Grinding & Finishing

By S K Mondal
 Abrasive Machining Processes
Process Features
Grinding Uses wheels, accurate sizing, finishing, low MRR;
can be done at high speeds .
Creep feed Uses wheels with long cutting arc, very slow feed
grinding rate and large depth of cut
Abrasive High MRR, to obtain desired shapes and approximate
machining sizes
Abrasive water Water jets with velocities up to 1000 m/sec carry
jet Machining abrasive particles (silica and garnet)
Honing "Stones" containing fine abrasives; primarily a hole -
finishing process
Lapping Fine particles embedded in soft metal or cloth;
primarily a surface-finishing process
 Grinding
⚫ Grinding is the most common form of abrasive machining.
⚫ It is a material cutting process which engages an abrasive
tool whose cutting elements are grains of abrasive material
known as grit.
⚫ These grits are characterized by sharp cutting points, high
hot hardness, and chemical stability and wear resistance.
⚫ The grits are held together by a suitable bonding material to
give shape of an abrasive tool.
⚫ Grinding can be compared with milling with an infinite
number of cutting edge.
Fig- cutting action of abrasive grains
 Why is high velocity desired in grinding?
⚫ It is desired to off set the adverse effect of very high
negative rake angle of the working grit, to reduce the force
per grit as well as the overall grinding force.
 Advantages of Grinding
⚫ Dimensional accuracy

⚫ Good surface finish

⚫ Good form and locational accuracy

⚫ Applicable to both hardened and unhardened material

 Applications of Grinding
⚫ Surface finishing

⚫ Slitting and parting

⚫ Descaling, deburring

⚫ Stock removal (abrasive milling)

⚫ Finishing of flat as well as cylindrical surface

⚫ Grinding of tools and cutters and resharpening of the same

 On which factors does the transverse roughness
of workpiece depend during grinding?

⚫ It mainly depends on the shape of the grits and overlap cuts

made by the grits in the transverse direction. Lateral plastic
flow of the material as a result of ploughing also influences
the surface roughness.
 Grinding
⚫ If each abrasive grain is viewed as a cutting tool then in grinding
operation.
High
⚫ Rake angle can be positive, zero, or negative ranging from +45o
to -60o, dull, rounded grits has large negative rake angle
⚫ Cutting speed is very high
⚫ Very high specific energy of cutting
Low
⚫ Low shear angle
⚫ Low feed rate
⚫ Low depth of cut
 Interaction of the grit with the workpiece
⚫ Shape of grit is very important because it determines the grit
geometry e.g. rake and clearance angle.
⚫ The grits do not have definite geometry unlike a cutting tool.
 Interaction of the grit with the workpiece
⚫ Grit with favourable geometry can produce chip in shear
mode.
⚫ However, grits having large negative rake angle or rounded
cutting edge do not form chips but may rub or make a
groove by ploughing leading to lateral flow of the workpiece
material.

Fig- Grits engage shearing, ploughing and rubbing

 How is chip accommodation volume is
related to material removal rate?
⚫ Volume of chip accommodation space ahead of each grit
must be greater than the chip volume produced by each grit
to facilitate easy evacuation of the chip from the grinding
wheel.
Specific energy consumption in grinding
 How may the specific grinding energy vary
with material removal rate in grinding?
⚫ Specific grinding energy will start decreasing with material
removal rate because rake angle of the grit becomes more
favourable with increase of grit depth of cut. However, if
increase of material removal rate causes chip
accommodation problem in the available inter-grit space
then specific energy may increase.
 G Ratio
⚫ The grinding ratio or G ratio is defined as thee cubic mm of
stock removed divided by the cubic mm of wheel lost.

⚫ In conventional grinding, the G ratio is in the range 20: 1 to

80: 1.

⚫ The G ratio is a measure of grinding production and reflects

the amount of work a wheel can do during its useful life.

