UNIT-V

Abrasive machining processes

 Objectives
 Understand the basic principles of abrasive processes
 Understand the designation of the grinding wheel and the significance of the
various elements of the codes
 Appreciate the different types of grinding machines and their applications
 Understand the grinding process and the variables that affect the operation
 Estimate the time and power required for the grinding operation
 Utilise various types of abrasive processes such as honing and lapping for final
finishing operation

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 Grinding
 Machining materials which are too hard for other machining processes such as tool and die steels and
hardened steel materials,
 Close dimensional accuracy of the order of 0.3 to 0.5 m, and
 High degree of surface smoothness such as Ra = 0.15 to 1.25 m.
 Specific energy of grinding  50 J/mm3
 Specific energy of other processes  2 to 5 J/mm3

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Grinding machines

Surface Grinder
Belt Grinder
Grinding Wheel Designation and Selection

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 Abrasive types
 Aluminium oxide (Al2O3),
 Silicon Carbide (SiC),
 Cubic Boron Nitride (CBN), and
 Diamond

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 Grain size

 Grade
 Hard
 Soft

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Structure

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Type of bond
 Bond
 Vitrified
 Silicate
 Synthetic resin
 Rubber
 Shellac, and
 Metal

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 Wheel Balancing
 In view of the high rotational speeds used, any residual
unbalance left would be harmful for the machine part and
also produces poor surface finish.
 Static balancing
 Dynamic balancing

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 Dressing and Truing
 Loading
 Glazing
 Dressing
 A simple dressing is done by means of small steel disks, which
are free to rotate at the end of a stick.
 To obtain a true surface of the grind wheel in terms of either the
form or concentricity can be achieved with the help of a diamond
dressing tool.

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 Types of Grinding Machines
 Cylindrical grinding for generating cylindrical surfaces
 Surface grinding for generating flat surfaces, and
 Centre less grinding for generating axi-symmetric
shapes.
 Tool and cutter grinder machine

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Cylindrical Grinding machine
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 Surface Grinding
 Horizontal spindle and rotating table
 Vertical spindle and rotating table
 Horizontal spindle and reciprocating table
 Vertical spindle and reciprocating table

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Horizontal spindle and reciprocating table
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Vertical spindle and reciprocating table
 Centre less Grinding
 Centreless grinding makes it possible to grind cylindrical
workpieces without actually fixing the workpice using
centres or a chuck. As a result, no work rotation is
separately provided.
 External centerless grinding
i. Through feed centre less grinding
ii. In feed centre less grinding
iii. End feed centre less grinding
 Internal centerless grinding

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 Through feed Centre less Grinding
 The process consists of two wheels, one large grinding wheel and
another smaller regulating wheel. The work is held on a work-rest
blade. The regulating wheel is mounted at angle to the plane of the
grinding wheel.
 The centre of the workpiece is slightly above the centre of the
grinding wheel. The workpiece supported by the rest blade and
held against the regulating wheel by grinding force.
 As a result, the work rotates at the same surface speed as that of
the regulating wheel. The regulating wheel is generally a rubber or
resinoid-bonded wheel with a wide face.
 The axial feed of the workpiece is controlled by the angle of tilt of
the regulating wheel. Typical work speeds are about 10 to 50
m/min.
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 In feed centreless grinding
 The grinding is done only by plunge feedings so that any
form surface could be produced. This is useful if the
workpiece has an obstruction, which will not allow it to be
traversed past the grinding wheel. The obstruction could
be a shoulder, head, round form, etc. The workpiece will
be loaded into the machine, while the work-rest blade
and the the regulating wheel are drawn.
 End feed centreless grinding shown in fig.9.12c,
where tapered workpieces can be machined.

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 Advantages of Centre less Grinding
 There is no need for having and maintaining centres and centre
holes.
 Workpieces can be loaded and unloaded from the machine rapidly.
 Backing up the workpiece by the regulating wheel and work rest
blade practically eliminates any deflection of the workpiece.
 Minimum wear is observed in view of the large grinding wheels
used. This will maximises the periods of time between wheel
dressings.
 Workpieces may often be loaded into the machine by the
automatic feeding devices.

