Grinding

Grinding
Grinding
 Material removal process in which abrasive particles

are contained in a bonded grinding wheel that
operates at very high surface speeds
 Grinding wheel is usually disk-shaped and
precisely balanced for high rotational speeds
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Basic Classification of Grinding
Machines
(a) Surface grinding machine

(b) Cylindrical grinding machine
(c) Internal grinding machine
(d) Tool and cutter grinding machine
Surface grinding machine
Four Types of Surface Grinding
 (a) Horizontal spindle with reciprocating worktable,

(b) horizontal spindle with rotating worktable
Four Types of Surface Grinding….
 (c) Vertical spindle with reciprocating worktable, and

(d) vertical spindle with rotating worktable
Surface Grinder
 Surface grinder
with horizontal
spindle and
reciprocating
worktable (most
common grinder
type)
Different Grinding Actions
(a) Traverse grinding (b) Plunge grinding
Cylindrical Grinding
 Two types of cylindrical grinding: (a) external and

(b) internal
External Cylindrical
Grinding
Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge
grinding, and (c) profile grinding.
Internal Cylindrical Grinding
External Centerless Grinding
Centerless Grinding
Centerless grinding process A computer numerical control

cylindrical grinding machine.
Tool and cutter grinder machine
Tool grinding may be divided into two

subgroups: tool manufacturing and tool
resharpening. There are many types of
tool and cutter grinding machine to meet
these requirements.
Types of Grinding Machines
The Grinding Wheel
 Consists of abrasive particles and bonding

material
 Abrasive particles accomplish cutting
 Bonding material holds particles in place and
establishes shape and structure of wheel
Common Grinding Wheel
Shapes
Grinding Wheel Shape
 Some standard grinding wheel shapes: (a) straight, (b)

recessed two sides, (c) metal wheel frame with abrasive
bonded to outside circumference, (d) abrasive cut- off wheel
Grinding Wheel Parameters
 Abrasive material
 Grain size
 Bonding material
 Wheel grade
 Wheel structure
Standard Marking System of
Abrasives
Standard Marking System for
Diamond and CBN Bonded Abrasive
Abrasive Material Properties
 High hardness
 Wear resistance
 Toughness
 Friability - capacity to fracture when cutting edge
dulls, so a new sharp edge is exposed
Traditional Abrasive Materials
 Aluminum oxide (Al2O3) - most common abrasive

 Used to grind steel and other ferrous high-strength
alloys
 Silicon carbide (SiC) - harder than Al2O3 but not as
tough
 Used on aluminum, brass, stainless steel, some
cast irons and certain ceramics
Newer Abrasive Materials
 Cubic boron nitride (cBN) – very hard, very expensive

 Suitable for steels
 Used for hard materials such as hardened tool
steels and aerospace alloys
 Diamond – Even harder, very expensive
 Occur naturally and also made synthetically
 Not suitable for grinding steels
 Used on hard, abrasive materials such as
ceramics, cemented carbides, and glass
Grain Size
 Small grit sizes produce better finishes

 Larger grit sizes permit larger material removal rates
 Harder work materials require smaller grain sizes to
cut effectively
 Softer materials require larger grit sizes
Measurement of Grain Size /Grit size
 The grain or grit number indicates:
 size of the abrasive grains used in making a wheel,
 or the size of the cutting teeth.
 Grain size is denoted by a number indicating the number of meshes
per liner inch (25.4 mm) of the screen through which the grains pass
when they are graded after crushing.
 The following list ranging from very coarse to very fine includes all
the ordinary grain sizes commonly used in the manufacture of
grinding wheels.
Coarse 10 12 14 16 20 24 -
Medium 30 36 46 54 60 - -
Fine 80 100 120 150 180 - -
Very Fine 220 240 280 320 400 500 600

Bonding Material Properties
 Must withstand centrifugal forces and high

temperatures
 Must resist shattering during shock loading of
wheel
 Must hold abrasive grains rigidly in place for
cutting yet allow worn grains to be dislodged to
expose new sharp grains
Bonding Materials
 A bond is an adhesive material used to held abrasive particles

