Grinding machine and abrasive

 Introduction
 Grinding is a process of removing the wheel on the surface of the work piece material by the
abrasive action of a revolving.

 The wheel used for performing the grinding operation is called a grinding wheel.

 Grinding wheel consists of sharp crystals which are called abrasives held together with the
bonding materials.

 During the grinding process, the material is removed in the form of small chips .

 Machine tool used for providing a good surface finish and high accuracy to the components
by removing the small amount of material with the help of the grinding wheel is called
grinding machine .

 Working principle of grinding machine

 In a grinding machine, the grinding wheel is mounted on the spindle which is driven by an
electric motor.

 During the process a high-speed revolving grinding wheel is brought in contact with the
work piece .

 When the work piece is also revolving is called cylindrical grinder (1 st image) , and in some
of the machines reciprocating is called surface grinders ( 2 nd image ) .
Types of grinding machines

[ 1 ] Rough or Non-Precision grinders

 The main purpose of roughing grinders is to remove more material than that
can be removed by the other types of grinders this class of grinders includes
followings grinding machines .
a) Bench, pedestal or floor grinders
b) Swing frame grinders
c) Portable grinders
d) Belt grinders

[ a ] Bench , pedestal or floor grinders

 These types of grinders are mostly used for Snagging and Off-hand grinding of different
materials and cutting tools in the tool room, foundries, general workshops, etc.
 It consists of a horizontal spindle having grinding wheels mounted at both ends.
 A bench grinder can be easily bolted on a bench at a convenient height. (1 st image)
 The floor or pedestal grinders are nothing but a bench grinder that can be mounted on a
steel stand or pedestal of suitable height.( 2 nd image )
 The working principle of these grinders is similar to bench grinders.
 These grinders are also used for polishing by replacing the grinding wheel with a polishing
wheel .

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[ b ] SwingFrame Grinder
 Swing frame grinders have a 2 to 4 meters long horizontal frame which is freely suspended
at its center .( Pic 1 )
 The frame carries a grinding wheel at one of the ends and a motor at the other end.
 During the operation, to cover the required grinding area the motor revolves the wheel and
the frame is swung by the operator about its suspension point.
 This is used for snagging, particularly for casting that is too large for the operator to hold up
to the wheel.

[ c ] Portable grinder
 Portable grinders are similar to a portable electric drill, in construction and operation.
 The only difference is that the drill spindle carries a drill chuck and the grinder carries the
grinding wheel. ( Pic 2 )
 For safety purpose, a safety guard is provided over the wheel .
 These grinders are widely used for finishing of castings, forgings. Welded joints, removing
burrs and nicks, jigs and fixtures, etc.
 Portable grinders can be of the electric type or pneumatic type.

[ d ] Belt Grinders
 Belt grinders are designed for using an endless abrasive belt for grinding instead of the
regular grinding wheel.The belt runs around the pulleys and the work piece is fed against
the revolving abrasive coated belt.
 Machines are available in various varieties such as wet belts, dry belts, combination
machines, etc.

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[ 2 ] Cylindrical grinders

 Cylindrical grinding involves holding of the work piece rigidly on centres, in a chuck or in a
suitable holding fixture, rotating it about its axis and feeding a revolving grinding wheel
against the same.

 If the work piece is longer than the face width of the grinding wheel, then the work piece
is traversed past the wheel or wheel is traversed past the work piece.

 Traversing of the wheel is done either hydraulically, mechanically or manually.

 When the face width of the wheel is more or equal to the work piece, then traversing of
work piece or wheel is not required and that is called plunge grinding.

 There are three main types of cylindrical grinding machines :

(a) Plain grinders
(b) Universal grinders
(c) Centreless grinder

[ a ] Plain cylindrical grinders

 It consists of two centers i.e. one in the headstock and other in the tailstock and the Work
piece is held between these two centers.
 While operation, the rotating work piece is traversed across the face width of the grinding
wheel.
 The amount of feed of the work piece is equal to the depth of cut.
 Tailstock and headstock both can be moved along the table as per the workpiece
requirement, but generally,
 the headstock center is not disturbed.
 The table is made in two parts i.e. the upper table and the lower table.
 Fig below !

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[ a ] Universal cylindrical grinders
 Universal cylindrical grinder contains all the parts and movements of a plain cylindrical
grinder and some additional features are as follows :
 The headstock spindle may be used alive or dead so that the work can be held and
revolved by chuck and grounded between the centers.
 The headstock can be swivelled in a horizontal plane.
 Its wheel head can be raised or lowered and also swivelled to ± 90° for grinding taper
surfaces having large taper angles.

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[ b ] Centreless Grinders < Picture above >

 The working principle of centreless grinding is different than the center type grinding.

 In centreless grinding, the workpiece is supported by a combination of the grinding

wheel, regulating wheel and a work rest blade.

 Picture shows the principle of centreless grinding which is used for both external and
internal grinding.

 Many hollow cylindrical and tapered work pieces such as bushes, pistons, valves,
tubes, and balls are easily grounded on centreless grinders.

 It contains a heavy base and two-wheel heads i.e. grinding wheel (bigger one) and
regulating wheel (smaller one).

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  Each wheel head carries a separate truing mechanism for the wheel it carries.
 The workpiece rests on the work rest blade between these two wheels.

 The grinding operation is performed by the grinding wheel only whereas; the
regulating wheel provides

 support to the workpiece when it is pushed away by the cutting pressure of the
grinding wheel

 Also, bottom support is provided by the work rest as the workpiece during rotation
rests on the work rest blade.

 Due to this, the work piece remains in contact with the grinding wheel.
 The direction of rotation of the grinding wheel and regulating wheel is the same

 The common methods used for feeding the workpiece are as follows :
a) Through feed
b) linefeed
c) End feed

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