⚫ As the wheel losses material, it must be reset or repositioned

to maintain workpiece size.
 GATE -2011 (PI)
Grinding ratio is defined as
 GATE-2018
A grinding ratio of 200 implies that the
(a) grinding wheel wears 200 times the volume of
the material removed.
(b) grinding wheel wears 0.005 times the volume of
the material removed
(c) aspect ratio of abrasive particles used in the
grinding wheel is 200
(d) ratio of volume of abrasive particle to that of
grinding wheel is 200
 Parameters for specify a grinding wheel
1) The type of grit material
2) The grit size
3) The bond strength of the wheel, commonly known as
wheel hardness
4) The structure of the wheel denoting the porosity i.e. the
amount of inter grit spacing
5) The type of bond material
6) Other than these parameters, the wheel manufacturer
may add their own identification code
prefixing or suffixing (or both) the standard code.
Abrasive Material Comments and Uses
Aluminium oxide Softer and tougher than silicon
carbide; use on steel, iron, brass
Silicon carbide Used for brass, bronze, aluminum,
stainless steel and cast iron
cBN (cubic boron For grinding hard, tough tool steels,
nitride) stainless steel, cobalt and nickel
based superalloys, and hard coatings
Diamond Used to grind nonferrous materials,
tungsten carbide and ceramics
IES 2009
⚫ 2 marks
 Why is aluminium oxide preferred to
silicon carbide in grinding steel?
⚫ Al2O3 is tougher than SiC. Therefore it is preferred
to grind material having high tensile strength like
steel. Moreover, Al2O3 shows higher chemical
inertness than SiC towards steel leading to much
improved wear resistance during grinding.
 Grit size
⚫ The grain size affects material removal rate and the surface
quality of workpiece in grinding.
⚫ Large grit- big grinding capacity, rough workpiece surface
⚫ Fine grit- small grinding capacity, smooth workpiece surface
 Why does single layer grinding wheel show progressive
rise of force during grinding of high speed steel?

