To study grinding of mild steel and silver

steel and surface roughness produced at

different grinding parameters
#LAB_4
BITS Pilani Presented by: Naveen P T
Pilani Campus
Instructor
OBJECTIVE:- To study grinding of mild steel and silver steel and surface roughness
produced at different grinding parameters

EQUIPMENT:- Cylindrical grinding machine, grinding wheel, mild steel & silver steel rod
dia. 25mm*250mm.

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Grinding Process: basics

Grinding: a material removal process accomplished by abrasive particles that are

contained in a bonded grinding wheel rotating at very high surface speeds.

Grinding wheel: Consists of –

• abrasive particles and
• bonding material

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Grinding Process: facts

• Abrasive grains: irregular shapes and spaced randomly along the periphery of wheel

• Average rake angle of the grains: highly negative, typically – 60° or even less

• Plastic deformation: much larger than they do in other machining processes.

• Cutting action: different radial positions of the grains; not all grains are active

• Surface speeds (i.e., cutting speeds): very high –

✓ Typically, 20 to 30 m/s (4,000 to 6,000 ft/min), and
✓ In high-speed grinding, may be as high as 150 m/s (30,000 ft/min)

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Grinding Process: wheel

Parameters of a grinding wheel:

• Abrasive material: high hardness, wear
resistance, toughness, and friability.

• Grain size: determines surface finish and

material removal rate (small grit sizes produce
better finishes)
• Bonding material: holds the abrasive grains and establishes the shape and structural
integrity of the grinding (strength, toughness, hardness, and temperature resistance)

• Wheel grade: grinding wheel’s bond strength in retaining the abrasive grits during cutting (soft
or hard)

• Wheel structure: relative spacing of the abrasive grains in the wheel (open or dense)
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Grinding Process: wheel

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Grinding Process: mechanisms

Schematic illustration of the surface-grinding process

Mechanism of chip formation

Types of grain action in grinding:

(a) cutting, (b) plowing, and
c) rubbing

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Grinding Process: types

• Surface grinding
• Cylindrical grinding
• Internal Grinding
• Centerless Grinding
• Creep-feed Grinding
• Heavy Stock Removal by Grinding

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Grinding Process: surface finish

Surface finish: The surface finish of the work part is affected by the size of the individual
chips formed during grinding.
• One obvious factor in determining chip size is grit size—smaller grit sizes yield better
finishes.

where v = wheel speed, mm/min (in/min); w = cross-feed, mm (in); and C = grits per
area on the grinding wheel surface, grits/mm2 (grits/in2)

• Surface finish will be improved by increasing the number of chips formed per unit
time on the work surface for a given width w.

• Therefore, increasing v and/or C will improve finish.

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Theory

• This experiment takes into account the effect of mainly three process parameters of
cylindrical grinding process i.e. Wheel Grain size and Depth of cut on Surface
Roughness with reference to Mild Steel & Silver steel. All other process parameters
of cylindrical grinding operation are kept constant.

Chemical Composition of Mild steel Chemical Composition of Silver steel

Fe % C % Si % Mn % P % Fe % C% Si % Mn % Cr % P % S%
98.7 0.17 0.2 0.54 0.16 97.9 1.0 0.3 0.35 0.40 0.02 0.02

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Procedure

1. Do the cylindrical grinding on Mild steel & silver steel rod by using various parameters.
Please follow the below tables.
Table no. 1 for Mild Steel rod & Silver steel rod
Exp. Wheel Spindle Grain Depth of Surface
No. Speed speed size of cut Roughness
(RPM) wheel
(RPM) (mm)
1 0.4
2 0.8
69
3 1.2
4 0.4
5 0.8
2100 137 46
6 1.2
7 0.4
8 0.8
273
9 1.2

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Procedure

2. Use other parameters as constant for all grindings.

3. Use different rods for different parameters.

4. Collect all specimen for measurement.
5. Measure surface roughness on each rod by using Mitutoyo surface roughness tester.

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Practical Demonstration

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