Arab Academy for Science, Technology,

and Maritime Transport

Material Removal Processes (IM 213)

Department of Industrial & Management Engineering

College of Engineering and Technology

Lecture 7: Grinding
Abrasive Machining
 Abrasive machining is a machining process where
material is removed from a workpiece using a
multitude of small abrasive particles.
 Common examples include grinding, honing, and
polishing.
 Abrasive processes are usually expensive, but
capable of tighter tolerances and better surface
finish than other machining processes.
 Machining by Abrasion

Grinding
Finishing

Honing
Surface Lapping
Cylindrical Polishing
Superfinishing
Grinding Wheel

Voids
Wheel speed
Bond

Abrasives

Workpiece

Feed
Grinding Wheel
 Abrasive Materials
1. Aluminum Oxide (Al2O3)
2. Silicon Carbide (SiC)

3. Boron Carbide B4C

4. Boron Nitride (CBN)
5. Diamond
 Grain Size

 Coarse: 10, 12, 14, 16, 20, 24

 Medium: 30, 36, 46, 56, 60
 Fine: 70, 80, 90, 100, 150, 180,
200, 220, 240, 280, 320, 400, 500,
600
Wheel Bond
 The wheel bond keeps the abrasive grains together under the action of the grinding forces.
 Wheel Bond
 Types of Wheel Bond:
 Vitrified (V)
 Resinoid (B)
 Silicate (S)
 Rubber (R)
 Shellac (E)
 Oxychloride (O)
 Metal
 Wheel Grade (Hardness)

 Very soft: C, D, E, F, and G

 Soft: H, I, J, K
 Medium: L, M, N, O
 Hard: P, Q, R, S
 Very hard: T, U, V, X, Y, Z

 Soft grades are, generally, used for machining

hard materials

 Hard wheels are used for soft materials

 Wheel Structure
 Open structure wheels are used for high
material removal rates and consequently
produce a rough surface finish.
 Dense structures are used for precision form
grinding operations.

Very compact: 1, 2
Compact: 3, 4
Semi-compact: 5, 6
Porous: 7, 8
Very porous: 9, 10
Extra porous 11 to 15
 Wheel Marking

A 54 M 5 V
Abrasive Grain size Grade Structure Bond
type
Wheel Shapes
 Wheels Selection
The selection of a grinding wheel for a particular operation depends on:-
 Material to be machined.
 Accuracy and surface finish.
 Machining variables.
 Grinding machine condition.
Wheel Balancing
 Truing and Dressing
Grinding wheel

Tool holder

3o – 15o

Tool holder

30o

Grinding wheel
 Truing and Dressing

 Dressing clears the cutting surface of the

wheel of any dull grits, and embedded swarf
in order to improve the cutting action.

 Truing is employed to remove material from

the cutting surface to bring the wheel to the
required geometric shape. It also restores the
cutting action of a worn wheel as in the case
of dressing
Grinding Operations
 Some of the grinding operations are:
 Surface grinding
 Straight cylindrical external grinding
 Plunge cylindrical external grinding
 Internal cylindrical grinding
1-Surface Grinding

bg

dg

St vg

vw
e

bw l
2- Straight External
Cylindrical Grinding

Grinding wheel

ag

dg, vg

St dw, vw

Workpiece
 3-Plunge Cylindrical External
Grinding
Grinding wheel

Infeed dg, vg

dw, vw

Workpiece
 4- Internal Cylindrical Grinding
vw

St

ag

l Workpiece

Grinding wheel