Machine Tools

UNIT-3 B

UNIT-2Straight Motion Mechanism

Dr. M Sandeep Kumar

08/06/2024 B. V. Raju Institute of Technology, Narsapur

1
12 mm
1 mm 1- 0.3 mm DOC
2- 0.3 mm 0.9 mm
3- 0.2 mm

4- 0.15 mm
5- 0.05 mm- final finishing

1. Rough machining
2. Semi machining
3. Finish machining
10 mm
Feeds and Speeds and Surface Finish

Feed
 Feeds and Speeds and Surface Finish
@ constant Speed
Decrease Feed Increase

Good Surface Good MRR

finish
`
 Types of Grinding Machines

1. Rough or Non-Precision grinders

a) Bench, pedestal or floor grinders
b) Swing frame grinders
c) Portable grinders
d) Belt grinders
2. Precision grinders :
i. Cylindrical grinders: iii. Internal grinders:
a) Plain cylindrical grinders a) Plain internal grinders
b) Universal cylindrical grinders b) Universal internal grinders
c) Centre less grinders c) Planetary internal grinders
ii. Surface grinders : d) Centre less internal grinders
d) Reciprocating table iv. Special grinding machines
Horizontal spindle
Vertical spindle
e) Rotary table
Horizontal spindle
Vertical spindle
 1. Rough or Non-Precision grinders

Bench, Pedestal or Floor Grinders

These types of grinders are mostly used for Snagging and Off-hand grinding of
different materials and cutting tools in tool room, foundries, general workshops,
etc.
 Swing Frame Grinder
•Swing frame grinders have 2 to 4 metres long horizontal frame which is freely
suspended at its centre.
•The frame carries a grinding wheel at one of the ends and a motor at the other
end
•During the operation, to cover the required grinding area the motor revolves
the wheel and the frame is swung by the operator about its suspension point.
•The motor drives the grinding wheel by using a belt drive.
•This is used for snagging, particularly for casting that are too large for the
operator to hold up to the wheel.
 Portable Grinders:

•Portable grinders are similar to portable electric drill, in construction and

operation.
•The only difference is that, the drill spindle carries a drill chuck and grinder
carries the grinding wheel.
•For safety purpose, a safety guard is provided over the wheel,
•These grinders are widely used for finishing of castings, forgings. Welded joints,
removing burrs and nicks, jigs and fixtures, etc.
•Portable grinders can be of electric type or pneumatic type.
 Belt Grinders

•Belt grinders are designed for using an endless abrasive belt for grinding
instead of regular grinding wheel.
•The belt runs around the pulleys and the workpiece is fed against the revolving
abrasive coated belt.
•Machines are available in various varieties such as wet belt, dry belt,
combination machines etc
 Cylindrical Grinders
•Cylindrical grinding involves holding of the workpiece rigidly on centres, in
a chuck or in a suitable holding fixture, rotating it about its axis and feeding a
revolving grinding wheel against the same
•If the workpiece is longer than the face width of grinding wheel, then the
workpiece is traversed past the wheel or wheel is traversed past the
workpiece.
•Traversing of wheel is done either
hydraulically, mechanically or manually.
When face width of wheel is more or
equal to the workpiece, then traversing
of workpiece or wheel is not required
and that is called as plunge grinding.
There are three main types of cylindrical grinding machines :
1. Plain grinders 2. Universal grinders 3. Centre less grinder
Plain Cylindrical Grinders
•The amount of feed of the workpiece is equal to the depth of cut.
•Tailstock and headstock both can be moved along the table as per the
workpiece requirement, but generally headstock centre is not disturbed.
•The table is made in two parts i.e. upper table and lower table.
•The upper table contains tailstock, headstock and workpiece.
•Also, the upper table can be swivelled in a horizontal plane up to 10 on either
side, along the circular ways provided on the lower table,
Universal Cylindrical Grinders

•Universal cylindrical grinder contains all the parts and movements of a plain
cylindrical grinder and some additional features are as follows
•The headstock spindle may be used a live or dead, so that the work can be held
and revolved by chuck and grounded between the centers.
•The headstock can be swivelled in a horizontal plane.
•Its wheel head can be raised or lowered and also swivelled to ± 90 for grinding
taper surfaces having large taper angles.
 External Centreless Grinders

•The working principle of centreless grinding is different than the center type
grinding.
•In centreless grinding, the workpiece is supported by a combination of grinding
wheel, regulating wheel and a work rest blade
Advantages:

•In centreless grinding, the need of centering and use of fixtures is totally
avoided.
•This method is applicable for both internal and external grinding,
•The process is continuous and hence, suitable for production work.
•During the operation, the workpiece is rigidly supported and can be subjected to
heavy cuts, resulting in a rapid and economical grinding.
•Large grinding wheels are used hence; errors due to wheel wear are reduced.
Less maintenance of the machine.
•For operating the machine high skilled operators are not required.
•Direct adjustment of sizes can be made which results in higher accuracy

Disadvantages:

•Workpiece having multiple diameters is difficult to handle.