⚫ The geometry of grit undergoes irreversible change in the

form of rounding or flattening due to wear caused by
rubbing action of hard carbides present in high speed steel.
 Grade
⚫ The worn out grit must pull out from the bond and make
room for fresh sharp grit in order to avoid excessive rise of
grinding force and temperature.
⚫ A soft wheel should be chosen for grinding hard material.
⚫ A hard wheel should be chosen for grinding soft material.
 Structure / concentration
⚫ The structure should be open for grinding wheels engaged in
high material removal to provide chip accommodation
space.
⚫ The space between the grits also serves as pocket for holding
grinding fluid.
⚫ Dense structured wheels are used for longer wheel life, for
holding precision forms and profiles.
 Why is coarse grain and open structured wheel
is preferred for stock removal grinding?
⚫ Coarse grit allows large grit protrusion and open structure
provides large inter grit chip space. Thus in combination
those two provide large space for chip accommodation
during stock removal grinding and risk of wheel loading is
minimized.
 Bonding Materials for Grinding wheels
Type of Bond Attributes
Vitrified bonds Composed of clays and other ceramic
substances, porous, strong, rigid, and
unaffected by oils, water, or temperature.
Brittle and can not be used for high wheel
speed.
Resinoid, or Plastic bond, replaced shellac and rubber
phenolic resins wheels, not with alkaline grinding fluid.
Shellac bond For flexible cut off wheels, replaced by
resin bond.
 Bonding Materials for Grinding wheels
Type of Bond Attributes
Rubber bond For use in thin wheels, replaced by resin
bond.
Oxychloride Limited use.
bond
Metal bond Extensively used with super abrasive
wheels, high toughness, high accuracy,
large stock removal.
Electroplated Used for small wheel, form wheel and thin
bond super abrasive wheels, for abrasive milling
and ultra high speed grinding. Replace by
electroplated bond
 Bonding Materials for Grinding wheels
Vitrified bonds
⚫ They are composed of clays and other ceramic substances.
⚫ Vitrified wheels are porous, strong, rigid, and unaffected by
oils, water, or temperature over the ranges usually
encountered in metal cutting.
⚫ The operating speed range in most cases is 1500 to 5000
m/min.
 What is the main short coming of vitrified
bond?
Vitrified bond is brittle and can not with stand high impact
loads. This bond can not be used for high wheel speed due to
risk of wheel breakage under centrifugal force.
 Resinoid, or phenolic resins
⚫ Because plastics can be compounded to have a wide range of
properties, such wheels can be obtained to cover a variety of
work conditions.
⚫ They have, to a considerable extent, replaced shellac and
rubber wheels.
⚫ Resin bond is not recommended with alkaline grinding fluid
for a possible chemical attack leading to bond weakening.
 Shellac bond
⚫ At one time this bond was used for flexible cut off wheels.
⚫ At present use of shellac bond is limited to grinding wheels
engaged in fine finish of rolls.
 Rubber bond
⚫ Its principal use is in thin wheels for wet cut-off operation.
⚫ Rubber bond was once popular for finish grinding on
bearings and cutting tools.
 Oxychloride bond
⚫ It is less common type bond, but still can be used in disc
grinding operation. It is used under dry condition.
 Metal bond
⚫ Metal bond is extensively used with super abrasive wheels.
Extremely high toughness of metal bonded wheels makes
these very effective in those applications where form
accuracy as well as large stock removal is desired.
 Electroplated bond
⚫ This bond allows large (30-40%) crystal exposure above the
bond without need of any truing or dressing. This bond is
specially used for making small diameter wheel, form wheel
and thin super abrasive wheels. Presently it is the only bond
for making wheels for abrasive milling and ultra high speed
grinding.
 Brazed bond
⚫ This is relatively a recent development, allows crystal
exposure as high 60-80%. In addition grit spacing can be
precisely controlled. This bond is particularly suitable for
very high material removal either with diamond or cBN
wheel. The bond strength is much greater than provided by
electroplated bond. This bond is expected to replace
electroplated bond in many applications.
 Glazing
⚫ With continuous use a grinding wheel becomes dull with the
sharp abrasive grains becoming rounded.
⚫ This condition of a dull grinding wheel with worn out grains
is termed as glazing.
 Loading
⚫ Some grinding chips get lodged into the spaces between the
grits resulting in a condition known as loaded wheel.
⚫ Loading is generally caused during the grinding of soft and
ductile materials.
⚫ A loaded grinding wheel cannot cut properly and need
dressing.
 Dressing
⚫ Dressing is the conditioning of the wheel surface which
ensures that grit cutting edges are exposed from the bond
and thus able to penetrate into the workpiece material.
⚫ In dressing attempts are made to splinter the abrasive grains
to make them sharp and free cutting and also to remove any
residue left by material being ground.
⚫ Dressing therefore produces micro-geometry.
 GATE-2014
Match the Machine Tools (Group A) with the probable
Operations (Group B):
Group A Group B
P: Center Lathe 1: Slotting
Q: Milling 2: Counter-boring
R: Grinding 3: Knurling
S: Drilling 4: Dressing
P Q R S P Q R S
(a) 1 2 4 3 (b) 2 1 4 3
(c) 3 1 4 2 (d) 3 4 2 1
