Grinding

A study of Grinding Process and forces

M.E 407 Lab Lectures Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

GRINDING
A type of abrasive machining process
which involve material removal by the action of abrasive particles. Abrasive particles are:
Small in size Hard and brittle Sharp edges Irregular shapes
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

GRINDING
Generally used as FINISHING operation
A last and final operation performed on previously machined or manufactured part. Grinding removes very small amount of material from the surface of work piece.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Grinding Symbols on drawing

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Grinding Symbols on drawing

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

GRINDING MEDIA AND ITS SHAPES

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

GRINDING WHEEL
Abrasives particles (many cutting teeth) are bounded with the bonding material in a DISK like shape .
Wheel is precisely balanced for rotation speed The rotating grinding wheel (cutting tool) is fed relative to the work piece (similar to Milling process) to accomplish the material removal.
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Abrasive Materials
Must have
High hardness
High wear resistance High Toughness High friability

Common Used Abrasive materials are:

Aluminum Oxide (Al2O3) Silicon Carbide (SiC) Cubic Boron Nitride (CBN) Diamond

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Abrasive Grit Size

Size of an abrasive particle is identified by grain size number or Grit Size.

Small grit size has larger grain size. For example

10 grit size is very rough or coarse 100 grit size is fine 500 grit size is very fine

Smaller grit size remove large amount of material Harder work piece needs small grit size
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Abrasive Bounding
Bounding material holds the abrasive grains and establishes the shape and structural integrity of grinding wheel. Bounding material must include high
strength Toughness Hardness Temperature resistance

Bounding materials
Vetrified Bond Silicate Bond Rubber bond Resinoid Bond Shellac Bond Metallic Bond
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Wheel Structure and Grade

In addition to the abrasive grains and bond material, grinding wheels contains air gaps or pores. Wheel structure refers to the relative spacing of the abrasive grains in the wheel. The structure of the bonded abrasive ranges from Dense to Open.

The wheel grade indicates the grinding wheels bond strength in retaining abrasive grits during cutting. The grade of bonded abrasive ranges from Soft to Hard.
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Marking System of Grinding Wheels

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Grinding Wheels shapes and varieties

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Grinding Wheels shapes and varieties

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

GRINDING MACHINES

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Surface Grinders

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

External Cylindrical Grinders

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Internal cylindrical Grinders

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Center less Grinder

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Tool and cutter Grinders

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Profile Grinders

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Lab Experiment on Grinding

Objectives: I. To become familiar with the surface-grinding machine, grinding wheel designation, and the mechanics of grinding and process variables. 2. To study the effect surface grinding process variables (a) Wheel depth of cut, d. (b) The table feed velocity , v. on cutting force (Fc) and Trust Force (Ft) And surface roughness
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Lab Experiment on Grinding

Ft

Fc

Table Speed, V

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Design of Experiment
Table : Surface Grinding Process

No

Depth of Cut d (mm)

Table Feed v (m/s)

Cutting Force Fc
(N)

Thrust Force Ft (N)

Roughness Microns

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Experimental setup

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Experimental setup

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Safety
Grinding machines are used daily in a machine shop. To avoid injuries follow the safety precautions listed below. Wear goggles for all grinding machine operations. Check grinding wheels for cracks before mounting. Never operate grinding wheels at speeds in excess of the recommended speed. Never adjust the workpiece or work mounting devices when the machine is operating
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Safety
Do not exceed recommended depth of cut for the grinding wheel or machine. Remove workpiece from grinding wheel before turning machine off. Use proper wheel guards on all grinding machines.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Report writing for Grinding

1. Cover Page 2. Objectives of Experiment 3. List of Equipment and tooling 4. A brief procedure of experiment (step by step) 5. Complete the Table provided in the lab. 6. Plot Ra vs table speed (v) and depth of cut (d) on separate paper. 7. Plot Fc (Cutting Force) and Ft (Thrust Force) vs table speed (v) on the same graph paper 8. Plot Fc (Cutting Force) and Ft (Thrust Force) vs depth of cut (d) on the same graph paper 9. What uses can you have for these plots?

10. 11.

Discussion of the Results Conclusions and Comments

Conclude your report with the remarks, What you learned from the experiment and any further improvement in the experiment.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh