MANUFACTURING SCIENCE AND TECHNOLOGY-II

(Grinding and Unconventional Machining)

Q1. (a) Giving proper reasons write the wheel specifications for (I) Resinoid bonded SiC hard wheel with
open structure of coarse abrasives (II) Metal bonded soft diamond wheel with high concentration fine grains.
(b) In a certain grinding operation the grade of the grinding wheel should be “M” but the only available wheel is
of grade “T”. How the available wheel can be used to full-fill the requirement?
(c) Explain why (I) the specific energy in grinding is higher than other cutting operations? (II) The same grade
wheel of smaller size would appear to be softer as compared to a large diameter wheel? (III) The thermal
damage during surface grinding of a material using diamond wheel is less than the Al2O3 wheel. (IV) soft
wheels are used for hard materials and hard wheels for soft materials (V) axis of regulating wheel is kept at
some angle to the axis of grinding wheel in case of centreless grinding (VI) larger wheel with high RPM are
more suited for finish grinding

Q2. A wheel of size 152 mm X 20 mm X 10 mm is used in a peripheral surface grinding operation. The
wheel speed and the depth of cut used are 1500 m/min and 0.08 mm respectively. If the number of active grits
per square cm of the wheel surface is 78 and measured cutting force is 176 N then determine number of chips
formed per minute, average volume per chip, surface unevenness and specific energy for grinding.

Q3. In a peripheral surface grinding, the length of the workpiece is 100 mm and its width is 50 mm. The
cross-feed is set at 0.25 mm and depth of cut is 0.1 mm. The frequency of worktable reciprocation is 60 per
minute. Calculate (I) MRR (II) Grinding power if specific energy consumption for the conditions is 30 GJ/m3
(III) Cutting and Thrust force on a wheel of diameter 250 mm rotating at 4000 RPM.

Q4. Estimate the average workpiece surface temperature during dry cylindrical grinding of 30 mm diameter
rod of 10 mm length using a 450 mm X 20 mm Al2O3 grinding wheel at 900 RPM and 0.20 mm depth of cut.
The tangential grinding force is 700 N. What will be percentage change in maximum temperature rise at the
workpiece surface if CBN wheel is used in place of Al2O3 wheel? Take: Thermal conductivity of grinding
wheel and workpiece material is 17 W/m-K and 50 W/m-K, respectively. Thermal diffusivity of grinding wheel
and workpiece material are 8.2 X 10-6 and 1.6 X 10-5 m2/s, respectively.

Q5. A cylindrical workpiece of length 12 m and diameter 100 mm is ground by external centreless grinding
operation using depth of cut of 40 micron and grinding speed 2000 m/min. The grinding wheel dimension is
500 mm X 20 mm and regulating wheel dimension is 300 mm X 15 mm. The angle between the axis of grinding
wheel and regulating wheel is kept 30. FIND (I) RPM of the workpiece (II) Grinding time of the workpiece (III)
Percentage change in RPM of the workpiece and grinding time if RPM of regulating wheel is reduced by 50%.
(IV) MRR (V) Percentage change in feed rate if the angle between the axis of grinding wheel and regulating
wheel is doubled.

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Q6. A 15 mm square cross-section hole of depth 5 mm is made in MS workpiece (melting temperature 1435
o
C) using sinking EDM process with Cu tool and liquid dielectric of strength 106 V/m. The Process is
performed with 15 A current at the IEG of 0.15 mm. The supply voltage of pulsating power supply is 250 V
having pulse frequency of 10 kHz with pulse off time of 40 microsecond. FIND (I) Duty factor of power supply
(II) MRR using Workpiece Melting Temperature Model and Breakdown Average Power Model (III) Time of
machining for the hole using Hemi Spherical Crater Model.

Q7. A 40 mm diameter hole of depth 10 mm is made in HSS workpiece using Sinking EDM process with RC
circuit based pulsating DC power supply. The tool used is brass and dielectric is kerosene. The resistance and
capacitance used in RC circuit are 50 ohm and 15 microfarad, respectively. The supply and discharge voltages
are 220 V and 120 V, respectively. FIND (I) Frequency of sparking (II) Discharge Power (III) MRR (IV)
Surface Finish (V) Time of machining for the required hole.

Q8. A rectangular cross-section through hole of dimension 15 mm X 10 mm is made in an iron plate (Atomic
weight=56, valency=2 and density=7.8 g/cc) of thickness 30 mm using Sinking ECM process at current of
1000 A with 90% current efficiency. Faradays constant is taken as 96500. FIND (I) MRR and Feed Rate if (II)
the time of machining for the hole with 2000 A current (III) percentage change in current if machining time is
reduced by 40% (IV) mass of material removed if 2000 A current is supplied for 30 s.

Q9. An alloy containing 18% Co, 62% Ni and 20% Cr is machined using Sinking ECM process. Assume
Faradays constant as 96500. FIND (I) MRR and Feed Rate with current of 1500 A. (II) Over all density of the
alloy. (III) Charge required to remove all Cr element present in the alloy
The data given in following table can be used for calculations.
Element Gram Atomic Weight Valency of dissolution Density (g/cm3)
Cobalt (Co ) 58.93 2 8.85
Nickel (Ni) 58.71 3 8.90
Chromium (Cr) 51.99 6 7.19

Q10. USM is used to machine a square cross-section hole (5mm X 5mm) in a WC plate (fracture hardness=
6900 N/mm2) up to 4 mm depth. The abrasives used have 1000 mesh number. The average feed force is equal
to 3.5 N. The amplitude of tool oscillations is 25 m and frequency is equal to 20 kHz. Sonotrode used is
copper having fracture hardness equal to 1500 N/mm2. The slurry contains one part of abrasive to four parts of
water. depth of penetration of single grain as 0.0005 mm. Find: (I) Number of grains making impact per cycle
(II) MRR by hammering mechanism (III) Percentage change in machining time when abrasives used is changed
to 500 grit number and slurry concentration to o.5 keeping all other parameters same including grain penetration
(IV) Percentage change in MRR when frequency is increased by 25% and penetration of grain is reduced by 50
% keeping all other conditions same.