1 7.1 Grinding Process ZL Dofluition Grinding moans to proas and break nomothing into very m Te in tamed Lo make wo) powilor bots, all pleco or into hing sharp oF am I Woy: rubbing two hard aurficot or on # special mnck it on a rough hird surfaeo, It enn bo done gonorally torlnls, IL enn bo divited in two parts. a all (1) Rough or Non Provision Grinding @) Procision Grinding Q) Rough Grinding + Rough grinding ia nwod to remove nw much we mate »portant, [tenn be ured to-eut off piecon of n matorinl thot aren't nocenan, a terin| e@ I na pornible, ompecially whom tho fing of the surface ia not very Tt ean bo used in claining of casting, to remove fash of forged jab, ta remove oxcenn odge from wold or to romove corrosion. In thia type shagging: or off hand grinding: pracann in involve (2) Precision Grinding + Precising grinding ia n form of grinding thnt focuses on nceurney and. is used acroun m divone wo n particuly range of induatrios. It is used to remove small amount of matorial in ardar to ach finish or tight toloranee dimensions on part surfaces, Based on tho surface produced on the job it ean bo brondly classified a : ) Cylindrical Grinding (a) Surface Grinding @) Form or Profile Grinding (©) Controloss Grinding (e) Plunge Cut Grinding (a) Surfacc Grinding : 7 The different types of surface grinding process i grinding the grinding wheel is rotated about ita axis. While the wor machine table and two other types of feed are given which are called cross—feed (parallel to the width of the work) and pluge feed (parallel to the depth of the work). Generally surface grinding is used to obtain flat surfaces but by special arrangements it can be used to grind tapered surface shown in fig. 7.1. In cach typo of aurfac is rotated with the help oft— o curnia wonar Fig 7.1 Surfaco Grinding Ty Burfice grinding with varlieal axin of spindla ith herizontal ypindle ()) Surface grinding (Surface grinding with round tabla & vortienl spindle (@ Surface grinding with round tnble & horizontal spindle (0) Surface grinding with Jongitudinal table and horizontal axix of the spindle (b) Cylindrical Grinding + ‘Tho external and internal iylindsienl grinding operations aro shown in fig. 7.2, In external grinding the warkpices ia held in betwean two ecentrea for grinding fat & tapered surfaces. ‘The intornal flat & tapered rinding of cylindrical surfaces in done by fixing & rotating the work in a chuck, (c) Contreless Grinding : fe) xTeRIUL CYUNORIEAL GRNOING (8) INTERNAL GTUNDRICAL, GRINDING Fig, 7.2 Cylindrical Grinding jm mass production. In contre less grinding, the work is supported by the grinding wheel, Regulating or feed wheel and work-rest. ‘Therefore fixture is th the wheels are rotated in the same direction Tot required for the work in centreless grinding. Bo ‘tdifloront speed, so that required motion can be provided to the work by keeping the small regulating Wheel slightly slopping & running it at lesser speed than grinding wheel. The work is pressed by ‘heed shoe! towards the grinding wheel for removal af the metal. After completion of the oe This grinding operation is generally usedManufacturing Enginocrings ion, tho work is pushod out by tho uso of push-out arrangomont, Tho two LyPow oF conta. Tinding ave shown in fig. 7) $$$ REGULATING GRINDING WHEEL, wie lap ta INTERNAL CENTRELESS GRINDING: EXTERNAL CENTRELESS GRINDING Fig. 7.8 Controless Grinding (a) Form or Profile Grinding : ‘This is a type of precision grinding, Tho required profilo and special contour can be obtained ‘by this operations, @) Form Grinding + ‘Tw form grinding operation opposite profile on the grinding wheel is used in comparison ts the requicéd profile of tho work. Only cross-feed is given to the wheel during the operation, The wheel is pulled back after removal of desived amount of material (rom the workpiece. Desired profile can be genernted by this operation on genr teeth, thrends & spline shafts. Gi) Profile Grinding : Tn this type of grinding the wheel used is not having any opposite profile to the required profile, ‘The wheel is provided combined longitudinal & cross feed to obtain the desired profile on the work piece, The profile grinding is used when number of workpiceos are less, Work profile is: complicated 80 that it is difficult. to generate opposite profile on the wheel and is costly. This operation is shown in Gg. TAQ). “ae 1 (3) PROMLE GsmKoees () PLUNGE Chimps ig. 14 Profile Grinding & Plunge