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 Limitations of centreless grinding
 Set-up time for a centreless grinding operation is usually
large.
 This process is useful only for large volume production. It
may be necessary to have special equipment and
additional set-up time for special profiles.
 This process is not suitable for large workpiece sizes.

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 Internal Centre-less Grinding
 It is also possible to apply centre-less grinding for internal
surfaces as well. However in this case the workpiece need to
be supported by two support rolls.
 The main advantage of the process is that the ground hole
will be concentric with the outside diameter of the work.
 The process is capable of grinding straight cylindrical or
tapered holes.
 These holes can be blind, through, interrupted, or even with a
shoulder.

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 Creep Feed Grinding
 In creep feed grinding the entire depth of cut is completed in one pass only using
very small in feed rates.
 High depth of cut of the order of 1 to 30 mm with low work speeds of the order of 1
to 0.025 m/min.
 Idle time (stopping and wheel/table reversal) gets reduced since the grinding
operation is completed in one pass.

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 Creep Feed Grinding
 The cutting forces and consequently the power required increases
in the case of creep feed grinding, but has a favourable G-ratio.
 Use soft and open wheels to take care of the wheel dressing and
accommodate large volume of chips generated in the process.
 The grinding fluids used are oil based in view of the low grinding
speeds employed.

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 Grinding Process parameters
 Wheel speed
 Work speed (in case of cylindrical grinding)
 Traverse feed of the wheel
 In feed, and
 Area of contact.

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 Honing
 Correction of geometrical accuracy
 Out of roundness
 Taper
 Axial distortion
 Dimensional accuracy

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 Honing Conditions
Work Hardness Abrasive Grade Grain size for a Surface
material finish, m
BHN 0.01 0.025 0.3 0.4

Steel 200 - 300 Al2O3 R 600 500 400 320

330 - 470 O 600 500 400 320
50 - 65 RC J 500 400 320 280
Cast iron 200 - 470 SiC Q 500 400 280 280
50 -65 RC SiC J 400 280 220 150
Aluminium SiC R 600 500 400 320
Copper 120 - 140 SiC R 600 500 400 320
180 - 200 SiC R 600 500 400 320

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 Lapping
 Lapping is generally the final finishing operation done
with loose abrasive grains.
 Extreme accuracy of dimension
 Correction of minor imperfection of shape
 Refinement of surface finish
 Close fit between mating surfaces

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Tool and cutter Grinder
 Super Finishing
 Super finishing is another abrasive process utilising either
a bonded abrasive like honing for cylindrical surfaces or a
cup wheel for flat surfaces.
 Removing surface fragmentation.
 Reduce surface stresses and burns and thus restore
surface integrity.
 Correct inequalities in geometry.

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 Summary
 Grinding is a process utilising bonded abrasives to remove material
from very hard surfaces, and in the process generate good surface
finish and high dimensional accuracy.
 It is also inefficient in material removal consuming more energy
compared to other processes such as milling.
 Grinding wheel is characterised by the type of abrasive used, as
well as its size, bond used and structure.
 Conventional abrasives such as aluminium oxide and silicon carbide
are more commonly used for a majority of grinding operations.
Cubic boron nitride and diamond are more expensive and hence
are used for special applications.

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 Summary
 Grinding wheel need to be properly balanced before operation. Also
dressing and truing are the necessary operations carried on the
grinding wheel to keep it sharp as well as have the necessary form.
 Cylindrical grinding machine is used for axi-symmetric
components, while surface grinders are used for plane surfaces.
Surface grinding machines have both horizontal axis as well as
vertical axis.
 Centre less grinding machines are used for large volume
manufacture to get very accuracies and faster operation.

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 Summary
 Creep feed grinding is an operation used for large material
compared to the conventional grinding operation by using soft
grinding wheels and large depths of cut.
 Honing is an operation using abrasive sticks to develop very high
finish for inside cylindrical surfaces.
 Lapping is an operation used to generate extremely high surface
finish on flat surfaces using loose abrasive.

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 References

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