Grinding Machine

1. Grinding is the most common form of abrasive machining. It is a material cutting process that
engages an abrasive tool whose cutting elements are grains of abrasive material known as grit.
2. These grits are characterized by sharp cutting points (abrasive grains), high hot hardness,
chemical stability and wear resistance. The grits are held together by a suitable bonding material
to give shape of an abrasive tool.
3. Grinding machine is employed to obtain high accuracy along with very high class of surface finish
on the work piece. However, advent of new generation of grinding wheels and grinding
machines, characterized by their rigidity, power and speed enables one to go for high efficiency
deep grinding (often called as abrasive milling) of not only hardened material but also ductile
materials.
Grinding machine, often shortened to Grinder, is any of various power tools or machine
tools used for grinding, which is a type of machiningusing an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear
deformation.

Grinding is used to finish workpieces that must show high surface quality (e.g., low surface
roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in grinding is
of the order of 0.000025 mm, in most applications it tends to be a finishing operation and removes
comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some roughing
applications in which grinding removes high volumes of metal quite rapidly. Thus, grinding is a
diverse field.
Construction:
The grinding machine consists of a bed with a fixture to guide and hold the work piece, and a power-
driven grinding wheel spinning at the required speed. The speed is determined by the wheel’s
diameter and manufacturer’s rating. The grinding head can travel across a fixed work piece, or the
work piece can be moved while the grind head stays in a fixed position.
Fine control of the grinding head or table position is possible using a vernier calibrated hand wheel,
or using the features of numerical controls.
Grinding machines remove material from the work piece by abrasion, which can generate substantial
amounts of heat. To cool the work piece so that it does not overheat and go outside its tolerance,
grinding machines incorporate a coolant. The coolant also benefits the machinist as the heat
generated may cause burns. In high-precision grinding machines (most cylindrical and surface
grinders), the final grinding stages are usually set up so that they remove about 200 nm (less than
1/10000 in) per pass - this generates so little heat that even with no coolant, the temperature rise
is negligible.

Types

These machines include the:

1) Belt grinder, which is usually used as a machining method to process metals and other materials, with the aid
of coated abrasives. Analogous to a belt sander (which itself is often used for wood but sometimes metal). Belt
grinding is a versatile process suitable for all kind of applications, including finishing, deburring, and stock
removal.
2) Bench Grinder, which usually has two wheels of different grain sizes for roughing and finishing operations and
is secured to a workbench or floor stand. Its uses include shaping tool bits or various tools that need to be
made or repaired. Bench grinders are manually operated.

3) Cylindrical Grinder, which includes both the types that use centers and the center less types. A cylindrical
grinder may have multiple grinding wheels. The work piece is rotated and fed past the wheel(s) to form a
cylinder. It is used to make precision rods, tubes, bearing races, bushings, and many other parts.

4) Surface Grinder, which has a head that is lowered to a work piece, which is moved back and forth under the
grinding wheel on a table that typically has a controllable permanent magnet (magnetic chuck) for use with
magnetic stock (especially ferrous stock) but can have a vacuum chuck or other fixture means.

The most common surface grinders have a grinding wheel rotating on a horizontal axis cutting around the
circumference of the grinding wheel. Rotary surface grinders, commonly known as "Blanchard" style grinders, have
a grinding head which rotates the grinding wheel on a vertical axis cutting on the end face of the grinding wheel,
while a table rotates the work piece in the opposite direction underneath.

This type of machine removes large amounts of material and grinds flat surfaces with noted spiral grind marks. It
can also be used to make and sharpen metal stamping die sets, flat shear blades, fixture bases or any flat and
parallel surfaces. Surface grinders can be manually operated or have CNC controls.

5) Tool and cutter Grinder, which usually can perform the minor function of the drill bit grinder, or other
specialist toolroom grinding operations.
6) Jig Grinder, which as the name implies, has a variety of uses when finishing jigs, dies, and fixtures. Its primary
function is in the realm of grinding holes for drill bushings and grinding pins. It can also be used for complex
surface grinding to finish work started on a mill.

7) Gear Grinder, which is usually employed as the final machining process when manufacturing a high-precision
gear. The primary function of these machines is to remove the remaining few thousandths of an inch of
material left by other manufacturing methods (such as gashing or hobbing).

8) Die Grinder, which is a high-speed hand-held rotary tool with a small diameter grinding bit. They are typically
air driven (using compressed air), but can be driven with a small electric motor directly or via a flexible shaft.

9) Angle Grinder, another handheld power tool, often used in fabrication and construction work.

GRINDING (Abrasive Machining)

• Grinding is a surface finishing operation where very thin layer of material is removed in the form of fine dust
particles. (thickness 0.25-0.5mm).

• “Grinding can be defined as a material removal process by the abrasive action between rotating abrasive
wheel & the work piece.”
• Grinding machine is a power operated machine tool where, the work piece is fed against a constantly rotating
abrasive wheel which is also called as Grinding wheel so that a thin layer of material is removed from the
work piece.

PRINCIPLE OF GRINDING

The work piece is fed against a constantly rotating abrasive

wheel so that a thin layer of material is removed from the it.

FIG. GRINDING
 GRINDING WHEEL

Abrasive + Bonding Materials = Grinding wheels.

Abrasives Bonding Grinding
materials wheel
 ABRASIVES

• Abrasives: These are the mineral materials

employed for sharpening, grinding & polishing
operations.
• Abrasives are classified as natural &
artificial.
• Natural Abrasives: Emery, Corundum, Diamond etc,.

• Artificial Abrasives: Silicon Carbide(SiC), Aluminum Oxide(Al2O3), Cubic Boron Nitride(CBN) etc,.
FIG. COATED &MOUNTED ABRASIVE WHEELS
 CLASSIFICATION OF GRINDING
MACHINES

Grinding machines are classified based on their

construction & type of surface produced.

1. Bench Grinding Machine

2. Surface Grinding Machine
3. Cylindrical Grinding Machine
4. Centerless Grinding Machine
5. Internal Grinding Machine
6. Special Purpose Grinding Machine
SURFACE GRINDING MACHINE
Principle: The work piece is fed against a constantly
rotating abrasive wheel so that a thin layer of
material is removed from the it.

Work Piece Type:

Flat,
Angular & Irregular
surfaces
FIG. PRINCIPLE OF SURFACE GRINDING
FIG. SURFACE GRINDING MACHINE
 CYLINDRICAL GRINDING MACHINE
Principle:
The work piece is held between two centers & and the
rotating grinding wheel is fed against it.

External Grinding machine

Work Piece Type:

Cylindrical surfaces may be
straight, curved or contoured.

FIG. PRINCIPLE OF CYLINDRICAL

GRINDING
FIG. CYLINDRICAL GRINDING MACHINE
 CENTERLESS GRINDING MACHINE
Principle: The work piece is placed on work rest blade between two wheels
namely grinding & regulating wheel, which are rotating in clockwise & work
piece rotates counter clockwise. Grinding wheel remove material from W/P
surface & regulating wheel regulates the W/P.

Centerless: Means work piece is not

held between centers.
Work Piece Type: Curved or
Cylindrical surfaces of long slender
rods which cannot be ground on
cylindrical grinding.

FIG. PRINCIPLE OF
CENTERLESS GRINDING
FIG. CENTERLESS GRINDING MACHINE
 REFERENCES

• www.google.com
• www.youtube.com

• A Text Book of Mechanical

Engineering
- K R Gopalkrishna
• Elements of Mechanical
Engineering -M Sreenivasa
Reddy
• Elements of Mechanical
Engineering
- Kestoor Pravin