Neel Nadpara

HW# 4
Due: Monday, November 09, 2015
QUALITATIVE PROBLEMS

1. Why does grinding temperature decrease with increasing work speed (Eq. 27.4)?
Does this mean that for a work speed of zero, the temperature is infinite? Explain.
(8 points)
1
1 3
𝑉 2
Equation 26.4: Δ𝑇 ∝ 𝐷 𝑑4 4 (𝑣 )

There are numerous factors that influence grinding temperatures such as depth of cut which has
one of the largest impacts (as the depth of cut increases the grinding temperature does as well.
However, there are numerous other factors such as the work speed. The heat generated during
grinding operations depends on the time of contact between the grinding wheel and the
workpiece. Thus, by increasing the work speed, the contact time can be reduced which leads to
less heat evolution and less heat entering the workpiece (important since heat addition can affect
the material properties of the workpiece) meaning that the grinding temperature decreases. If one
is to just look at the equation, it could seem that for a work speed of zero, the temperature
becomes infinite. However, this is not true since during the grinding operation a certain amount
of material is to be removed (the portion in contact with the grinding wheel) and when this
material is removed there is no longer contact with the workpiece, thus no additional heat would
be generated.

2. Explain the reasons for the large difference between the specific energies involved in
machining versus grinding. (8 points)

The specific energy involved in grinding is significantly higher than that for machining. This is
due to the presence of wear flats (similar to flank wear in traditional machining) that cause high
amounts of friction and large negative rake angles that are generally found in abrasives. The
negative rake angles also affect the formation of the chips during grinding as the chips formed
are required to undergo a larger degree of deformation which requires more energy. Moreover,
since the chips generated during grinding are small, there is greater surface area for frictional
losses per volume of material removed. This phenomenon is deemed the size effect which
effectively means that as the chip becomes smaller, the energy required to produce the chip
increases.

3. Describe the effects of a wear flat on the overall grinding operation. (8 points)

After a certain amount of usage a grinding wheel develops a wear flat this is similar to flank
wear in machining. This is due to the wheel rubbing against the ground surface continuously
causing dissipation of frictional energy which in turn increases the temperature of the operation.
Wear flats are unwanted since they increase the frictional forces at the wheel-workpiece interface
and cause surface damage while offering no positive advantages.

4. Generally, it is recommended that, when grinding hardened steels, the grinding

wheel should be of a relatively soft grade. Explain the reason. (8 points)

Grinding wheels are assigned a grade which is a measure of an abrasive’s bond strength
(hardness) so a hard wheel has a stronger bond and or larger amount of bonding material
between the grains than a soft wheel. Using a soft wheel on hardened steel is recommended due
to the fact that when the wheel develops wear flats during grinding and softer wheels allow for
grains to become dislodged from the wheel. This prevents the damage to the surface of the
workpiece and other adverse effects including burning, heat checking, and the amount of residual
stresses can be controlled. The only issue is that softer wheels wear faster, however due to the
nature of grinding (a very fine finish) this is neglected as long as the quality of the workpiece is
not affected. Furthermore, it is possible for softer wheels to reduce chatter while grinding.

5. We know that grinding can produce a very fine surface finish on a work piece. Is
this necessarily an indication of the quality of a part? Explain. (8 points)

Grinding has the potential to generate a very fine finish on a workpiece; however this alone is
not a mark of quality. Surface finish is a geometric property but surface integrity encompasses
much more in terms of mechanical and metallurgical properties. If the surface is burned it can
affect the mechanical properties of the material depending on how the part cools (quick cooling
can lead to hardening while slow cooling can cause annealing or dendrite formation). Thus,
grinding has the potential to cause many adverse effects on the performance of a part by
affecting its strength, hardness, and fatigue life.

6. If you require a part to be finished after a rough turn on a lathe (typically 500 Ra)
to a ground finish of 32 Ra by what percentage would the cost of the part increase
for the additional grinding operation? (10 pts)

Despite advances such as the use of automation, grinding is a additional operation and thus the
cost of a part should increase significantly due to the extra operation due to there being more
time needed and wear on machine tools (abrasive wheels). From figure 26.37:
Machining cost percent at 32 Ra = 260%

Machining cost percent at 500 Ra = 45%

(Note these are the best approximates that can be made from such a small line lacking gridlines.
Thus, the percent increase in cost is determined by the difference:

𝐶35𝑅𝑎 − 𝐶500𝑅𝑎 = 260% − 45% = 215%

Thus, the cost increases by a factor of 215%.

QUANTITATIVE PROBLEMS

1. Calculate the chip dimensions in surface grinding for the following process
variables: D=15 in., d=0.0015 in., v=100 ft/min, V=6,000 ft/min, C=300 per in2, and
r=20. (15 points)
2. A surface grinding operation is being performed on aluminum part. The wheel is 1”
wide x 12” diameter. N=3,700 RPM, depth of cut (d) = 0.0015”, feed rate (v) = 60
in/min. Use 5.0 hp-min/in3 for specific energy requirements. Calculate the cutting
force (Fc) (tangential) and the thrust force (Ft) (normal) to the wheel. Please box
your answers for MRR, Power, Torque, (Fc) , (Ft) (6 pts each x 5 = 30 pts)
3. From Q1 calculate the RPM of the wheel ( 5 pts)