Grinding —=er s—~SYS;Grinding Proconson 107 rs (o) Phango Cut Grinding + jon the width of the whool Ln geontor than or equal to tho length wloeklod food rato townrde the work mm whower in Ube fig ob in obtained! than the wheol in pulled bnek, Por achieving, unlforat jad upto 3 men in longitulinn) direction, Due to Uhik movement HM compared Lo tho traverne grinding whown in fig. 7.200), rally adopted for highor f In thin typo of grinding ope of the work, Phe whoot in pushed at p l(b), Whon eoquirod abve of U avony on tho wheal the work in Jour neritehion veo loft on the jurti whieh in the gronter bonofit of thin operation, Phung eut grinding in production, Example of plunge ent grinding tthe gelsding of enn mba ala Cutting Action of Grinding Whoot and Baste Working Principle + Fy Grindlingt, the convontionnl eulting took in reploeed by amall wiz wbranive toali whoww cutting glomonti ave of mbranive runtorints, ‘The abrasives urod for this purposo have high rowistanea to wort and -hont and porwox luego bardnens, ‘tho abrasives aro in dha form of wmall geulan that are held fogothor by monns of bonding matorint to form a nhaped tool. The geinding tools wre in the form of whools, A magnofied view of n grinding wheol and ite cutting nection ix whown in fig. 7.6, projecting nenine of the ubrnaive material neo hold femly by the bond. ‘Tho grains during rotntion af the wheol vomove very thin chips whase | Fi. 7.6 Cutting Operation ! cross-section is similar to that obtnined in milling. For this operation of Grinding Wheel high whee! apeoda re nornully employed which is upta 75 mm/sec. Aw the section of the chip romovedL ducing the process is small and high cutting speeds are involved, this operntion results into very good surfinco finish nnd high aecurney. ‘The cdgos of nbensive particles are becoming inuctive speedily, but due to the self sharpening nection, it is not necessary to resharpen the wheel frequently. The quality & neeneney obtnined by this process is mainly dopends on the following fnetors : 1. ‘The type of product motal 2 ‘The type of Grinding wheel ‘The type and condition of Grinding Machine 4. ‘The process parameters like a. Tho speed of Grinding wheel v. Tho feed of the job c, ‘The depth of cut 5. Personal reasons like skill of the operator The above discussion revenls that tho following threo elements aro invelved in the grinding proves, : 1. Product : Whose shape and physical dimensions are as per their requirement. 2. Grinding wheel: Its selection is based upon type of grinding process and product 3, Grinding machine ; Its selection is based upon required accuracy plus the shape & size of the product,158 turing Engineering The special features of grinding process are us follows + Operation is intermittent in nature, Tt produces discontinuous chips, The grain geometry is highly random. ‘The time of contact between chip & an abrasive grain is very small. Grinding wheel has 2 self sharpening character. The load acting om individual greins is) non-uniform. Grinding is associated with high specific cutting energy as compared to conventional cutting eperations. @ The rapid grain wear occurs due to high temperature encountered in the range of 10.0%, = 1400eC. &. The effective eke angle of abrasive grains is highly negative. 1G, The grinding anion is highly dependent cpon the characteristics of the grinding wheel 7.12 Balancing of The Grinding Wheel : ‘The balancing of the wheel is checked during his inepemice sage #0 thet the wheel can rotate ichos: jocks and beve gaol aotec of the whed wh the job sorlace, Tele ingen sage ces be stleved ts the new, roe dresaed wheels ct echable feservel of ime. Tee whee! fs scatically belemocd during thes tent. As shown ia Be 78, Hangee, sleeve and mbeel to be belated are fastened on a special mye of mands, This aveonbly is then milled on special ype of stand made from bars or by place oe the pollers, Whee the contre of gravis of the wheel occupies lower: position, the wheel *Z beers mestiomary on the stand In the Lange of large wheel recesses are cut to place counter bales weigizs for talencing the wheel Balaccng cf the whee! with the belp of balance weights can be doce 28 dewribed below. A. Firet place the central weight et maximum height é place remaining both at sides with the baelp of grab screme 2. Slightly push the heel wo that & starts to roll dwn on the bara. When weight come dows, the wheel will booms steady. 