 Can a resin bonded cBN wheel be
electrochemically dressed?
⚫ Electrochemical dressing is not possible with resin bonded
wheel because it is not electrically conducting.
 Is dressing necessary for single layer
wheel?
⚫ Conventional macro level dressing is not required because
the wheel inherently has an open structure. However, touch
dressing is carried out to obtain better uniformity in grit
height in order to improve surface finish of the workpiece.
 Truing
⚫ Truing is the act of regenerating the required geometry on
the grinding wheel.
⚫ Truing is also required on a new conventional wheel to
ensure concentricity with specific mounting system.
⚫ Truing and dressing are commonly combined into one
operation for conventional abrasive grinding wheels, but are
usually two distinctly separate operation for super abrasive
wheel.
 Balancing Grinding Wheels
⚫ Because of the high rotation speeds involved, grinding
wheels must never be used unless they are in good balance.
⚫ Grinding wheel must be balanced Statically and
Dynamically.
⚫ A slight imbalance will produce vibrations that will cause
waviness in the work surface. It may cause a wheel to break,
with the probability of serious damage and injury.
 Creep feed grinding
⚫ This machine enables single pass grinding of a surface with
a larger down feed but slower table speed than that adopted
for multi-pass conventional surface grinding.
⚫ In creep-feed grinding, the entire depth of cut is completed
in one pass only using very small in-feed rates.
 State the basic advantage of a creep feed
grinder over a conventional surface
⚫ Productivity is enhanced and life of the grinding wheel is
extended.
 IES 2011 Conventional
What is creep feed grinding? Discuss its salient
features, advantages, and application.
[10 marks]
 Cylindrical Grinding
⚫ Center-type cylindrical grinding is commonly used far
producing external cylindrical surfaces.
⚫ The grinding wheel revolves at an ordinary cutting speed,
and the workpiece rotates on centers at a much slower speed.
⚫ Grinding machines are available in which the workpiece is
held in a chuck for grinding both external and internal
cylindrical surfaces.
 What are the characteristic features of a
universal cylindrical grinder?
⚫ Characteristic features of a universal cylindrical grinder not
possessed by plain cylindrical grinder are:
• Swivelling wheel head
• Swivelling wheel head slide
• Swivelling head stock
 Centerless Grinding
⚫ Centerless grinding makes it possible to grind both external
and internal cylindrical surfaces without requiring the
workpiece to be mounted between centers or in a chuck.
⚫ This eliminates the requirement of center holes in some
workpieces and the necessity for mounting the workpiece,
thereby reducing the cycle time.
⚫ Two wheels are used. The larger one operates at regular
grinding speeds and does the actual grinding. The smaller
wheel is the regulating wheel. It is mounted at an angle to
the plane of the grinding wheel.
 Centerless Grinding
⚫ The regulating wheel controls the rotation and longitudinal
motion of the workpiece and usually is a plastic- or
rubber-bonded wheel with a fairly wide face.
⚫ The workpiece is held against the work-rest blade by the
cutting forces exerted by the grinding wheel and rotates at
approximately the same surface speed as that of the
regulating wheel.
Centerless Grinding
Centerless Grinding
 Centreless internal Grinding
⚫ This machine is used for grinding cylindrical and tapered
holes in cylindrical parts (e.g. cylindrical liners, various
bushings etc).
⚫ The workpiece is rotated between supporting roll, pressure
roll and regulating wheel and is ground by the grinding
wheel.
 State the disadvantages of centreless
cylindrical grinding machine?
• It does not grind concentrically with centres.
• Large diameter short workpiece are difficult to control
in the process
• It may not improve workpiece perpendicularity.
Surface Grinding Machines
⚫ Surface grinding machines are used primarily to grind
flat surfaces.
⚫ However formed, irregular surfaces can be produced
on some types of surface grinders by use of a formed
wheel.
Four basic types of surface grinding machines are:
1. Horizontal spindle and reciprocating table
2. Vertical spindle and reciprocating table
3. Horizontal spindle and rotary table
4. Vertical spindle and rotary table
 Is transverse feed provided in vertical
spindle reciprocating table surface grinder?
⚫ Usually no transverse feed is provided in such machine. The
wheel diameter is kept larger than the width of the
workpiece surface to be ground.
Finishing Processes
 Lapping
⚫ Lapping is basically an abrasive process in which loose
abrasives function as cutting points finding momentary
support from the laps.
⚫ Material removal in lapping usually ranges from .003 to .03
mm but many reach 0.08 to 0.1mm in certain cases.
 Characteristics of lapping process
⚫ Use of loose abrasive between lap and the workpiece
⚫ Usually lap and workpiece are not positively driven but are
guided in contact with each other
⚫ Relative motion between the lap and the work should change
continuously so that path of the abrasive grains of the lap is
not repeated on the workpiece.
⚫ Cast iron is the mostly used lap material. However, soft
steel, copper, brass, hardwood as well as hardened steel and
glass are also used.
 Abrasives of lapping
⚫ Al2O3 and SiC, grain size 5 ~100 μm

