Question 1

a)Define term grinding

- Grinding is a process of removing material by abrasive action of a revolving
wheel on the surface of a workpiece in order to bring it to required shape and
size.
Advantages of grinding:
 Dimensional accuracy
 Good surface finish
 Good form and locational accuracy
 Applicable to both hardened and unhardened material
b)Describe and sketch the basic element of grinding wheel features

 Work piece material: shape, hardness, stiffness, thermal and chemical

properties
 Grinding machine: type, control system, accuracy, stiffness, temperature
stability, vibrations
 Kinematics: the geometry and motion between grinding wheel and motion
 Grinding wheel: abrasive, grain size, bond, structure, hardness, speed,
stiffness, thermal and chemical properties
 Dressing conditions: type of tool, speed and feed, cooling, lubrication and
maintenance.
 Grinding fluid: flow rate, velocity, pressure, physical, chemical and thermal
properties
C) Reasons why there such a wide variety of types, shape, and size of
grinding wheel
 Grinding wheel is a wheel composed of an abrasive and wide variety of
shapes used for various grinding and abrasive machining operation.
 Various types and size are available depending on the intended usage for the
wheel.
 Life span of grinding wheel can be different depending on the use case.
 Generally, soft abrasive material is required to machining hard and brittle
material.
D) Define following marking on the grinding wheel
55 - C - 120 - E - 3 - R – 28
55 - Manufacturer symbol
C - Abrasive type ( silicon carbide)* klau A- aluminium oxide
120 -Abrasive grain size(fine)
E -Grade(soft)* (A,B,C,….K-soft), (L,M,N,..W-medium), (X,Y,Z-hard)
3 -Structure (1sampai 5-dense) (6 keatas Open)
R -Bond type (rubber)
28 -Manufacturers record

Grinding wheel- what is abrasive and bond

 Abrasive: it is that material of grinding wheel which does the cutting action
- Abrasive is a hard, tough substance containing many sharp projecting
cutting edges or points
- the most important properties of abrasives is hardness.
 Bond is the substance that acts as a binder to hold the abrasive grains together
Types of grinding wheel
Question 2
a) Generally, it is recommended that, in grinding hardened steels, the
grinding be wheel of a relatively soft grade. Explain the statement.
- Hard, brittle materials generally require a wheel with fine grit size and softer
grade. Hard material resists the penetration of abrasive grains and cause them to
dull quickly.
- The combination of finer grit and softer grade lets abrasive grains break away
as they become dull, exposing fresh, sharp cutting, avoid vibration and chatter
occur.
- To avoid loading or glazing wheel occur.
- Keep the temperature low and improve surface finish.
b) Explain why speeds are much higher in grinding than in machining
operation.
- Because the grinding wheel removes small chips of material at a time, the
wheel speed must increase to maintain a reasonable production throughout. There
is no detrimental effect of higher wheel speed unless it causes the wheel to
exceed allowable internal stresses and fail and fly apart.

b) Compute the undeformed chip, l and thickness, t for the following

parameter; let D=300mm, d=0.030mm, v=40m/min, and v=1800m/mm.
Assuming that c= 1 per 𝒎𝒎𝟐 and r=30. Formula are given as following.
d) Define the following terms;
I. Grinding ratio
- Is a measure of grinding production and reflects the amount of work a
wheel can do during its life.

II. Truing
- Is the process of making a grinding wheel round and concentric with the
grinding wheel spindle axis truing is also the process of forming a
specific shape of face of the wheel.
III. Dressing
- Is the process of conditioning the surface of a trued wheel to expose the
grains for efficient and grinding action.
IV. Attritions wear
- Is undesirable leads to the grains dulling by developing flat spots and
rounded edges on the wheel which can affect the wheel ability to remove
material.