2. Now slowly shift tath side weights & arrange the wheel so that it remain steady in any potition, Ie sheild remain steady even when it is pushed. Fix such wheel on the grindicz machine and make it true, : ‘When the wheel is used, its diameter reduces and ite balancing is disrupted. Hence frequent balancing of the wheel ix wo Le dune during its usage. This way we brings the common C.G. f the wheel & flanges og the axis around which the wheel rotates. In this tert wheel balance stax4 PPP Pe Pe | | = 78 Balancing of The Grinding Wkedl |Grinding Processes: 159 ioe Beil lo ee de mandrel are required, In some machine facility is provided to balance the wheel when it is rtating. In this arrangement weight are given with the machine spindle. As per modern practice manufacturer ‘sre providing the wheels having diameter 251 mm and less in duly halaneed condition. Hence no balancing is required when the wheel is new. The wheel which pass through the above test are mounted by the following mothed, which is aloo shown in fig. 7.7. J. Clean the machine spindle, wheel hole & Mange. 2. Place the washer having size equal tm the size of flange and made from bloting paper, which prevents the damage to the wheel and distribute the clamping foree equally on the wheel. i 3. Place the wheel on the spindle by passing the spindle through the wheel hale. Take care that the wheel should move easily on the spindle towards the flange, Clean the outside flange & place it on the spindle, Slowly tighten the spindle aut with the help of reg. Do not tight the aut firmly, because strain is induced in the wheel due to that the chances of wheel breakage increases , For doing the above work, following are ta be remembered for the wheel. ‘ 1. Do not allow the wheel to fall down. t 2 Do not rotate the wheel on its edges. 3 3. Stack the wheels with care to prevent damages to it, ; 4 Do not place toals or material on the wheel. i 5, Always keep the wheels in dry atmosphere to protect them from moisture, which affects / their efficiency. 7.4 Mounting of Grinding Wheel : For safe and satisfactory operation of the grinding steel, it is necessary to mount the wheel properly on winding machine. The bearing is at one side of machine, makes replacement of wheel easy. Wheel is fastened by using flanges, Washer, bush & screw, The details of which can be obtained from IS : 1991 : 1973. (1) Visual Inspection : Fig. 7.7 Mounting of Grinding Wheel During the visual inspection stage it is ascertain that the wheel is free from crack and cut oH fragment, Because these defects increases the chances of wheel breakage during its operation, which can cause the damage to the operator, job or the machine.ee te Fig. 7 Striking Location for The Sound Tose ‘The Wheel for Sound Test (2) Sound Test : In this inspection stage grinding heel is held on a rod as shown in fig. 7.8. Then the is striked by wooden hammer or ecrew driver handle of dierent ples by rotating it by 4. time as shown in fig, 7.9. Striking produces the sound, If the sound produced is metailig J cracks internal holes ete. When dull sound pry than the wheel is free from defects like internal 8 @ on striking than we can say that the grinding wheel i# defective, 7.2 Grinding Machines (Construction and Classification) : 71.2.1 Construction and Classification + Grinding machines are classified as per the type of surface generated or work done eq, “4 Grinding Machines —_i—- L ¢ Cylindrical grinders Surface grinders Tool & cutter grinders Floor stand & bench grinders Portable or exible shaft grinders ee 1 2. 3, Swing frame grinders 4, Abrasive belt grinders ‘The rough grinders are used when the material removal is the main objective. When main objective is to obtain accurate dimension & quality surface, the precision grinders are used. (1) Bench and Pedastal Grinders : ‘The bench grinder is mounted on a base or pedastal as shown in fig, 7.10, It has » horizontal spindle with grinding wheels uouelly at both ends. The one wheel out of the two wheels ia hard grade wheel and other is a soft grade wheel. Spindle is driven by the electric motor. Spocial grinders Fig, 7.10 Bench and Pedastal GrindeeGrinding Processes 181 ——_—_— The complete machine is supported by @ rigid base. The reste are provided to support the workpiece and the wheel is covered for the purpose of safety. In certain construction, the grinding wheels are directly fixed on the motor spindle, hence they are called bench grinders. In certain construction, the motor is supported on a square piller, such grinders are called pedastal grinders. Working Principle = When motor is connected to electrical supply, it starts rotating at high speed. Therefore the wheels on its spindle are rotating. When the workpiece supported on rest is pressed against the wheel by hand, the grinding action is caused between rotating wheel and stationary work-piece. Due to the grinding action, the metal removal take place. Application = Generally bench grinder is used for snagging operation and off hand grinding of tools and variety of work-pieces. 