Chapter 1: Introduction to Machine Shop – Key o Charles Babbage: Designed a

Terms and Definitions mechanical general-purpose

computer.
1. Machine Shop
o Required precision machining for
• Definition: A facility where machining its components, influencing
processes are conducted, involving the modern machining and
shaping of materials using machine tools. computing.
• Types of Work: Can include metalworking, • American System of Manufacturing
plastic machining, wood machining, and (Mid-19th Century)
even glass shaping.
o Eli Whitney: Developed mass
• Common Tools: Lathes, milling machines, production techniques with
drill presses, grinding machines, and CNC interchangeable parts.
machines.
o Led to the assembly line concept
• Production Types: Small-scale (job in manufacturing.
shops), medium-scale (limited
production), and large-scale (mass • Taylorism and Scientific Management
production). (Late 19th – Early 20th Century)

2. Historical Evolution of Machine Shops o Frederick Taylor: Introduced

principles of scientific
• Early Craftsmanship (Pre-Industrial management.
Revolution)
o Focus on efficiency, task
o Manual metalworking conducted standardization, and time-motion
by blacksmiths and artisans. studies.
o Reliance on hand tools for • World Wars and Precision Machining
shaping and forming materials. (20th Century)
• Industrial Revolution (Late 18th – 19th o Demand for high-precision
Century) military components accelerated
machining advancements.
o Introduction of steam engines
and mechanized processes. o Introduction of specialized
machine tools for war-related
o Advancements in iron and steel
production.
production.
• CNC Machining and Automation (1950s
o Standardization of parts and
– Present)
mechanized manufacturing
methods. o Introduction of Computer
Numerical Control (CNC) for
• Development of Machine Tools (Early
automation and precision.
19th Century)
o Modern CNC machines handle
o Henry Maudslay: Developed
complex machining tasks with
precision machine tools,
minimal human intervention.
including the screw-cutting lathe.
3. Fundamental Principles of Machine Shop
o Introduction of interchangeable
Practices
parts for efficient assembly.
• Precision and Accuracy
• Babbage’s Analytical Engine (1837)
 o Importance of meeting tight o Balancing efficiency with tool
tolerances. longevity.

o Use of calibrated measuring • Chip Control and Lubrication

instruments (micrometers,
calipers, CMM machines). o Managing chip formation and
evacuation.
• Safety
o Use of cutting fluids to reduce
o Personal Protective Equipment heat and wear.
(PPE): Goggles, gloves, hearing
protection, and respirators. • Quality Control

o Awareness of common hazards o Periodic measurement and

(rotating machinery, sharp tools, inspection of machined parts.
electrical risks). o Addressing deviations from
• Tool Selection and Maintenance specified tolerances.

o Choosing tools based on • Continuous Improvement and

material, cutting speed, and Innovation
required finish. o Adopting lean manufacturing
o Regular sharpening and principles.
maintenance of cutting tools. o Integrating modern techniques
• Material Knowledge like CAD/CAM for process
optimization.
o Understanding mechanical
properties of metals, plastics, • Environmental Considerations
and composites. o Safe disposal of metal shavings,
o Adjusting machining parameters cutting fluids, and chemical
based on material behavior. waste.

• Machine Setup and Calibration o Adherence to regulatory

guidelines for industrial waste
o Proper alignment of machine management.
components.
4. Types of Machine Shops
o Secure clamping and positioning
of workpieces. • Job Shop

• Work Holding Techniques o Small-scale machining facility

handling customized or low-
o Use of vises, clamps, fixtures, volume production.
and chucks for securing
materials. o Flexible operations with various
machining capabilities.
o Ensuring stability to prevent
workpiece movement. • Limited Production Shop

• Cutting Speeds and Feeds o Medium-scale production,

balancing job shop flexibility with
o Adjusting speeds based on tool mass production efficiency.
material, workpiece material,
and operation type. • Mass Production Shop
 o High-volume production with o Houses CNC mills and lathes for
extensive use of automated and automated machining.
CNC machines.
• Tool and Die Section
o Focus on efficiency and cost-
effectiveness. o Dedicated to designing and
producing specialized tooling.
• Specialized Machine Shops:
• Assembly Area
o Prototype Shop – Produces
prototype components for testing o Final product assembly using
and design verification. machined components.