•In hollow workpiece, there is no certainty that the outside diameter will be
concentric with the inside diameter
 Surface Grinders

a) Reciprocating table
Horizontal spindle
Vertical spindle
b) Rotary table
Horizontal spindle
Vertical spindle
 Reciprocating Table Type surface Grinders
•The horizontal spindle machine carries a straight wheel whereas; vertical spindle
machine carries a cup type wheel.
•The cutting action is carried by the periphery of the straight wheel in case of
horizontal spindle machine, whereas on the revolving edge of the cup wheel in
case of vertical spindle machine
•On these machines, the workpiece is generally held on a magnetic chuck.
•These machines are mostly used for grinding flat surfaces

Horizontal
spindle
reciprocating

Vertical spindle reciprocating

 Rotary Table Type Surface Grinders
•ln these machines the workpiece are held on a magnetic chuck and arranged in a
circle
•In both of the machines, the direction of rotation of wheel and table is opposite.
•In horizontal spindle grinder, the cross feed is given by the horizontal
movement of the wheel spindle whereas in vertical spindle grinder it is by
sliding a table on a slide

Horizontal spindle rotary table surface grinder Vertical spindle rotary table surface grinder
 Internal Cylindrical Grinders
a. Plain internal grinders c. Planetary internal grinders

b. Universal internal grinders d. Centreless internal grinders

 Plain Internal Grinders

•It carries an individually driven wheel head mounted on a cross-slide.

•To hold the workpiece, the work head carries either a chuck or face plate, or
sometimes fixture attached a to the work head spindle.
•For grinding the tapered holes, the warhead can be swivelled.
 Universal internal grinder

•Universal internal grinder carries all the similar features of plain internal grinder.
•In addition its work head is mounted on a cross-slide which provides a cross-feed
to the work head.
•Another important feature of universal grinders is that, its work head can be
swivelled through 90.
 Planetary internal Grinders :
•In planetary grinding, workpiece is mounted on a slide and remains stationary.
•The wheel head carries a mechanism, because of which the axis of the rotating
grinding wheel travels along a circular path around the hole axis
•The longitudinal traversing movement can be obtained in following two ways :
•By reciprocating movement of the grinding wheel.
•By moving the slide (forward and backward), on which the workpiece is
mounted.
•Planetary grinders are used to grind holes in large, irregular shaped and hard
workpiece
 Centreless internal Grinders
•The principle of internal centreless grinding is almost similar to external
cylindrical grinding.
•Only the method of supporting the workpiece is different.
•In an internal centreless grinding the workpiece is supported between three
rolls i.e. pressure roll, supporting roll and a regulating wheel
•All the three rolls, rotate in the same direction whereas, workpiece and the
grinding wheel rotate in the opposite direction.
•The grinding wheel remains in contact with the internal surface of the
workpiece at the horizontal centre line of the regulating wheel.
•It ensures a uniform wall thickness of the workpiece and hence, concentricitv
of the grounded internal hole with the external surface of the workpiece.
•For loading and unloading of the workpiece, the pressure roll can be swung to
a side.
 Special Grinding Machines

• Tool and cutter grinders

• Piston grinders
• Tool post grinders
• Camshaft grinders
• Disc grinders
• Thread grinders
 Common Grinding Wheel Shapes

Shape Name Application

Straight Cylindrical, centreless, internal,

cutter, surface and off hand
(Type 1) grinding operations
Cylinder Surface grinding on horizontal and
(Type 2) vertical spindle grinders.

Tapered (both It is primarily used for grinding

sides) thread, gear teeth, etc.
(Type 4)
Recessed Cylindrical, centreless. internal,
(one side) and surface grinders; recess,
(Type 5) provides clearance for mounting ;
the flange
Straight cup Cutter and tool grinder and
(Type 6) surface grinding on vertical and
horizontal spindle machines.
Recessed Cylindrical, centreless and surface
(both sides) grinders; its recess provides
(Type 7) clearance for mounting the flanges

Flaring cup Cutter and tool grinder; it used

(Type 11) mainly for sharpening milling cutters
and reamer.

Dish (Type Cutter and tool grinder its used edge

12) permit it to be used in narrow slots

Saucer (Type It is generally used for sharpening of

13) circular or band saw
Method of specifying or marking of grinding wheel

1. Abrasive
2. Grit or grain size
3. Grade
4. Structure
5. Bond
Soft A B CD E F GH
Medium I J K L M N OP
Hard QR S T U V WX Y Z
Which of the following is a correct range for grain number of the grinding wheel for coarse
grains?
a) 220-600
b) 80-180
c) 30-60
d) 10-24

Which of the following is the correct range for grain number of the grinding wheel for
medium grains?
a) 220-600
b) 80-180
c) 30-60
d) 10-24