together; relatively stable that constitute a grinding wheel. Different
types of bonds are :
(a) Vitrified bond,
(b) Silicate bond,
(c) Shellac bond,
(d) Resinoid bond,
(e) Rubber bond, and
(f) Oxychloride bond
Bonding Materials…
Vitrified Bond:
 This bond consists of mixture of clay and water.
 Clay and abrasives are thoroughly mixed with water to
make a uniform mixture.
 The mixture is moulded to shape of a grinding wheel and
dried up to take it out from mould.
 This bond is denoted by symbol ‘V’ in specification.
 Perfectly shaped wheel is heated in a kiln just like brick
making. It this way clay vitrifies and fuses to form a
porcelain or glass grains. High temperature also does
annealing of abrasive.
 Disadvantage of this type of wheel are, it is sensitive for
heat, water, oil and acids.
Silicate Bond
 Silicate bonds are made by mixing abrasive
particals with silicate and soda or water glass.
 It is moulded to required shape, allowed to dried up and
then taken out of mould.
 The raw moulded wheel is baked in a furnace at more
than 200°C for several days.
 These wheel exhibits water proofing properly so these
can be used with coolant.
 These wheels are denoted by ‘S’ in specification.
Shellac Bond
 These are prepared by mixing abrasive with shellac then
moulded by rolling and pressing and then by heating
upto 150oC for several hours.
 This bond exhibit greater elasticity than other bonds with
appreciable strength.
 Grinding wheels having shellac bond are recommended
for cool cutting on hardened steel and thin sections,
finishing of chilled iron, cast iron, steel rolls,
hardened steel cams and aluminium pistons.
 This bond is denoted by ‘E’ in specifications.
Resinoid Bond
 These bonds are prepared by mixing abrasives with
synthetic resins like backelite and redmanol and
other compounds.
 Mixture is moulded to required shape and baked up to
200°C to give a perfect grinding wheel.
 These wheels have good grinding capacity at higher
speed.
 These are used for precision grinding of cams, rolls and
other objects where high precision of surface and
dimension influence the performance of operation.
 A resinoid bond is denoted by the letter ‘B’.
Rubber Bond
 Rubber bonded wheels are made by mixing abrasives with
pure rubber and sulphur.
 After that the mixture is rolled into sheet and wheels are
prepared by punching using die and punch. The wheels are
vulcanized by heating then in furnace for short time.
 Rubber bonded wheels are more resilient and have larger
abrasive density.
 These are used for precision grinding and good surface finish.
 Rubber bond is also preferred for making thin wheels with
good strength and toughness.
 The associated disadvantage with rubber bond is, these are
lesser heat resistant.
 A rubber wheel bonded wheel is denoted by the letter “R”.
Oxychloride Bond
 These bonds are processed by mixing abrasives with
oxides and chlorides of magnesium.
 The mixture is moulded and baked in a furnace to
give shape of a grinding wheel.
 These grinding wheels are used for disc grinding
operations.
 An oxychloride bonded wheel is specified the letter
‘O’.
Wheel Grade
 Indicates bond strength in retaining abrasive grains

during cutting
 Depends on amount of bonding material in wheel
structure (Pb)
 Measured on a scale from soft to hard
 Soft" wheels lose grains readily - used for low
material removal rates and hard work materials
 Hard wheels retain grains - used for high stock
removal rates and soft work materials
Grade of Wheel
 The term "grade" of grinding wheel refers to:
 Tenacity or hardness with which the bond holds the cutting
points or abrasive grains in place.
 And not the hardness of the abrasive grain.
 Letter “A” denoting the softest and the letter “Z” denoting the
hardest grade.
 The term "soft" or "hard" refer to the resistance a bond offers
to disruption of the abrasives.
 A wheel from which the abrasive grains can easily be
dislodged is called soft, whereas the one which holds the
grains more securely is called hard.
 The grades are denoted below.
Surface Finish
 Most grinding operations are performed to achieve

good surface finish
 Best surface finish is achieved by
 Small grain sizes
 Higher wheel speeds
 Denser wheel structure
 Means more grits per wheel area

Grinding

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Grinding

Caricato da

Copyright:

Formati disponibili

Grinding

 Material removal process in which abrasive particles

(a) Surface grinding machine

 (a) Horizontal spindle with reciprocating worktable,

 (c) Vertical spindle with reciprocating worktable, and

(a) Traverse grinding (b) Plunge grinding

 Two types of cylindrical grinding: (a) external and

Centerless grinding process A computer numerical control

Tool grinding may be divided into two

 Consists of abrasive particles and bonding

 Some standard grinding wheel shapes: (a) straight, (b)

 Aluminum oxide (Al2O3) - most common abrasive

 Cubic boron nitride (cBN) – very hard, very expensive

 Small grit sizes produce better finishes

Fine 80 100 120 150 180 - -

Very Fine 220 240 280 320 400 500 600

 Must withstand centrifugal forces and high

 A bond is an adhesive material used to held abrasive particles

 Indicates bond strength in retaining abrasive grains

 Most grinding operations are performed to achieve

Potrebbero piacerti anche