Manufacturing Processes II

Subject Code: 302051

GRINDING AND FINISHING

PROCESS
प्रा.सुबोध पाटील
जे.एस.पी.एम.
वाघोली, पुणे

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 SYALLABUS
Unit – III Finishing processes

Grinding machines
Introduction: Types and Operations of grinding machines

Grinding wheel – Shapes, Designation and selection, Mounting, Balancing

and Dressing of grinding wheels, Machining time calculation for cylindrical and
plunge grinding.

Super-finishing processes – Introduction to Honing, Lapping,

Buffing and Burnishing. (Construction, working and controlling parameters)

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 INTRODUCTION

 Material cutting process.

 Most common form of
abrasive machining
 The process in which tool with
abrasives (whose cutting
elements are grains of abrasive
material) known as grit, is used
to remove material from the
workpiece is called grinding.

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 INTRODUCTION

 Grinding Wheel ->

(Abrasives + Binder) ->
 Controlled connection
with workpiec
 Removal of chips from
workpiece (Minute size)

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CHARACTERISTICS OF GRITS
Sharp cutting
points,
High hot
hardness,
Chemical
stability and
Wear
resistance.

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 CUTTING ACTION OF
ABRASIVE GRITS

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 Advantages And Applications
Of Grinding
Advantages
• Dimensional Accuracy
• Good surface finish
• Good form and locational accuracy
• Applicable to both hardened and unhardened materials

Applications
• Surface finishing
• Stock removal (abrasive milling) finishing of flat as well as
cylindrical surface
• Grinding of tools and cutters and resharpening of the same.
Grinding Wheel and Workpiece
Interaction
 TYPES OF GRINDING
MACHINES
GRINDING
MACHINES

NON -
PRECISION
PRECISION
 NON -
PRECISION

Bench Portable Belt

For large removal of material.

Inaccurate & rough finishing.

 Bench Grinder
• Horizontal Spindle having grinding wheels @
both ends.
• Can be bolted @ a convenient height.
Bench Grinder
 Portable Grinder
• Portable
• Connected to an electric motor.
• Can be adjusted to any angle & any height.
Portable Grinder
 Belt Grinder
• Uses an endless abrasive belt for grinding.
• Workpiece is to fed against the abrasive belt
for grinding.
Belt Grinder
 PRECISION

Cylindrical Surface Internal

FOR REMOVAL OF SMALL AMT. OF MATERIAL.

ACCURATE & BETTER FINISHING.

 Cylindrical Grinder
• Holding of workpiece in
chick or a fixture rigidly.

• Workpiece is rotating.

• A grinding wheel
(revolving) is fed against
the workpiece.
Cylindrical Grinding Machine
 Surface Grinder
Used to machine flat , tapered ,irregular surfaces.

Horizontal Spindle
a) Reciprocating Table .
Vertical Spindle

Horizontal Spindle
b) Rotary Table.
Vertical Spindle
Horizontal Spindle Reciprocating Table
Grinder
Vertical Spindle Reciprocating Table
Grinder
Vertical Spindle Reciprocating Table
Grinder
Vertical Spindle Reciprocating Table
Grinder
Internal Grinder
 Introduction to Grinding Wheels
• Grinding wheel consists of hard abrasive grains called
grits, which perform the cutting or material removal,
held in the weak bonding matrix.
• The conventional wheels include aluminium oxide and
silicon carbide wheels while diamond and cBN (cubic
boron nitride) wheels fall in the category of
superabrasive wheel.
• Specification of Grinding Wheels:: Types;
• A) Geometrical Specifications
• B) Compositional Specificationals
Grinding Wheels
 Grinding Wheels and Material
Grinding Wheel Parameter
Type of Abrasive Material
Bonding material
Grain size
Wheel grade
Wheel structure

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 Grinding Wheels and Material
1. Abrasive
2. Bond

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 Grinding Wheels and Material
1. Abrasive
Abrasives are extremely hard material
consisting of very small particles called
Grains.
The grain having number of sharp cutting
edges and corner

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 Grinding Wheels and Material
Abrasive
Two types of Abrasive
1. Natural
2. Artificial or Manufactured

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 Grinding Wheels and Material
1. Natural
They are obtained from mines directly

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 Grinding Wheels and Material

The most commonly used natural abrasive are

Stone
Emery
Quartz
Corundum
diamond

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 Grinding Wheels and Material
Stone

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 Grinding Wheels and Material
Emery: Emery (or corundite) is a dark
granular rock used to make abrasive powder.