⚫ Cr2O3, grain size 1 ~ 2 μm

⚫ B4C3, grain size 5 - 60 μm

⚫ Diamond, grain size 0.5 ~ 5 μm

 Vehicle materials for lapping
⚫ Machine oil

⚫ Rapeside oil

⚫ grease
 Technical parameters affecting lapping processes are
⚫ unit pressure

⚫ the grain size of abrasive

⚫ concentration of abrasive in the vehicle

⚫ lapping speed
 Honing
⚫ Honing is a finishing process, in which a tool called hone
carries out a combined rotary and reciprocating motion
while the workpiece does not perform any working motion.
⚫ Most honing is done on internal cylindrical surface, such as
automobile cylindrical walls. The honing stones are held
against the workpiece with controlled light pressure. The
honing head is not guided externally but, instead, floats in
the hole, being guided by the work surface.
 Honing
⚫ It is desired that
1. Honing stones should not leave the work surface
2. Stroke length must cover the entire work length.
3. In honing rotary and oscillatory motions are combined
to produce a cross hatched lay pattern.

⚫ The honing stones are given a complex motion so as to

prevent every single grit from repeating its path over the
work surface.
 Honing

Fig. Honing tool Fig. Lay pattern produced by combination of rotary and
oscillatory motion
 The critical process parameters are
⚫ 1. rotation speed

⚫ 2. oscillation speed

⚫ 3. length and position of the stroke

⚫ 4. honing stick pressure

 Buffing
⚫ Buffing is a polishing operation in which the workpiece is
brought into contact with a revolving cloth wheel that has
been charged with a fine abrasive, such as polishing rough.
⚫ The wheels are made of disks of linen, cotton, broadcloth, or
canvas, and achieve the desired degree of firmness through
the amount of stitching used to fasten the layers of cloth
together.
⚫ Negligible amount of material is removed in buffing while a
very high luster is generated on the buffed surface.
⚫ The dimensional accuracy of the parts is not affected by the
buffing operation.
 Super Finishing