Which of the following grinding wheel will give a better result for rough machining?
a) Fine grain
b) Very fine grain
c) Coarse grain
d) None of the mentioned
Which of the following symbol’s range of alphabet represent hard grain in grinding
wheel?
a) D – H
b) I – P
c) A – D
d) Q – Z
Mounting of Grinding Wheel
 Loading and Glazing of Grinding Wheels:

•After continuous usage of grinding wheel, the cutting points of the abrasive
grains become dull.
•They lose their cutting ability, sharpness and are severely worn out.
•Hence the wheel become smooth and a provide a short of rubbing action only,
Instead of cutting the work material.
•The above phenomenon which makes the ineffective for cutting is known as
glazing of grinding wheel.
•It is more predominate in harder wheel at higher speed.
•The grinding wheel affected by this phenomenon is called glazed wheel.
•Another problem associated with grinding wheel during the operation is the
adherence of cut particle of the work material to the face of grinding wheel.
•The open space between the cutting point is lost by these particles.
•Hence sharpness of the cutting point is lost and face become smooth
•This phenomenon is called as loading of wheel and the wheel affected by this is
termed as load wheel
•This effect is mostly observed in those wheel which carry a hard bond when
softer material are ground at slow speed.
•Also high depth of cut contributes towards this effect
 Truing and dressing of Grinding wheel

The truing and dressing operation are perform for following purpose
•To make wheel concentric with its circle
•To make its side true and to recover the lost shape of its face
•To use the full cutting capacity of a grinding wheel which has gone dull or got
clogged with some foreign material

For dressing of grinding wheel following common devices are used :

1. Wheel dressers
2. Abrasive sticks
3. Abrasive wheels
4. Diamond
5. Crush dressing fixtures
Major advantages and applications of grinding
Advantages
Dimensional accuracy
Good surface finish
Good form and locational accuracy applicable to both hardened and
unhardened material

Applications
Surface finishing
Slitting and parting
De-scaling , De-burring
Stock removal (abrasive milling) finishing of flat as well as cylindrical surface
Grinding of tools and cutters and re-sharpening of the same
 Manufacturing Technology
• Finishing Operations
– Lapping
– Buffing
– Honing
– Super finishing
– Wire brushing
– Polishing
– Electro polishing
– Magnetic-field-assisted polishing
 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.
•Cast iron is the mostly used lap material. However, soft steel, copper, brass,
hardwood as well as hardened steel and glass are also used.
 Manufacturing Technology
Characteristics of lapping process:
• Use of loose abrasive between lap and the work piece
• Usually lap and work piece 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 work
piece.
 Manufacturing Technology
• Lapping

Figure (a) Schematic illustration of the lapping process. (b) Production lapping on
flat surfaces.(c) Production lapping on cylindrical surfaces.
 Manufacturing Technology
Polishing
• Polishing is a finishing operation to improve the surface finish by means of a
polishing wheel made of fabrics or leather and rotating at high speed. The abrasive
grains are glued to the outside periphery of the polishing wheel. Polishing operations
are often accomplished manually.
Buffing
• Buffing is a finishing operation similar to polishing, in which abrasive grains are not
glued to the wheel but are contained in a buffing compound that is pressed into the
outside surface of the buffing wheel while it rotates. As in polishing, the abrasive
particles must be periodically replenished.
• As in polishing, buffing is usually done manually, although machines have been
designed to perform the process automatically.
• Buffing wheels are made of discs of linen, cotton, broad cloth and canvas
 Manufacturing Technology
Buffing
 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
 Manufacturing Technology
Honing
• Honing is a finishing process performed by a honing tool, which contains a
set of three to a dozen and more bonded abrasive sticks. The sticks are
equally spaced about the periphery of the honing tool. They are held against
the work surface with controlled light pressure, usually exercised by small
springs.
• The honing tool is given a complex rotational and oscillatory axial motion,
which combine to produce a crosshatched lay pattern of very low surface
roughness

Honing tool
 Manufacturing Technology
Honing
 Manufacturing Technology
• Stone
– Al2O3 or SiC bonded abrasives

• The critical process parameters are:

– Rotation speed

– Oscillation speed

– Length and position of the stroke

– Honing stick pressure

• Parameters that affect material removal rate (MRR) and surface roughness (R) are:
– Unit pressure, p
– Peripheral honing speed, Vc

– Honing time, T
 Manufacturing Technology
Super finishing
• Super finishing is a micro finishing process that produces a controlled
surface condition on parts which is not obtainable by any other method. The
operation which is also called ‘micro stoning’ consist of scrubbing a stone
against a surface to produce a fine quality metal finish.
• The process consists of removing chatter marks and fragmented or smear
metal from the surface of dimensionally finished parts. As much as 0.03 to
0.05 mm of stock can be efficiently removed with some production
applications, the process becomes most economical if the metal removal is
limited to 0.005 mm
 Manufacturing Technology
Super finishing

Figure Schematic illustrations of the super finishing process for a cylindrical part. (a)
Cylindrical mircohoning, (b) Centerless microhoning.