Grinding Machine Project

Machine Tools

Grinding Maching

What is a Grinding machine?

 A grinding machine is a machine tool used for grinding, which is a type of machining
using a moving abrasive wheel, surface or belt as the cutting tool. Each grain of abrasive
on the wheel's surface cuts a small chip from the work piece via shear deformation.
-Google Definitions

Main Types used in Industrial Applications that Require Machining

 Belt Grinder
 Bench Grinder(Pedestal)
 Jig Grinder

Belt Grinder

 A machine which uses a conveyor type motion of a moving belt of abrasive material to
carry out a shaping process of material

Bench Grinder(Pedestal)

 A Bench-top grinder which uses two circular abrasive wheels, affixed to a body via
flanges to carry out the shaping process of material.

Jig Grinder

 A larger machine which uses a abrasive bit to carry out complex machining operations
where the highest degrees of accuracy and finish are required. (Is it the only grinder
mentioned that can machine holes)

Other Types of grinding machines

 Cylindrical Grinder
 Surface Grinder
 Tooth and Cutter Grinder
 Gear Grinder
Main Components of a Typical Grinding machine (Bench Grinder/Belt Grinder/Jig
Grinder)

 Abrasive Wheels ,Belt or Bit (Shaping tool)

 Motor-with connected Rollers (Belt), Connected Flanges (Bench), or Socket Flanges
(Bit)
 Operational controls (device electronics, Start- Stop)
 Body (Frame or Housing)
 Base (Pedestal, Workbench, Stand)

The Abrasive wheel (Grinding Wheel)

 The wheels are generally made from a matrix of coarse particles pressed and
bonded together to form a solid, circular shape, various profiles and cross
sections are available depending on the intended usage for the wheel.
 They may also be made from a solid steel or aluminium disc with particles bonded to the
surface.

The Abrasive Belt

 This is the tool used for shaping in a Belt Grinder. It is similar to sand paper but
differs in its construction and use. It offers the widest surface for grinding of the
three main types and wears the fastest due the thin nature of the belt.

The Abrasive Bit

The abrasive bit carries out grinding operations on a smaller and intricate scale. It is
comprised of a hardened steel or aluminum cylinder which is coated with abrasive
material of differing coarseness. Bits vary in length and thickness.

Characteristics of Abrasive Machining Parts (Wheels, Belts, Bits)

Material
  Aluminum oxide
 Silicon Carbide
 Diamond (Industrial)
 Cubic Boron Nitride

N.B – The material chosen varies with the harness of the material to be machined.

Grain Size

 The sizes range from 8 (coarsest) 600 (finest), determines the physical size of the
abrasive grains . A larger grain will cut freely, allowing fast cutting but poor surface
finish. Ultra-fine grain sizes are for precision finish work.

Adherent Grade (Hardness)

 This ranges  from A (soft) to Z (hard), determines how tightly the bond holds the abrasive.
Grade affects almost all considerations of grinding, such as wheel speed, coolant flow,
maximum and minimum feed rates, and grinding depth.

Grain spacing

 Ranges from 1(Densest) – 16 (Less dense). The less dense wheel will cut freely, it will also be
able to take a deeper cut and has the greatest effect on the finish.

Belt width

 Varies from 1 in to over a foot in width and this allows for larger components to be machined.

Resultant Friction

 The friction caused by the component and the abrasive material can created large amounts of
heat and thus creates a fire hazard. Therefore the susceptibility to heat of the object being
machined must be considered, and the appropriate abrasive material is chosen. To minimize
the problem with heat and friction, Cooling solutions such a water baths and jets are
implemented into the body of the grinding machine.
Types of Grinding Wheels (abrasive wheels)

 Straight wheel
 Cylinder or Ring wheel
 Tapered wheel
 Straight cup
 Dish Cup
 Saucer Wheel
 Diamond wheel
 Cut off Wheel

These Types vary mainly on the shape of the wheel

Water as a coolant is often used in Bench Grinding processes.

Types of Grinding Belts

 Stroke Belt
 Platen Belt
 Wide Belt
 Backsand Belt
 Centreless

These type vary only on the placement of the Belt Rotaries and position.

Water as a coolant is often used in Belt Grinding Processes

Types of Jig Bits

 Wide Pointed bit

 Narrow Pointed Bit
 Tapered Bit
 Wide Blunt (Rounded tip) Bit
 Narrow Blunt (Rounded tip)

The Variations of types of Bits are mainly a factor of the machining process to be carried out

Water as a coolant is often used in Jig Grinding Processes

Motor and operational controls

 In most grinding machines, a typical variable speed, variable set speed or

single speed electric motor is used to supply the rotational motion of the
grinding tool.

The motor may be controlled in the following three ways to supple motion:

 On/Off Switch (Single Speed motor)

 Stop/Start Pedal (Single speed)
 Variable Speed pedal (Variable Speed motor)
 Switchable control speeds (Variable set speed motor)
 Variable speed trigger (Variable speed motor)

The speed of most motors range from around 5000RPM at the slowest to about
20 000 RPM(Bench Grinder and Jig Grinder only)

N.B – Due to the complexity of parts of the Belt grinder, its speeds are very
limited.

Body, Housing and Base

In most industrial application, a cast iron based body or frame is used, due to its
head resistance and weight.

N.B The motion being transmitted in the grinding process results in vibration and
movement of the body or housing. Therefore, the body of the machine is affixed
to the work surface or workshop floor with rubber feet to reduce vibration and
thus stabilize the machine during operation.
Application

The type of grinding machine used depends of the material to be machined. It is

dependent on:

 Shape
 size
 Composition (Make up)
 Level of accuracy or detail intended

N.B - These factors also determine the type of abrasive material used on the
grinding machine.

Operational Safety

The main function of a grinding machine is the deformation and removal of

existing material of the component being grinded. Therefore Debris is a result.

The safe operation of a grinding machine includes:

 Protective eyewear
 Gloves
 Mask (Dust)
 Long sleeved apparel

End of Presentation

Questions?
Images

Types of Grinding machines

Abrasive components