o Tool and Die Shop – • Quality Control and Inspection Area

Manufactures tools, dies, and
o Equipped with measuring
molds for industrial production.
instruments for verifying part
o CNC Machining Shop – dimensions and tolerances.
Dedicated to precision CNC
• Materials and Stock Area
machining.
o Stores raw materials and semi-
o Fabrication Shop – Specializes
finished components.
in metal cutting, welding, and
assembly. • Finishing and Surface Treatment
Section
o Aerospace Machine Shop –
Produces components for o Includes polishing, painting,
aviation and space industries. anodizing, and other finishing
processes.
o Medical Machining Shop –
Manufactures parts for medical • Welding and Fabrication Area
devices and implants.
o Dedicated to metal joining and
o Automotive Machine Shop – fabrication tasks.
Focuses on machining
automotive components. • Heat Treatment Section

o Plastic Machining Shop – Works o Performs processes like

with plastic materials for annealing, quenching, and
precision manufacturing. tempering for improved material
properties.
o Die Casting Shop – Uses molds
and casting methods for metal • Maintenance Workshop
component production.
o Responsible for the upkeep and
o Electronics Machining Shop – repair of machinery.
Produces small precision parts
for electronic devices. • Programming and CAD/CAM Section

5. Key Areas of a Machine Shop o Develops CNC machining

programs using CAD/CAM
• Machining Area software.

o Central workspace for lathes, • Research and Development (R&D)

milling machines, and grinding Section
machines.

• CNC Machining Section

 o Focuses on innovation, o Better employee retention and
prototyping, and process workplace culture.
improvements.

• Environmental and Safety Compliance

Area 2. Safety Regulations and Standards

o Ensures adherence to safety and • Philippine Occupational Safety and

environmental regulations. Health Standards (OSHS)

o DOLE regulations on machine

CHAPTER 02 - Machine Shop Safety shop safety.

1. Introduction to Machine Shop Safety o Requirements for workplace

hazard assessment and control.
• Definition of Machine Shop Safety
• International Safety Standards
o Importance of ensuring a hazard-
free environment in machining o Occupational Safety and Health
operations. Administration (OSHA)
regulations.
o The role of safety regulations,
training, and PPE in injury o International Organization for
prevention. Standardization (ISO 45001) for
workplace safety.
• Importance of Safety in the Machine
Shop • Company-Specific Safety Policies

o Reducing workplace injuries and o Workplace-specific rules and

fatalities. enforcement.

o Enhancing productivity by o Safety training programs for

maintaining a safe and organized machine operators.
workspace. o Compliance monitoring and
o Improving worker confidence and enforcement strategies.
morale through a secure work
environment.
3. Personal Responsibility for Safety
• Consequences of Workplace Accidents
• Awareness of Hazards and Regulations
o Physical Impact: Injuries,
disabilities, fatalities. o Understanding the risks
associated with different
o Financial Impact: Medical costs, machining operations.
compensation claims, machine
damage. o Regularly reviewing and updating
knowledge of safety protocols.
o Operational Impact: Downtime,
production losses, legal • Education and Training
repercussions.
o Attending safety orientations and
• Benefits of a Safe Work Environment refresher courses.

o Increased efficiency and fewer o Learning safe operating

work disruptions. procedures for all machines.

o Compliance with regulations and

avoidance of legal penalties.
• Use of Personal Protective Equipment • Leadership and Role Modeling
(PPE)
o Supervisors and senior workers
o Proper selection, use, and demonstrating safety-conscious
maintenance of PPE (covered in behavior.
detail later).

• Following Safe Work Practices

4. Hazards and Risks in the Machine Shop
o Adhering to machine operating
procedures. • Physical Hazards

o Ensuring correct lifting and o Mechanical Hazards:

carrying techniques. ▪ Moving parts, rotating
• Reporting Hazards and Incidents equipment, sharp
cutting tools.
o The importance of reporting
unsafe conditions. ▪ Risk of entanglement,
pinching, or amputation.
o Near-miss reporting and
preventive action. o Electrical Hazards:

▪ Exposed wiring, faulty

• Proper Equipment Use and
grounding, overloaded
Maintenance
circuits.
o Regular maintenance schedules.
▪ Electric shock, burns,
o Avoiding improper machine and fire hazards.
modifications.
o Noise and Vibration:
• Health and Wellness Considerations
▪ Long-term exposure
o Avoiding fatigue, dehydration, leading to hearing loss or
and poor posture during nerve damage.
operations.
o Dust and Airborne Particles:
• Communication and Teamwork
▪ Metal shavings, sawdust,
o Encouraging a cooperative and fumes affecting
approach to safety. respiratory health.