Fig. super finishing of end face

of a cylindrical work piece in radial mode

In this both feeding and oscillation of the super

finishing stone is given in the radial direction.
 Super Finishing

Fig. super finishing operation in plunge mode

In this case the abrasive stone covers the section of the

workpiece requiring super finish. The abrasive stone is slowly
fed in radial direction while its oscillation is imparted in the
axial direction. It reduce surface roughness and increase
bearing load capacity.
 State the specific application of a planetary
internal grinder.
⚫ Planetary internal grinders find application for grinding
holes in workpieces of irregular shape or large heavy
workpieces.
 GATE - 1995
Among the conventional machining processes,
maximum specific energy is consumed in
(a) Turning (b) Drilling
(c) Planning (d) Grinding
 GATE - 1998
Ideal surface roughness, as measured by the maximum
height of unevenness, is best achieved when, the material
is removed by
(a) An end mill
(b) A grinding wheel
(c) A tool with zero nose radius
(d) A ball mill.
 GATE - 1998
In machining using abrasive material, increasing
abrasive grain size
(a) Increases the material removal rate
(b) Decreases the material removal rate
(c) First decreases and then increases the material removal
rate
(d) First increases and then decreases the material removal
rate
 GATE - 2000
Abrasive material used in grinding wheel selected for
grinding ferrous alloys is
(a) Silicon carbide (b) Diamond
(c) Aluminium oxide (d) Boron carbide
 GATE - 2002
The hardness of a grinding wheel is determined by the
(a) Hardness of abrasive grains
(b) Ability of the bond to retain abrasives
(c) Hardness of the bond
(d) Ability of the grinding wheel to penetrate the work
piece
 GATE - 2006
If each abrasive grain is viewed as a cutting tool, then
which of the following represents the cutting parameters
in common grinding operations?
(a) Large negative rake angle, low shear angle and high
cutting speed
(b) Large positive rake angle, low shear angle and high
cutting speed
(c) Large negative rake angle, high shear angle and low
cutting speed
(d) Zero rake angle, high shear angle and high cutting speed
 GATE - 1997
List I List II
(A) Grinding 1. Surface for oil retention
(B) Honing 2. Surface for max. load
capacity
(C) Super-finishing 3. Surface of limiting friction
D) Burnishing 4. Surface of matte finish
5. Surface for pressure sealing
6. Surface for interference fit.
 IES - 2005
Consider the following statements in respect of
grinding?
1. The pitch of the grit cutting edges is larger than the pitch
of the milling cutter.
2. The cutting angles of the grits have a random geometry.
3. The size of the chip cuts is very small for grinding.
Which of the statements given above are correct?
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3
 IES - 2009
Which one of the following is NOT used as abrasive
material in grinding wheels?
(a) Aluminium oxide
(b) Silicon carbide
(c) Cubic boron nitride
(d) Manganese oxide
 IES - 1997
Which one of the following materials is used as the
bonding material for grinding wheels?
(a) Silicon carbide
(b) Sodium silicate
(c) Boron carbide
(d) Aluminum oxide
 IES - 1996
Grinding wheel is said to be loaded when the
(a) Metal particles get embedded in the wheel surface
blocking the interspaces between cutting grains.
(b) Bonding material comes on the surface and the wheel
becomes blunt.
(c) Work piece being ground comes to a stop in cylindrical
grinding.
(d) Grinding wheel stops because of very large depth of cut
 IES - 2001
Specific cutting energy is more in grinding process
compared to turning because
(a) Grinding (cutting) speed is higher
(b) The wheel has multiple cutting edges (grains)
(c) Plaguing force is significant due to small chip size
(d) Grinding wheel undergoes continuous wear
 IES - 1996
Specific energy requirements in a grinding process are
more than those in turning for the same metal removal
rate because of the
(a) Specific pressures between wheel and work being high.
(b) Size effect of the larger contact areas between wheel
and work.
(c) High cutting velocities
(d) High heat produced during grinding.
 IES - 1994
The ratio of thrust force to cutting force is nearly 2.5 in

