Approximate specific Energy Requirements for Surface Grinding.

Work piece Hardness Specific Energy

Material w.s/mm3 hp.min/in3
Aluminum 150 HB 7-27 2.5-10
Cast iron (class 40) 215 HB 12-60 4.5-22
Low carbon 110 HB 14-68 5-25
steel(1020)
Titanium 300 HB 16-55 6-20
Tool steel(TIS) 67 HRC 18-82 6.5-30

Example: Calculation of forces in surface grinding

Assume that you are performing a surface grinding operation on a low-carbon steel
with a wheel of diameter D =10 in. and rotating at N=4000rpm and a width of cut
w=1in. depth of cut d=0.002 in. and the feed rate v of the work piece is 60 in. /min.
Calculate the running force (force tangential to the wheel) Fc and the thrust force
Fn (normal to the work piece surface)

Solution:

We first determine the MRR, as follows:

MRR=dwv= (0.0020(1)(60)=0.12 in3 /min

The Power assumed is given by

Power = u (MRR)

For the low-carbon steel, let us estimate it to be 15hp.min/in3. Hence,

Power= (15)(0.12)= 1.8 hp

By noting that 1 hp=33000 ft.lb/min=39600 in. lb/min, we obtain

Power = (1.8)(396000)= 712 800 in.lb/min

Since power is defined as

Power = Tw ; where T is the torque and is equal to

T=(Fc)(D/2) and w is the rotational speed of the wheel in radians per minute,
hence w=2 .

712800= Fc (10/2)(2)( )(4000) and therefore, Fc=57 lb

The thrust force Fn can be calculated by noting from experimental data in the
technical literature that it is about 30% higher than the cutting force Fc ,
consequently
 Fn= (1.3)(57)=74 lb

Surface Grinding

Undeformed chip length l

l= ; where D= diameter

d= depth (wheel depth of cut)

Undeforned chip thickness t

t= ;

where V= tangential velocity

v= velocity

C= number of cutting points (per unit area)

r= ratio of chip width to average undeformed
thickness

Grain Force (Tangential force on the wheel)

Grain Force ( ) strength of the material

Forces in the Surface Grinding

MRR= dwv ; where w=width

d= depth of cut

v= feed rate of workpiece

Power= u (MRR); where u=specific energy

 Power = Tw ; where T= (Fc)(D/2)

w=2

Surface Temperature

Temperature rise D1/4 d3/4 ( )1/2

Grinding Ratio

G=