• Compliance with Company Policies • Chemical Hazards

o Adhering to safety audits, o Flammable Liquids and Gases:

checklists, and guidelines.
▪ Risk of fire and explosion
• Continuous Improvement and from solvents,
Feedback lubricants, and coolants.

o Encouraging feedback from o Toxic Exposure:

workers to improve safety ▪ Inhalation, skin contact,
measures. or ingestion of hazardous
• Emergency Preparedness chemicals.

o Knowing evacuation procedures • Biological Hazards

and first aid response. o Contaminants from Poor
Ventilation:
 ▪ Mold, bacteria, or other o Using checklists for hazard
pathogens. identification.

• Ergonomic Hazards • Reporting Systems

o Repetitive Motion Injuries: o Open communication with

supervisors.
▪ Carpal tunnel syndrome,
musculoskeletal o Anonymous reporting channels
disorders. for safety concerns.

o Poor Posture & Improper Lifting: • Near Miss Reporting

▪ Risk of back injuries. o Encouraging proactive hazard
intervention.
• Environmental Hazards
• Incident Investigation
o Heat and Cold Stress:
o Determining the root cause and
▪ Working near hot implementing corrective actions.
furnaces or in poorly
ventilated areas. • Trend Analysis
o Slippery Surfaces and Falling o Identifying common safety
Objects: concerns and patterns.
▪ Oil spills, improperly
stored tools and
materials. 6. Risk Assessment and Mitigation

• Machine Guarding Issues • Job Hazard Analysis (JHA)

o Absence or removal of machine o Breaking down tasks to identify

guards increasing injury risk. specific risks.

• Confined Spaces Risks • Hierarchy of Controls

o Suffocation, toxic gas exposure, o Elimination – Removing the

lack of ventilation. hazard entirely.

• Lack of PPE Usage o Substitution – Using safer

materials or methods.
o Increased risk of eye injuries,
burns, and respiratory issues. o Engineering Controls – Installing
safety features like guards.
• Poor Housekeeping
o Administrative Controls – Training
o Cluttered workspaces increasing and policies to reduce risk.
trip-and-fall risks.
o PPE – The last line of defense.

5. Hazard Recognition and Reporting

7. Personal Protective Equipment (PPE)
• Identifying Hazards
• Types of PPE and Their Uses
o Conducting regular workplace
inspections. o Eye Protection (safety glasses,
goggles, face shields).
 o Hearing Protection (earplugs, • The role of individual responsibility in
earmuffs). workplace safety.
o Hand Protection (cut-resistant • The importance of leadership in fostering
gloves, heat-resistant gloves). a safety-conscious culture.
o Foot Protection (steel-toed • Reinforcing the idea that safety is a
shoes, slip-resistant soles). shared responsibility among all
employees.
o Respiratory Protection (dust
masks, respirators). *******************************************
o Head Protection (hard hats, Chapter 3: Basic Machine Tool Operations
bump caps).
I. Module Objectives
o Body Protection (coveralls, safety
vests, aprons). II. Introduction to Basic Machine Tool
Operations
• Proper Selection, Use, and
Maintenance Historical Background:

o Ensuring PPE fits correctly and is Pre-Industrial Revolution: Hand tools were the
used consistently. primary means of shaping metal.

Industrial Revolution: The advent of machine

tools revolutionized manufacturing, enabling
8. Safe Work Practices mass production and precision.
• Housekeeping and Work Area Modern Era: Ongoing technological
Organization advancements have led to highly automated,
complex machine tools.
• Machine Setup and Operation Procedures
Modern Machine Tools:
• Proper Tool Handling and Storage
Vary in size from small benchtop machines to
• Lockout/Tagout (LOTO) Procedures massive industrial equipment.
• Emergency Procedures and Preparedness Increasingly incorporate computer controls (CNC)
for precision and efficiency.
• Safe Lifting and Carrying Techniques
________________________________________

III. Classification of Machine Tool Operations

9. Maintaining a Safe Work Environment
1. Drilling and Boring
• Effective Communication and Teamwork
Drilling:
• Ongoing Safety Training and Education
A process for creating round holes using a rotating
• Building a Positive Safety Culture drill bit.
• Regular Safety Audits and Assessments Equipment: drill press, radial drill, hand drill.
• Continuous Safety Improvements Common drills: twist drills, center drills, spade
drills.

Boring:
10. Conclusion: Commitment to Safety
Enlarges or finishes holes that have already been
drilled or cast.
Uses a single-point cutting tool, often resembling Planer-Type Milling Machine: Combines planing
a lathe tool. and milling operations.

Reaming: Gear Hobbing Machines: Specialized for gear

cutting.
Expands and smooths holes to tight tolerances.
4. Planing
Removes only small amounts of material.
Planing Machines:

Remove metal by advancing a workpiece against a

Tapping: stationary cutting tool.
Cuts internal threads in pre-drilled holes. Used for large, flat surfaces.
Used for creating threads to accommodate bolts Shaping Machines:
and screws.
Reverse the planing process: the cutting tool
2. Turning moves while the workpiece stays stationary.
Lathe Operations: Slotting Machines:
Involves rotating a metal workpiece while Vertical shapers for cutting internal slots or
advancing a cutting tool against it. keyways.
Produces cylindrical shapes like shafts, rods, and Broaching:
bolts.
Uses a tool with multiple teeth to cut a shape in
Turret Lathes: one stroke.
Equipped with a multi-sided turret holding Applied internally (square holes) or externally (flat
multiple tools. surfaces).
Allows sequential machining without resetting 5. Grinding
tools.
Grinding Process:
Single- and Multiple-Spindle Automatics:
Shapes metal by bringing it into contact with a
Perform multiple cutting operations on several revolving abrasive wheel.
workpieces simultaneously.
Used for high-precision finishing.
Used for mass production.
Abrasive Machining:
3. Milling
Heavy-duty grinding for removing significant
Milling Process: material.
A rotary cutting tool removes material by bringing Lapping:
the workpiece into contact with it.
Uses abrasive pastes for fine polishing and high
Can produce flat surfaces, slots, gears, and precision.
contoured shapes.
Honing:
Types of Milling Machines:
Employs rotating heads with abrasives to finish
Vertical Milling Machine: Cutting tool rotates holes accurately.
vertically.
Applications:
Horizontal Milling Machine: Cutter spindle is
horizontal. Cylindrical, surface, and internal grinding.
6. Metal Forming Gas Forming: Shapes metal using high-pressure
gases.
Shearing:
Hot Machining: Heats the workpiece during
Cuts metal sheets into desired shapes. cutting.
Stamping: Hydroforming: Forms metal using high-pressure
Punches holes or shapes into metal sheets. fluids.

Pressing: Laser Cutting: Uses concentrated light beams to

cut metal.
Shapes metal under high pressure using dies.
Magnetic Forming: Shapes metal using magnetic
Types: mechanical press, hydraulic press. pulses.
Forging: Plasma Machining: Uses plasma jets to remove
material.
Drop Hammer: Hammers white-hot metal into
shape. Spark Forming: Similar to EDM, uses electrical
discharges.
Forging Machine: Squeezes metal into die cavities.
Ultrasonic Cutting and Forming: Uses high-
________________________________________ frequency sound waves.
IV. Advanced Metal Shaping Processes Applications and Industry Influence:
Modern Machining Techniques: Aerospace, atomic energy, and rocket research
Abrasive Machining: Heavy material removal using have driven innovation.
abrasives. Many processes adapted for industrial production
Capacitor Discharge Machining: Uses electrical (e.g., EDM, electrochemical milling).
discharges for shaping. ________________________________________
Cold Extrusion: Forces metal through a die V. Supporting Skills for Machining
without heat.
Reading Technical Drawings:
Combustion Machining: Uses controlled
explosions to cut material. Interpreting blueprints, tolerances, and symbols.
Electrical Discharge Machining (EDM): Removes Measuring and Gauging:
metal using electric sparks.
Using tools like micrometers, calipers, and dial
Electromechanical Machining: Applies electric indicators.
and magnetic forces.
Troubleshooting and Maintenance:
Electrolytic Machining: Dissolves material through
electrochemical reactions. Diagnosing and fixing machine malfunctions.

