Grinding

Processes in
Bearing
Manufacturing
 Topics Covered

 GW Nomenclature
 Selection of GW
 Mechanics of Grinding
 Face Grinding Process
 C/less Grinding Process
 Track Grinding Process
 Bore Grinding Process
 Bore Grinding
Internal grinding is a form of cylindrical grinding, applicable to internal
diameters.
Work

In bore grinding Sulphur treated wheels are used. During grinding, because
of high temperature, melted sulphur acts as lubricant.
 Parameters in Bore Grinding

1. Selection of Wheel Diameter

2. Grinding Wheel & Work Speed
3. Material Removal Rate & Feed Rates
 Selection of Wheel Dia

Equivalent Wheel 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
 Wheel Diameter

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),
RPM Ratio should be between 40 ~ 60

Grinding Wheel Surface Speed (π*Ds*Ns)

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

Surface Speed Ratio is generally kept between 30 ~ 40

 GW & Work Speeds

Grinding Wheel Surface Speed = 2700 m/min (45m/sec)

GW & Work Surface Speed Ratio = 30 ~ 40

Work Surface Speed = Grinding Wheel Speed / Speed Ratio

 Material Removal Rate & Feed Rates
Volume of Material cut in 1 second per 1 mm of Grinding Width

M Vaules (mm3/mm.sec)
MRR (M) = π * D * (V/2) Rough1 4.5 ~ 5.5

Rough2 2.5 ~ 4.0

Where,
D = Work Diameter in mm
Finish 0.7 ~ 1.0
V = Feed Rate on Dia (mm/sec)

On the basis of M-Values, Feed Rates are calculated

 Grinding Cycle

There are basically two types of grinding cycle

1 Sizematic
* Size is controlled by Feed Amount
Work
* Total Feed Amount is Fixed

2 Gaugematic
* Size is controlled by in-process gauge Gauge

* Feed Amount is also controlled by Gauge Fingers

 Grinding Cycle

Main elements of Grinding Cycle

1 Index
2 Approach
3 Grinding Feed (R1, R2, Fine)
4 Spark Out (Quill Bending)
5 Retraction
 Grinding Cycle

Index is the movement of Feed Slide from its retracted position

to Grinding Position
Approach is the movement of Feed Slide from Index Position
to the Feed Start Position (Wheel travels in air without touching
the job)
Grinding Feed is the movement of the Feed Slide after
Approach when actual grinding takes place
Spark-out is the time for which there is no movement of Feed
Slide after final position.
 Feed Mechanism

1. Controlled Force (Heald)

2. CNC (Izumi)
3. TAC (Toyo Adaptive Control)
 Feed Mechanism

Controlled Force
• Controlled force is a feed system devised by Heald machines.
• In this system, a constant hydraulic pressure is used to feed the
grinding wheel in to the workpiece
• As a result, Feed rate is determined by resultant Grinding Force
and it is variable
Numbering System - Heald

Working
SIZE TYPE Operation
Method

0
0 7 Straight &
3/8" ~ 3" OD Chucker Tapered
Bore

1
CF 8
1 Ball Tracks
Controlled Roll Type
7/8" ~ 4.5" OD & Formed
Force C/less
Bores

2
3" ~ 8" OD 9 2
Shoe Type Channel
3 C/less Races
2" ID ~ 24" OD
 Feed Mechanism

CNC
• Feed Rate is controlled by Stepper Motor through Ball Screw.
• Feed Rate is constant

TAC (Toyo Adaptive Control)

• Feed Rate is controlled by Grinding Power
• Feed Rate is determined by Grinding Power and is variable
 Process Accuracies

Following parameters needs to be checked after Bore Grinding.

1) Bore Size
2) Roughness
3) Roundness
4) Taper
5) Squareness
6) Grinding Burns

The values of each parameter depends upon the Job Diameter and
Tolerance Class.
 Trouble Shooting
Roundness:

 Spark out time not sufficient

 Bad roundness of locating diameter
 Insufficient stock removal in Fine Grinding
 Backing Plate Face Runout is more
 Quill radial run out more
 Excessive clamping pressure
 Off set not ok (job lifting tendency)
 Work head rpm not correct
 Work & wheel rpm ratio in whole number
 Trouble Shooting
Roughness:

 Dress lead not OK

 Blunt Diamond
 Spark out time less
 Feed rates too high
 Vibrations in machine
 Dirt in Coolant
 Trouble Shooting
Taper:

 Insufficient Spark Out

 Wheel not dressed properly
 In sufficient coolant
 Loose cross slide
 Excessive quill bending
 Loose work head slide
 Wheel axis & work axis not parallel
 Processing Condition
NATIO NAL ENGINEERING INDUSTRIES LTD., JAIPUR
PC
PROCESSING CONDITION T G13 091A
REV. 2 DATE 14/09/2004
PART BRG. SIZE M/C MODEL LINE NO. PAGE 1 OF 1
OPERATION BORE GRINDING
CONE M12644 IZUMI KN113B TG-1
OPERATION NO. CN 150

CONE BORE SIZE 19.05

GRINDING ALLOW. 0.200 ±0.05

SPINDLE TYPE 120EG-30-10.5

MAX. RPM OF SPINDLE 30000

ITEM SPECIFICATION
SPECIFICATION SUPPLIER 32A80K8VBE TR22 GNO
GRINDING SIZE (O.D. x WIDTH x BORE) mm 15.5 X 20 X 8
WHEEL SIZE APPLICABILITY (mm) 14.5
WEAR SIZE (mm) 12.4
SURFACE WHEEL SURFACE SPEED 1300
SPEED (M/MIN) WORK SURFACE SPEED 43 ~ 33
SURFACE SPEED RATIO 30 ~ 40
RPM GRINDING WHEEL RPM 28553
WORK RPM 543 ~ 724
 Processing Condition
COOLANT TYPE CONCENTRATION HOCUT B-60 (Water soluble) 3.5±1 %
QUANTITY (Lit. / min) 50
DRESSER TYPE CARAT SINGLE POINT 0.50
DRESSING WHEEL COMPENSATION 0.025
SKIP DRESS 2
DRESS LEAD (mm/rev) 0.040
DRESS STROKE (mm) 30
WHEEL DRESSING TIME (SEC) 1.58
DRESS IDLE TIME (SEC) 1.50
TOTAL DRESSING TIME (sec) 3.08
QUICK ROUGH1 ROUGH2 APP. FINISH TOTAL

FEEDING FEEDING AMT. (mm) 0.020 0.100 0.300 0.030 0.030 0.450
CONDITIONS FEED RATE (mm/sec) 0.200 0.184 0.134 0.030 0.033 -
"M" VALUE (mm3/mm.sec) - 5.5 4.0 - 1.0
TIME (sec) 0.10 0.54 2.24 1.00 0.90 4.78
TIME (sec) SPARK OUT TIME 1.00
GRINDING TIME 5.78
IDLE TIME 3.50
DRESS TIME PER PIECE 1.54
TOTAL C/T (CTJ100) 10.82