GRINDING THEORY

MECHANICS
OF
GRINDING
 GRINDING THEORY

• Grain Depth of Cut & Chip Thickness

• Various Forces
• Interaction of Tool (GW) with Work
• Selection of Tool (GW) Parameters
• Selection of Process Parameters
 Grain Depth of Cut
Wheel D = Wheel diameter
Job
T d = Job diameter
N = Wheel rpm
n = Job rpm
T = Depth of cut/job rev
a a = Grain depth of cut
Z = Grains/unit length
Vw = Work Surface Speed
Vs = Wheel Surface Speed

a = 2  dn  1+ 1  T a = 2  Vw  1 + 1  T
Z DN d D Z Vs d D
 Grain Depth of Cut

Why are we interested in the grain depth of cut

- the “a” value?

• It is a measure of the depth of the scratch on the

job surface and is linked to surface finish.

• It is a measure of the cutting force on the grain and

is linked to wheel wear.
 Grain Depth of Cut
Larger values of a correspond to: Smaller values of a correspond to:

* Poorer surface finish * Better surface finish

* Greater wheel wear * Lesser wheel wear
* Higher cutting forces * Lower cutting forces

* Use larger wheels and higher speeds for faster production

* Use finer grit sizes for better surface finish and harder
job material
Grinding Chip
 Chip Thickness

Where
Hc = Chip thickness
Vw 1 t Vw = Work surface speed
Hc = X X Vs = Wheel surface speed
Vs K XC De K = Grain Constant
C = Density of grain per unit area
t = Depth of cut
De = Equivalent diameter

For normal calculation , 1

Hc =
proportional chip thickness is given by-
Vs 0.5 x De 
0.25
 Cutting Forces in Grinding
The grinding forces acting in the cutting zone can be resolved
into three components.

GW Work
Work

Fn
Fx
GW
Fn
Ft
 Cutting Forces in Grinding

Ft =Cp . Vw 0.7. Vs 0.7. t 0.6

where
Cp = Coefficient depending upon the material
2.2 for hardened steel
2.1 for unhardened steel
2.0 for cast iron

Vw = Work surface speed in m/min

Vs = Wheel surface speed in m/min

t = Depth of cut in mm.

 Cutting Forces in Grinding
Ft (Tangential component)

• Acts along the tangent to the circumference of the wheel.

• Determines the rating for electric motor for driving the grinding wheel

P = Ft * V (where V is the cutting speed)

 Cutting Forces in Grinding
Fn (Normal or Radial Component)

•The ratio of Fn/Ft is about 2 for a freshly dressed wheel and

increases as the wheel becomes dull.

• More the radial force, more will be the material removal rate.

• It affects the geometrical and dimensional accuracy of the work

piece, surface finish and wheel wear.

• It has no direct influence on the power requirement of the wheel

motor

•It is taken into account for designing the components of the infeed
mechanism.
 Cutting Forces in Grinding

Fx (Traverse Feed Force)

• The feed force Fx is parallel to the traverse, and the magnitude is generally
small, of the order of 0.1 to 0.2 Ft.

• The power of the traverse drive motor can be calculated from the magnitude
of this component.
 Interactions in Grinding Process

Interactions Effects
Grain – Work Actual cutting

Chip - Bond No metal cutting

Bond fracturing
Chip – Work Scratch marks on
work-piece
No cutting
Heat generation
Bond – Work No cutting
Heat generation
 Selection of Wheel Dia

Equivalent diameter (De) is the diameter of the grinding wheel if the

given application is converted to a surface grinding mode (since for surface
grinding the equivalent diameter is equal to the wheel diameter).

De is calculated by formula given below

De = Ds / [1 ± (Ds/Dw)]
Where
Ds = Diameter of GW + for External Grinding
Dw = Diameter of Work - For Internal Grinding
 Selection of Wheel Dia
Higher equivalent diameter indicates –

 Higher arc of contact and therefore more grains in contact with

the work-piece i.e. lower force per grain.
 Grain and bond fracturing gets hampered due to low force per
grain and can lead to more rubbing and sliding of the abrasive while
grinding.
 Poor coolant availability in the grinding zone.
 Chip – Work Interaction The grinding chips have a higher
probability to be entrapped between the wheel and the work
leading to their increased frictional effect.
 Higher heat generation due to poor lubricity, higher friction and
inability to remove heat effectively from the grinding zone.
 Selection of Wheel Dia

EXTERNAL GRINDING
50.0
Equiv. Wheel Dia (mm)

40.0
30.0
20.0
10.0
0.0
0 5 10 15 20 25 30
Ratio Ds/Dw
 Selection of Wheel Dia

INTERNAL GRINDING
1200.0
Equiv. Wheel Dia (mm)

1000.0

800.0

600.0

400.0

200.0

0.0
0 0.2 0.4 0.6 0.8 1
Ratio Ds/Dw
 Selection of Speed Ratio

Grinding Wheel RPM

Rotational Speed Ratio =
Work RPM

Rotational Speeds are selected in such a way that Speed Ratio never
becomes an Integer (i.e. 1,2,3… etc)

Grinding Wheel Surface Speed (π*Ds*Ns)

Surface Speed Ratio =
Work Surface Speed (π*Dw*Nw)

Surface Speed Ratio is generally kept between 20 ~ 40

Increased work speed reduces the possibility of Grinding Burns