Electrospark Forming: Shapes metal with electric Performing routine maintenance.

sparks. ________________________________________
Electron Beam Machining: Uses a focused beam VI. Conclusion
of electrons.
Mastery of both basic and advanced machining
Explosive Forming: Shapes metal through processes is essential.
controlled explosions.
Emerging technologies continue to shape the
Fission Fragment Etching: Utilizes nuclear future of manufacturing.
reactions.
Skilled machinists are vital for industrial growth • Spindle: Transfers rotary motion from the
and innovation. drill head to the drill jigs and allows for
height adjustments.
________________________________________
• Chuck: Holds the drill jig in place, often
Chapter 4: Drilling
self-centering with a three-jaw
Module Objectives: mechanism.
The drilling module covers key aspects of drilling,
• Electric Motor: Typically a single-phase
its parts and functions, and different types.
AC motor running at speeds of 600-5000
Participants learn about various drilling methods,
RPM.
drill bits, and their applications in industries.
• Pulley or Gears: Used for power
transmission, with bevel gears enabling
Drilling Machine 90-degree power transmission.

A drilling machine is a tool used to create Power Transmission in Drilling Machines

cylindrical holes or other shapes in materials such
Power is transmitted from an electric motor using
as metal, wood, or plastic. It is a versatile machine
a V-belt and pulley system. The spindle speed is
with a rotating drill bit designed to penetrate the
adjusted by repositioning the belt on the pulley
material and create holes of specific sizes and
stack.
depths. Drilling machines are widely used in
factories, workshops, construction sites, and
other settings requiring precise and efficient hole-
making. Types of Drilling Machines

Drilling Machine Parts 1. Portable Drilling Machine: Small and

universal, suitable for drilling holes in
• Base: The foundation of the drilling rocks or rigid surfaces.
machine that supports the entire weight
and transfers it to the ground. Typically 2. Sensitive Drilling Machine: Bench-
made of cast iron or steel, it has slots for mounted, allowing precise manual feed
securing larger jobs. control.

• Column or Pillar: Located on one side of 3. Vertical or Pillar Drilling Machine:

the base, it provides support for the arm’s Heavy-duty machine with an adjustable
movement and houses a sliding table for table for large drills.
vertical adjustments.
4. Radial Arm Drilling Machine: Designed
• Upper Arm: Supports the drill head and for large workpieces, with a motorized
driving mechanism, often incorporating a drill head for positioning.
guideway for drill head movement. 5. Gang Type Drilling Machine: Multiple
• Worktable: Mounted on the column, it spindles on a long table for simultaneous
features T-slots and may have a vice. It drilling.
can be adjusted vertically and laterally. 6. Multi-Spindle Drilling Machine: Allows
• Drill Head: Contains feed and driving multiple holes to be drilled
mechanisms, holding the drill chuck and simultaneously with adjustable spindle
allowing vertical movement. distances.

7. Numerical Control (NC) Drilling

• Feed Mechanism: Transfers power from
Machine: Computer-controlled machine
the motor to the spindle using a V-belt
with automatic tool changing for precise
and pulley system. Includes manual and
drilling.
automatic feed options.
Drilling Machine Operations • Feed: The distance a drill moves into the
workpiece per spindle revolution.
• Plain Drilling: Creates circular holes Expressed in inches per revolution.
using a drill bit.
• Cutting Speed: The peripheral speed of
• Core Drilling: Cleans up rough holes the drill, expressed in feet per minute
formed during casting. (fpm).
• Step Drilling: Creates multiple diameters • Capacity: Defined by the maximum drill
in one operation. bit size, spindle travel, and table
• Boring: Enlarges existing holes, though adjustments.
less precise than reaming.

