— GRINDING AND OTHER ABRASIVE PROCESSES INTRODUCTION : The functional requirement of many components demand quality of working surface that cannot be produced by the usual machining. Good surface finish and dimensional accuracy are complementary, and can be obtained by abrasive processes. Abrasive process involves material removal by the cutting action of abrasive grains. In grinding abrasive wheel (grinding wheel) is rotated against the workpiece at high speed. Each sharp edge of a grain cuts a material in the form of small chips (swarf). It is regarded as finishing process as the metal removal rate is low. The other abrasive processés which provide better finish than grinding are honing, lapping, superfinishing, polishing and buffing. Differences between grinding other machining processes : There are significant differences between grinding and other machining processes. 1. Cutting tool for grinding is the grinding wheel which is made of small abrasive grains with sharp cutting edges. Each grain will acts as 2 -uiting tool. - The abrasive grains in grinding wheel are randomly oriented and possess very low rake angle (mostly negative rake angle). . A grinding wheel is self-sharpening as the dull grains either fracture to create fresh cutting edge or are pulled out of the wheel surface to expose new grains. 4. In grinding metal removal rate is very low, and is used as finishing process. High dimensional accuracy (0.3 to 0.5 um), and high degree of surface finish (R, = 0.15 to 1.25 pm) can be achieved. 5. Cutting speeds in grinding are much higher. 6. Very had materials can be machined by grinding. WORKING PRINCIPLE OF GRINDING MACHINE : 10 < In grinding process the workpiece is brought into contact with revolving grinding wheel. abrasive grain will acts as an individual cutting tool and removes the metal in the form of small chips. In doing so the grains became dull, the pressure and heat created between wheel and the workpiece causes the dull face to break away leaving new sharp cutting edges or dull grains turn out of the bond to expose new cutting grains, Hence, grinding wheel has a self- sharpening action. Fig. 10.1.2 shows the cutting action of the abrasive grain. Each {Chapter-10)310 ue f+) Ga ee Fig. 10.1.2: Cuving Acton of Abrasive Orin Fig. 10.1.1 Make-p of Grinding Wheel Purpose of Grinding : The main purposes of grinding are 1) to bring the component to size ; the dimensior 0.3t0.0.5 um curacy is In the order of 8) to obtain good surface finish inthe order of R, = 0.15 to 1.25 um, 0 machine very hard materials such as hardened steel, tool and die steels 10.3 ADVANTAGES AND LIMITATIONS OF GRINDING : ‘The main advantages of grinding are * The surface finish obtained is superior to that of any other machine tool ‘one of the most dimensionally accurate machining processes nd is also + Hardened components can be {even impossible for other machi + Grinding req ined by grinding, which would be difficulty or ol. very little pressure permitting its use on light and delicate parts However, it has the following disadvantages. + Wotk sure + Wheel chatter and vibrat the same dimensions. agets overheated, tions result inaccuracies, and duplicate pieces do not have * Grinding isnot suitable as a machining process where high metal removals required, 10.4 ABRASIVES : In modern industry, the use of abs with close tlerences and good surface finish following characteristics, {apt t4 0) id Other Abrasive Processes ——__ larder than ma ‘retains sharp culling edges at grinding temperature be capable to break when the e (0 workpiece. This abi yes is termed as fi 10.4.1 Types of Abrasives 4) Sand stone ch Corundurn 1,03) id quarte), emery, corundum and diamond, land cannot be used for grinding harder materials. Emery and }uminium oxides, and have @ greater hardness and better abrasive Diamond is one ofthe best natural abrasives but, due to high cost is use 1a cemented carbides, glass, marbles and gamets abrasives lack uni have baen almost totaly replaced by art land contain « high percentage of imp ‘abrasives They on nitride and manufactured diamond, SiC end Al,O, ace most widely used for grinding s. Theie characteristics are discussed below. Silicon carbide (it acovered in 1891) i manulacared nan lei inducion fra ‘The mince consisting of 82 par slic sand and 9 lurnace 12 pats of saw dusts aed to produce por shed produc 2 pars of tridd to assist in eroving the impure, The retuling SC then th ait and altalleso remove any emaning pure. The abrasives oe tnd graded tsi I's manfactured under de names of Carborundum, Cece, lecroton ots denoted by © There are two types of silicon carbide abrasives Green grit abrasives Black grit abrasives Green grit contains 97% SIC and mainly ured or cemented eis sect Black grt contains 95% SIG This ade: bu weer than gee cable sued for grinding cst Mon minum, cope befor grinding ceramics ee312 eras cutting and Machine Too! Engineering Aluminium oxide (first made in 1893) is man furnace. The furnace ish sic 1891 | 2200-2800 | 1500 - 2000 41,0; | 1893 | 1600-2100 | 1700 - 2400 10.8 BOND MATERIALS : ‘must be capable of holding grains in the moulded wheel sh and tebond, 4.Resinoid bond, 5. Rubber bond, and 6. Onychloride bond, 1. Vitrified bond : cr feldspar. This clay and water is the mixture is moulded to form the whet then baked in develop structural strength. As the burning in that holds the grains together. The wheels are then ished to size, inspected for dimensional accuracy baked at high temperatures they can 'ed uring grinding process. The bond is used in about 75% ied bond is denoted by ‘V". (© raptert9p— and high temperature gen of the wheels manufactured. Vit ied wheels are generally op erated at 1950 m/min oF below. The: impact ength, They cannot be used uhere the ate bond : Silicate bond is made fom grains, The mixture is moulded 1 wheel shan baked in furnace at a emperatre ‘of 260°C for several days. A silicate bond is denoted ate soda and is mixed with abr sensitive to shock, I snot strong 9s rasive grains more readi a bond : In shellac bond, abrasives in a heated container and is shaps baked at 150°C for several hours 1c wheels are compare and considerable stren possess « high degree of safety which mates them valuable for oper ing olf hae 1g thin wheel. The other applications of sheline wheels includes sharpening of sas, knives and fetlling of castings, Shellac wheels are not sultable for heavy duty, and wh produced 1m synthetic resins [bake "esin seis end holds the abrasive grains together. A resinoid bonded wheel Resinoid wheels are more flexible and can run at high speeds (2900 mi ‘bond wheels. They can remove stock rapidly. They are used for tabes and for the work needing a very high surlace finish ikely to be softened prolonged exposure to ingot operations. They produce high surface aces, Hubber bonded wheel car also be used ot regulatng whos in Sees34 ey ‘They generate more strength of bond deere the grains. Therefore, cu ting and Machine Too! Engineoring 6. Oxychloride bond : The oxychloride bonded wheels are made from oxide and chloride of magnesium. They are mixed with abrasive gains in the same way as for vitrified bond. An ‘oxychloride bonded wheel is designated by "0" Onychloride bonded wheels are than any other bond These wheels are suitable for dise grinders 10.6 GRIT, GRADE AND STRUCTURE OF WHEELS : Grit, Grade and Structure are important characteristics of grinding wheel. The meaning of these tetms are given below the size of abrasive grains. They are graded for size by passing them ite size of mesh. The according to the [Grain Type ‘size or Grit Coarse S10 1214 1620 2a Medium 30 36 46 54 60 Fine 70 80 100 120 150 18¢ Very fine 220 240 280 320 400 500 600 ‘rains required for grinding wheels depends on the following ‘The sie of the abrasive factors of finishing desired : Fine grains are used for producing smooth and being machined : Coarse grains are gene! ine grains for hard materials, + The amount of material to be removed : Coarse ‘amount of materials to be removed and surface finish is not important tended for soft are used where large shel and the workpiece : For wider area of used. (nape $9} us iates the degree of hardn nd the harciness wath whch the bond ve hardness of the abrasive material tn nding operation wees workpiece ring grinding tends to disrupt and distort the surface of the work. ish. After machining or grinding, some components undergo to improve accuracy and surface finish. Such operations include lapping, polishing, burnishing ete surface finish and to obtain small t between two mating surfaces. ‘The process is extensively used for the finishing of gauge blocks and fats. Lapping consists of ru abrasive part mostly used Graphite in the cast =e cut on lp suface and i n charged by spreading and pressing The lapping pressure is generally kept in the range of 0.01 - 0.2 Nimm?. The surface roughness obtained in this process is in the order of 0.08 to 0.4 um. ‘The lapping can be done by hand or by machine. In hand lapping either lap or the work is held by hand and a relative motion is produced ‘between them. The: the smooth surfaces finish. This method is employed for and valve seats ‘Machine lapping is pertorm« Many components like races of parts are finished by machine Finished surfaces in mass produetion. ‘and worm gears and various automobile + Due to low temperature, there is no metallurgical changes in the work materials. ‘+ The process is sultable for any materials, and can be used for finishing flat or cylindrical surfaces and holes. Disadvantages : + The process is very slow and metal removal rate is low. Machining allowance for lapping is taken to be 0.005 to 0.02 mm. + Hand lapping requires high operation skills. + Process cost is high and should not be recommended unless very accurate surface is ‘absolutely necessary,Motel Cutting and Machine Too! Engineering For honing, the honé stationary, and the metal ‘upon the work material, honing speed 19 of 1 to 3 Nimm?. Surface roughness be obtained + Removes considerable amounts of material and ind ani ‘and more accurate than somal ving. Fig, 10.37 () Superfnishing