(a) Turning (b) Broaching

(c) Grinding (d) Plain milling
 IES - 1992
Assertion (A): Vitrified bond is preferred for thin
grinding wheels.
Reason (R): Vitrified bond is hard brittle.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
 IES - 2000
Assertion (A): The ratio of cutting force to thrust force is
very high in grinding process as compared to other
machining processes.
Reason (R): Random orientation and effective negative rake
angles of abrasive grains increase the cutting force and
adversely affect the cutting action and promote rubbing
action.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the correct
explanation of A
(c) A is true but R is false
(d) A is false but R is true
 IES - 1995
Soft materials cannot be economically grind due to
(a) The high temperatures involved
(b) Frequent wheel clogging
(c) Rapid wheel wear
(d) Low work piece stiffness
 IES 2010
In relation to the peripheral or surface speeds of
the grinding wheel and that of the workpiece in
cylindrical grinding of alloy steel workpieces, the
grinding wheel speed is
(a) Less than the speed of the workpiece
(b) Same as the speed of the workpiece
(c) Double the speed of the workpiece
(d) 65 to 75 times the speed of the workpiece.
 IES - 2009
Given that the peripheral speed of the grinding wheel of
100 mm diameter for cylindrical grinding of a steel work
piece is 30 m/s, what will be the estimated rotational
speed of the grinding wheel in revolution per minute
(r.p.m.)?
(a) 11460 (b) 5730
(c) 2865 (d) 95
 IES - 2002
Which of the following materials are used in grinding
wheel?
1. Aluminium oxide
2. Cubic boron nitride
3. Silicon carbide
Select the correct answer using the codes given below:
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
 IES – 2001, ISRO-2009
The marking on a grinding wheel is '51 A 36 L 5 V 93'.
The code '36' represents the
(a) Structure
(b) Grade
(c) Grain- size
(d) Manufacturer's number
 IES - 2000
The sequence of markings "S 14 K 14 S" on a grinding
wheel represents respectively
(a) Bond type, structure, grade, grain size and abrasive type
(b) Abrasive type, grain size, grade, structure and bond type
(c) Bond type, grade, structure, grain size and abrasive type
(d) Abrasive type, structure, grade, grain size and bond type
 IES - 1995
In the grinding wheel of A 60 G 7 B 23, B stands for
(a) Resinoid bond (b) Rubber bond
(c) Shellac bond (d) Silicate bond.
 IES - 1993
Tool life in the case of a grinding wheel is the time
(a) Between two successive regrinds of the wheel
(b) Taken for the wheel to be balanced
(c) Taken between two successive wheel dressings
(d) Taken for a wear of 1mm on its diameter
 IES - 2001
Assertion (A): Hard wheels are chosen for grinding
hard metals.
Reason (R): In hard wheels only the abrasive grains are
retained for long time.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
 IES - 1994
Consider the following statements regarding grinding of
high carbon steel:
1. Grinding at high speed results in the reduction of chip
thickness and cutting forces per grit.
2. Aluminium oxide wheels are employed.
3. The grinding wheel has to be of open structure.
Of these statements
(a) 1, 2 and 3 are correct (b) 1 and 2 are correct
(c) 1 and 3 are correct (d) 2 and 3 are correct
 IES - 1999
Consider the following reasons:
1. Grinding wheel is soft
2. RPM of grinding wheel is too low
3. Cut is very fine
4. An improper cutting fluid is used
A grinding wheel may become loaded due to reasons stated
at
(a) 1 and 4 (b) 1 and 3
(c) 2 and 4 (d) 2 and 3
 IES - 2001
Dry and compressed air is used as cutting fluid for
machining
(a) Steel (b) Aluminium
(c) Cast iron (d) Brass
 IES - 1993
In centre less grinding, the work piece centre will be
(a) Above the line joining the two wheel centres
(b) Below the line joining the two wheel centres
(c) On the line joining the two wheel centres
(d) At the intersection of the line joining the wheel centres
with the work plate plane.
 IES - 2000
Consider the following advantages:
1. Rapid process
2. Work with keyways can be ground
3. No work holding device is required.
Which of these are the advantages of centre less grinding?
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
 IES - 1996
A grinding wheel of 150 mm diameter is rotating at
3000 rpm. The grinding speed is
 IES - 1993
Consider the following parameters:
1. Grinding wheel diameter.
2. Regulating wheel diameter.
3. Speed of the grinding wheel.
4. Speed of the regulating wheel.
5. Angle between the axes of grinding and regulating
wheels.
Among these parameters, those which influence the axial
feed rate in centreless grinding would include
(a) 2, 4 and 5 (b) 1, 2 and 3
(c) 1, 4 and 5 (d) 3, 4 and 5
 IES - 2007
Honing Process gives surface finish of what order?
(a) 10 µm (CLA) (b) 1.0 µm (CLA)
(c) 0.1 µm (CLA) (d) 0.01 µm (CLA)
 IES - 1992
CLA value for Honing process is
(a) 6 (b) 0.05 - 3.0
(c) 0.05 - 1.0 (d) 0.025 - 0.1
 IES - 2012
Statement (I): Honing is an abrading process to remove
stock from metallic surfaces.
Statement (II):Honing is commonly done on internal
surfaces.
(a) Both Statement (I) and Statement (II) are individually
true and Statement (II) is the correct explanation of
Statement (I)
(b) Both Statement (I) and Statement (II) are individually
true but Statement (II) is not the correct explanation of
Statement (I)
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
 IES - 2001
Match List-I (Cutting Tools) with List-II (Applications) and
select the correct answer using the codes given below the lists:

List I List II
A. Trepanning tool 1. For surface finishing by
honing
B. Side milling cutter 2. For machining gears
C. Hob cutter 3. For cutting keyways in shafts
D. Abrasive sticks 4. For drilling large diameter
holes
Codes:A B C D A B C D
(a) 1 3 2 4 (b) 4 3 2 1
(c) 1 2 3 4 (d) 4 2 3 1
 IES - 1992
A surface finish of 0.025 – 0.1 micrometer CLA values
is to by produced. Which machining process would you
recommend?
(a) Grinding (b) Rough turning
(c) Lapping (d) Honing
 IES - 1992
Buffing wheels are mode of
(a) Softer metals (b) Cotton fabric
(c) Carbon (d) Graphite
 IAS - 2004
The size effect refers to the increase in specific cutting
energy at low values of under formed chip thickness. It is
due to which one of the following?
(a) Existence of ploughing force
(b) Work hardening
(c) High strain rate
(d) Presence of high friction at chip-tool interface.
 IAS - 2000
Consider the following statements in respect of a
grinding wheel of specification, 51-A- 36-L-7-R-23, using
the standard alphanumeric codification:
1. Abrasive used in the wheel is aluminum oxide
2. The grain size of abrasive is medium
3. The wheel grade is medium hard
4. It has an open structure
5. It has resinoid as bonding agent
Which (If these statements are correct?
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 2, 3 and 5 (d) 1, 4 and 5
 IAS - 1999
Assertion (A): The grade of a grinding wheel is a
measure of hardness of the abrasive used for the wheel.
Reason (R): Grading is necessary for making right
selection of the wheel for a particular work.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
 IAS - 2001
Consider the following statements:
The set-up for internal centreless grinding consists of a regulating
wheel, a pressure roll and a support roll, between which the
tubular workpiece is supported with the grinding wheel within the
tube, wherein
1.The grinding wheel, workpiece and regulating wheel centers must
lie on one line
2.The directions of rotation of workpiece and grinding wheel are same
3.The directions of rotation of pressure roll, support roll and
regulating wheel are same
4.The directions of rotation of grinding wheel and regulating wheel
are same
Which of these statements are correct?
(a) 1, 2 and 3 (b) 1, 3 and 4
(c) 2 and 3 (d) 3 and 4
 IAS - 1997
Which of the following pairs are correctly matched?
1. Drill press : Trepanning
2. Centreless grinding: Through feeding
3. Capstan lathe: Ram type turret
Select the correct answer using the codes given below:
Codes:
(a) 1 and 2 (b) 1, 2 and 3
(c) 1 and 3 (d) 2 and 3
 IAS - 2007
Match List I with List II and select the correct answer using
the code given below the Lists:
List I List II
(Machine Tool/ Cutting Tool) (Part/ Characteristics)
A. Screw cutting lathe 1. Self locking taper
B. Drill 2. Chasing dial
C. End mill 3. Wiper insert
D. Grinding wheel 4. Self releasing taper
5. Balance weights
Code: A B C D A B C D
(a) 4 5 3 1 (b) 2 1 4 5
(c) 4 1 3 5 (d) 2 5 4 1
 IAS - 1999
Which one of the following processing sequences will
give the best accuracy as well as surface finish?
(a) Drilling, reaming and grinding
(b) Drilling, boring and grinding
(c) Drilling, reaming and lapping
(d) Drilling, reaming and electroplating
 IAS - 2001
Which one of the following grinding wheels (with
Grade, Grit and Bond) is suitable for cutter grinding?
(a) K 60 vitrified (b) K 320 vitrified
(c) T 60 resinoid (d) T 320 resinoid