templates.
(v) Grinding is the only method of removing material from materials after hardening.
4.1.3 Applications of Grinding Wheel :
(i) To remove a very small amount of metal from the workpiece to bring its dimensions
within very close tolerances.
(ii) To obtain better finish on the surface.
(iii) To machine hard surfaces which are otherwise difficult to be machined by the high
speed steel tools or carbide cutters.
(iv) To sharpen the cutting tools, etc.
4.2 Classification of Grinding Machines:
• Different types of grinding machines are based on the operations to be performed with the
help of grinding wheel. Those are
Rough grinders
Cylindrical grinders
Surface grinders
• A standard marking system for the grinding wheel provides convenient shorthand notation
to describe wheels in terms that are meaningful to those with at least a little grinding
experience.
• Properties of a grinding wheel marking system :
(i) Abrasive type (ii) Size of grain
(iii) Grade (iv) Structure
(v) Type of bond (vi) Manufacturers symbol for identification.
4.5 Types of grinding operations
Surface Grinding :
Spindle Table
Sr. No.
1. Horizonta Reciprocating
l
2. Horizonta Rotary
l
3. Vertical Reciprocating
4. Vertical Rotary
Production Processes 4-6 Grinding
Cylindrical Grinding:
[Asked in Exam: W – 04!!!]
Centreless Grinding :
[ Asked in Exam : S – 04, W – 04, S – 05 !!! ]
• In centreless grinding, the workpieces are held between the grinding wheel and the
regulation wheel and a work rest blade, as shown in Fig. 4.6.3. By tilting the rotational
axis of the regulating wheel with respect to the grinding wheel. The workpiece is given a
longitudinal force, creating movement or through feed. No manual handling of the part
is required.
• In this method, rate of production is high and cost of production is less.
Internal Grinding :
• Internal grinding is used to obtain very accurate sizes and good surface finish on holes
made by other operations. Machines are made, that are able to finish holes from a few
thousands of an inch in diameter to 5 feet or more .
• Here the grinding wheel diameter is smaller in size than that of the hole being ground.
Grinding wheels of small diameter wear out rapidly and require more frequent
dressings.
• Grinding machines are designed properly for finishing parts of cylindrical, flat surfaces.
The kind of surface machined largely determines the type of grinding machines.
• A cutter grinder is a machine which supports the cutter while a rotating abrasive wheel is
applied to the cutting edge for the purpose of sharpening it. These machines vary in
design from single purpose grinders used to sharpen cemented carbide tipped tool bits to
complex universal machines capable of doing any type of cutter grinding.
(a) Tool and cutter grinding (b) Block diagram of a tool and cutter
Fig. 4.6.4
• A typical thread grinding machine is shown in Figs. 3.9.1(a) and (b). Fig. 3.9.1(a) shows
circular disc with the thread form being given the feed equal to the pitch of the thread
under consideration. Again, Fig. 3.9.1(b), depicts a figure wherein the threads are
ground using a circular drum which has the desired thread profile and the height equal to
the complete length the threads. This is then plunged to achieve the objective.
• Way grinders : These are large, heavy single purpose machine used to grind the various
surfaces of the ways and beds of machines. The wheel is cup, ring or segmented
mounted on vertical spindle and can be tilted at any angle as shown in Fig. 3.9.2.
Q. 1 What are the abrasives? Name artificial abrasives used for manufacturing grinding
wheel. (Section 4.3) (4 Marks)
Q. 2 Explain working principle of centreless grinding, stating its advantages. Describe the
different methods of feeding the job on centreless grinding machine. (Section 4.6)
( 8 Marks)
Q. 6 List, sketch and state uses of any four types of grinding wheels. (Section 4.3)
(4 Marks)
Q. 9 Explain with neat sketch working principle of centreless grinding. State any four
advantages. (Section 4.6) (4 Marks)
Q. 10 What materials are used in the manufacture of grinding wheels ? (Section 4.3)
(4 Marks)
Q. 11 What are the different types of bonds used in the manufacture of abrasive wheels ?
(Section 4.3) (4 Marks)
(4 Marks)
Q. 13 What are the advantages of centreless grinding over centre type grinding ?
(Section 4.6) (4 Marks)