• Reaming: Finishing operation to achieve Work Holding Devices

precise hole size and smoothness.
• Parallels: Raise workpieces to prevent
• Counterboring: Enlarges an existing hole damage.
concentrically with a pilot for alignment.
• V-Blocks: Secure round stock for drilling.
• Countersinking: Creates an angled hole
entrance for screw or rivet heads. • Angle Plates: Assist in drilling parallel
holes.
• Spot Facing: Machines a flat surface
around a hole for proper seating of bolts • T-Bolts: Secure workpieces to the table.
or nuts.
• Straps or Clamps: Securely fasten
workpieces.

Twist Drill and Nomenclature • Step Blocks: Support clamps or straps to

maintain level positioning.
• Twist Drill: The most common drill bit,
usually made of high-speed steel.

• Major Components: Shank, body, and Advantages of Drilling Machines

point.
• Consistent and accurate hole production.
• Key Terms:
• Versatile for a variety of operations.
o Flutes: Helical grooves for chip
removal and coolant flow. • Permanent hole marking for industrial
applications.
o Lips: Cutting edges extending
from the chisel edge to the Disadvantages of Drilling Machines
periphery.
• Limited by hole size and depth
o Web: Central portion joining the constraints.
lands.
• Accuracy dependent on drill bit quality.
o Point Angle: The included angle
• Machine functionality restricted to drilling
between cutting lips.
operations.
o Helix Angle: The angle between
the leading edge of the land and
the drill’s axis. Applications of Drilling Machines

• Metal and woodworking industries.

Drilling Machine Parameters • Fabrication and assembly lines.
 • Manufacturing of machine components. o Motor rotates at 150–15,000
RPM.
• Construction and infrastructure projects.
o Rotational energy is transferred
• Production of automotive and aerospace to the grinding wheel via a v-belt
components. and cone pulley.

o The wheel grinds the workpiece

by abrasion.
CHAPTER 5: GRINDING
IV. Parts of a Grinding Machine
I. Module Objectives
A. Base or Bed
• Understand grinding wheels, their types,
and applications. • Horizontally positioned bottom support.
• Identify the different types and parts of • Acts as a vibration absorber.
grinding machines.
B. Column
• Define and explain the function of wheel
dressing. • Vertical structure housing the abrasive
wheel, wheel head, and wheel guard.
II. Introduction to Grinding
C. Worktable
• Definition: Shaping a workpiece using a
revolving abrasive wheel. • Flat surface where the workpiece is
mounted.
• Applications:
• Holds the workpiece using a magnetic
o Final finishing for close chuck or mechanical clamps.
dimensional accuracy.
D. Wheel Head
o Used on heat-treated, hardened
materials. • Houses the grinding wheel spindle and
supports the worktable.
o Increasing use in heavy-duty
metal removal (abrasive • Adjustable via feed hand for controlling
machining). contact with the workpiece.

III. Grinding Machines E. Grinding or Abrasive Wheel

A. Definition and Function • Rotating component responsible for

grinding.
• Industrial power tool using an abrasive
wheel to remove material. • Composed of bonded abrasive grains.

• Ensures high surface quality, shape F. Crossfeed Handwheel

accuracy, and dimension precision.
• Moves the grinding wheel across the
• Used for machining extremely hard workpiece.
materials.
• Controls vertical and lateral movement.
B. Working Principle
G. Coolant System
• Components: Electric motor, belt, pulley,
grinding wheel. • Maintains optimal temperature during
grinding.
• Operation:
• Removes chips and debris to prevent
overheating.
V. Types of Grinding Machines o Abrasive wheel, chuck (for
workpiece holding), and rotary
A. Major Categories table.
1. Non-Precision Grinding (Rough o Used for hardened and annealed
Grinding) ferrous metals.
o Offhand grinding: Removes metal o Includes a longitudinal slide
without high accuracy. coolant system.
o Used for sharpening tools and 2. Cylindrical Grinders
rough machining.
o Used for shaping external and
2. Precision Grinding internal cylindrical surfaces.
o High-accuracy metal removal. o Types:
o Produces complex shapes with ▪ Plain Cylindrical
tight tolerances. Grinders: Basic
B. Non-Precision Grinders cylindrical grinding.