V. Glazing
- It is the condition of the grinding wheel in which the cutting edges or the
face of the wheel takes a glass-like appearance. Glazing takes place if
the wheel is rotated at very high speeds and is made with harder bonds.
Rotating the wheel at lesser speeds and using soft bonds are the
remedies. The glazed wheels are dressed to have fresh, sharp cutting
edges.
VI. Loading
- The wheel is loaded if the particles of the metal being ground adhere to
the wheel. The openings or pores of the wheel face are filled up with the
metal. It is caused by grinding a softer material or by using a very hard
bonded wheels and running it very slowly. It may also take place if very
deep cuts are taken by not using the right type of coolant.
Question 3
A) identify 6 types of grinding operations (6m)
1) Surface grinding
2) Cylindrical grinding
3) Internal grinding
4) Centerless grinding
5) Creep-feed grinding
6) Heavy stock removal by grinding

b) Discuss the difference at centerless grinding and cylindrical grinding (6m)

Cylindrical
-Capable of grinding rolls with
large diameter.
-Can produce shape in which the
wheel is dressed to the workpiece
form.
-Workpiece spindle speed is
synchronized between the
workpiece and the wheel axis.
c) In the term of creep-feed grinding, discuss 2 of its advantage.
Centerless
-A high production process for
continuously grinding cylindrical
surface.
-Workpiece is supported by a
blade.
-Parts with variable diameters.

Grinding wheel Groove

Workpiece

-Grinding can be used for large scale metal removal operation to compete with
milling, broaching and planning.
Advantage:
-in creep-feed grinding, the wheel depth of cut, d is small and the workpiece
speed is low.
-to keep workpiece temperature low and improve surface finish, the wheel is
softer grade resin bonded and have an open structure.
d) Discuss 4 differences between grinding and hard turning.
1) Dimensional tolerances and surface finish in hard turning approaching to
those obtained with grinding.
2) Turning requires much less energy than grinding.
3) Cutting fluid not necessary and the machine tools are less expensive.
4)Work holding devices for large and slender workpiece for hard turning is a
problem.

Question 4
(a) Summarize four(4) effects of vibration on the workpiece.
 The major effect is poor surface finish
 Create noise and rigidity problem on workpiece
 Chatter marks are proof for the effect of the vibration on the workpiece
 Dimensional accuracy of job also effected
 Consume excessive power consumption
(b) Justify 4 factors could contribute to chatter in grinding
 Non- uniformities on the grinding wheel
 Uneven wheel wear
 Poor dressing technique
 Using grinding wheels that are not balanced properly
 High material removal rate

(c)Summarized 6 safety precautions that need to be followed in grinding

operation
 Parts should be designed so that they can be mounted securely
 Interrupted surface should be avoided as they can cause vibrations and
chatter
 Parts for cylindrical grinding should be balanced
 Short pieces should be avoided as they may be difficult to grind
 Design kept simple to avoid frequent form dressing of the wheel
 Holes should avoided

(d) Discuss 2 ways to reduce the tendency of chatter in grinding

 Using soft grade wheel
 Dressing the wheel frequently
 Changing dressing technique
 Reducing the material removal rate
Question 5
(a) Define the following terms and give 2 examples of each
i. Natural abrasive
 Is a hard material found in the earth and it used to shape other material
by grinding.
 Example sand stone and diamond
ii. Artificial abrasive
- These are material manufactured under controlled conditions in closed
electric furnaces in order to avoid the introduction of impurities and to
achieve the necessary temp for chemical motion to take place
- Example silicon carbide and aluminum oxide

(b) Explain the 6 characteristic of each type of bond used in bonded

abrasive
i. Vitrified bond
- Good strength and high porosity
ii. Silicate bond
- Waterproof, used for large diameter wheels. Grinding of fine edge tool
iii. Shellac bond
- Thin wheels, high elasticity, not suitable for heavy duty application
iv. Resinoid bond
- Rough grinding, high speed grinding
v. Rubber bond
- Thin wheels, fine finishing and polishing e.g. ball bearing races
vi. Oxychloride bond
- Disc grinders, less brittle

(c) Give 1 example of application for course and fine abrasive

- Course – rapid material removal workpiece
- Fine abrasive – for very high surface finish, grinding hard material