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 Grinding Wheels and Material
Quartz

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 Grinding Wheels and Material
Corundum

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 Grinding Wheels and Material
Diamond

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 Grinding Wheels and Material
2.Artificial or Manufactured
 They are manufactured in closed electric furnaces under
controlled condition to avoid of impurities and to achieve
required temperature for chemical reaction

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 Grinding Wheels and Material
Artificial or Manufactured
1. Aluminum oxide Al
2. Silicon carbide (SiC)
3. Artificial diamond

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 Grinding Wheels and Material
2.Bonds
Bond material of the grinding wheel acts as
binder to hold abrasive grains together
The Principal bond material are,
Vitrified bond
Silicate bond
Oxychloride bond
Resinoid bond
Rubber bond

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 Grinding Wheels and Material
Vitrified bond
It is a clay bond which is reddish brown colour
The base material is Felspar which is fusible clay

proper proportion of flux are added to felspar and

mixed thoroughly
This mixture together with abrasive grain is fed in
to revolving drum which contain water to form a
paste

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 Grinding Wheels and Material

Advantages
 The bond is very hard
 It is not affected by water,oil,acids or climate condition
 It remove material quickly

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 Grinding Wheels and Material

Silicate bond
The base material is silicate of soda
Light gray in colour
The process is similar to vitrified bond but at
low temp. which result is high strength

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 Grinding Wheels and Material

Advantages
 Process of manufacturing is fast
 Low temp is required
 The cutting action of the wheel is smoother and cooler

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 Grinding Wheels and Material

Oxychloride bond
The mixture of oxide and chloride of
magnesium
Grinding is done in dry condition
It is used for making of disc shaped wheels

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 Grinding Wheels and Material

Resinoid bond
 Manufactured from a mixture of abrasive grains,
synthetic resin and some compounds.
 This mixture is filled in moulds and fed in to the
furnace and baked at temp. about 200°C
 It is strong and flexible

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 Grinding Wheels and Material

Rubber bond
 Manufactured by passing a rubber and sulphur
through the mixing rolls and adding abrasive grains
slowly
 This mixture passed through another set of roll and
obtain desired shape/thickness
 The wheel are cut and vulcanized under pressure
 During grinding water can be used

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 Grinding Wheels and Material

Grains(grit)

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 Grinding Wheels and Material

Grains(grit)
Grit designation Grain size or grit number
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

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 Grade

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 Grade

Soft A B C D E F G H

Medium I J K L M N O P

Hard Q R S T U V W X Y Z

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 Structure
It indicates the spacing between the abrasive
grains or density of the wheel
Higher proportion of bond is considered as
open structure
Lower proportion of bond is considered as
Close structure

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 Stucture of grinding wheel

Structure type Represented by number

Dense/Close 1 2 3 4 5 6 7 8

Open 9 10 11 12 13 14 15 or up

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 Super finishing Processes
The component produced through turning,
milling and drilling etc. operations are fairly
accurate in size but do not carry a very high
degree of surface finish.
For producing extremely high surface finish ,
the component to some more operations
which are called as micro-finishing operations.
The surface finished through these processes
are specified in microns

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 Super finishing Processes
Types
Honing
Lapping
Super finishing
Polishing
Buffing
burnishing

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 Super finishing Processes
Types
Honing
It is an abrading process used for already
machined surface
It is used for finishing internal cylindrical
surface such as drilled holes
Tool is used hone (abrasive stone)
It can be done by hand or machines

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 Super finishing Processes

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 Super finishing Processes

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 Super finishing Processes

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 Super finishing Processes

Lapping
It is also an abrading process used for
improving surface finish by reducing roughness
,waviness and other irregularities on the
surface
It can be sued for both heat treated and non
heat treated parts

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 Super finishing Processes

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 Super finishing Processes

Lapping
It can be done in two ways
a. By hand
b. By machine

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 Super finishing Processes

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 Super finishing Processes

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 Super finishing Processes

Buffing
It is performed after polishing for providing a
high luster to polished surface
It removes very less amount of material
It can be done on very flat surface

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 Super finishing Processes

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 Super finishing Processes

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 Burnishing Processes

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