1. Floor or Bench Grinders ▪ Universal Cylindrical

Grinders: More versatile,
o Small machines used for lab- additional axes.
scale or small workpieces.
▪ Centerless Grinders:
o Example: Sharpening single- No spindle; uses two
point cutting tools for lathes. rotary wheels to hold the
workpiece.
2. Portable Grinders
3. Tool and Cutter Grinders
o Handheld; not fixed in position.
o Uses a CNC tool with up to 5
o Used for cutting tiles and small axes.
workpieces.
o Used for sharpening milling
3. Abrasive Belt Grinders cutters, drills, and step tools.
o Uses an abrasive belt instead of a VI. Grinding Machine Operations
wheel.
A. Surface Grinding
o Tilts 0–90 degrees for versatile
applications. • Workpiece mounted using a magnetic
chuck.
o Equipped with a 6-inch, 60-grit
white grinding wheel. • Grinding wheel moves transversely and
laterally.
4. Swing Frame Grinders
• Types:
o Used for heavy workpieces.
o Planer Type: Rectangular table,
o Stable steel construction,
moves under the wheel.
vibration-free at maximum load.
o Rotary Type: Circular table,
C. Precision Grinders
rotates under the wheel.
1. Surface Grinders
B. Cylindrical Grinding

• Used for cylindrical workpieces.

 • Types: • Different shapes, sizes, and faces
standardized by manufacturers.
o External Cylinder Grinding:
Removes excess material from B. Bonds and Types of Bonds
outer surface.
1. Vitrified Bond (V) – 80% of wheels, strong
o Internal Cylinder Grinding: and porous.
Smooths internal surfaces.
2. Silicate Bond (S) – Uses silicate of soda.
C. Centerless Grinding
3. Shellac Bond (E) – Uses naturally
• High-production method for grinding occurring shellac.
cylindrical surfaces without using a
spindle. 4. Rubber Bond (R) – Vulcanized rubber,
used for cutting operations.
D. Form Grinding
5. Resinoid Bond (B) – Thermosetting resin,
• Grinding wheel matches the exact shape also called organic wheels.
of the final product.
C. Wheel Structure
E. Wet vs. Dry Grinding
• Defines spacing between abrasive grains.
• Wet Grinding: Uses coolant to increase
wheel life and improve finish. • Structure numbers:

o 0–3 (close structure)

• Dry Grinding: No coolant; causes faster
wheel wear and uneven finish. o 4–6 (medium structure)
VII. Abrasives o 7–12 (coarse structure)
A. Definition D. Wheel Grading
• A material that wears away softer • Hardness determined by bond amount.
substances.
• Alphabet letters denote hardness (A =
B. Types of Abrasives soft, Z = hard).
1. Natural Abrasives E. Selection of Grinding Wheels
o Emery and Corundum: Used for • Factors affecting selection:
sharpening tools.
o Material type.
o Diamond: Hardest known
material; costly. o Stock removal requirement.

2. Artificial Abrasives o Accuracy needed.

o Silicon Carbide (C): Harder and o Finish quality.

brittle; used for ceramics,
tungsten carbide. o Contact area between wheel and
workpiece.
o Aluminum Oxide (A): Tougher;
suitable for steel grinding. o Machine type.

VIII. Grinding Wheels • General Rule:

A. Structure and Composition o Hard wheel → soft material.

• Made from aluminum oxide or silicon o Soft wheel → hard material.

carbide. F. Grinding Wheel Speed
 • Fixed in most machines; adjustable in
others.

• Safe speed: 5,000–6,500 surface feet per

minute.

• Formula for speed calculation:

Surface Speed (ft/min)=RPM×Wheel Circu
mference (inches)12\text{Surface Speed
(ft/min)} = \frac{\text{RPM} \times
\text{Wheel Circumference (inches)}}{12}

G. Grinding Wheel Life and Dressing

• Glazing: When dull grains stay on the

wheel, reducing efficiency.

• Dressing: Cleaning or fracturing the

wheel to expose fresh abrasive particles.

• Truing: Reshaping the wheel to run

concentric with the spindle axis.

IX. Coated Abrasives

• Components:

o Flexible backing material (paper,

cloth, rubber).

o Adhesive (glue, resin).

o Abrasive grains.