2) Portable and Flexible Grinder : As shown in fig. 7.11 the grinding wheel is directly attached on the motor spindle. The overall volume of this machine is smaller than other grinders, hence it is called a portable grinder. When the construction of machine is such that its shaft is flexible & grinding wheel is attached on its end, than it is ealled a flexible shaft grinder. It is shown in fig. 7.12, Such grinders can easily be shifted from one place to the | pig 7.11 Portable Grinder another. Working Principle : Grinding wheel is rotated by the electric motor connected with the electric power source. The material is removed by way of grinding by pressing the grinding wheel on the work with the help af a handle provided nearby the wheel. Application : ‘The product which is large or heavy or of complex shape are found by this gtinding machines. (8) Swing Frame Grinder : In the swing frame grinder as shown in fig. 7.18, a frame of 2 to 8 metre length is suspended at its centre of gravity, sa that it can be shifted around in the work area for grinding, At the one ond of this frame a large grinding wheel towards the worker is attached and a weight is fixed at the another end, which prevents the wheel from touching tho floor till it is used by the worker, This wheel can be used by auspending it with the help of 8 gib-erane, ME-II_Eng / 21 | 2023\ 462 Manufacturing Encineeingy Working Principle + ‘The material can be removed by grinding action by pressing the wheel on the work. The why: is rotating in relation to machine axis, Application : Portable & flexible grinders are mainly used for (4) Cylindrical Grinder + |A line diagram of cylindrical grinders is shown in fig. 7.14. These machines are complex ang heavy in their construction. The main types of cylindrical grinders are as under, 1. Plain Cylindrical Grinder 2. Centre-less Grinder 8, Universal cylindrical Grinder eging of castings. (6) BCTERNAL CYUNDRICAL GRONDER (b) INTERNAL CYLINDRICAL GRINDER Fig. 7.14 Cylindrical Grinder Tach of the above cylindrical grinders are having (1) Work head (2) Work head spindle () Turning & feed mechaniam and (4) work holding device as their main parts. Sometimes an arrangement for auto-feed is also included in thelr construction, @ Plain Cylindrical Grindes Constructional Feature ‘This is a production machine, Its base is a main casting & it support all other parts of the machine. Table ie generally made in two parts. Upper table provides the cupport to the head stock, tail atock and workpiece, while lower table is provided on guide—way's and it provides the longitudinal traverse to the upper table, Its different motions are manual or automatic. Grinding wheel is provided on the wheel head, arranged on guide-ways, As per the aurface ground by the machine, itis divided inte two types. 1, External grinders by which flat cylindrical, tapered, fillets Ii ground external aurfaces of the work parallel to the axis. geometrical shapes are 2. Internal grinders by which the cylindrical and tapered surfaces are ground inside the workpiece called internal surfaces. *Grinding Processes 163 a Working Principle ‘The workpiece is held firmly between the two centres. Sometime fixtures are used to hold the workpiece. The wheel rotating at high speed about its axis is provided feed towards the work- piece. By processing the wheel on the work, the grinding action takes place, which is called abrasive cutting action removes the material from the work eurface. The other required motions are obtained with the help of mechanism arranged in the machine. It is used to ground geometrical surfaces to the required size of the workpiece symmetrical to the axis. Grinding the shaft, roller, ring gauge, pin, sleeve etc. to desired sizes are the examples of workpieces ground on this machine. # Universal Cylindrical Grinder : ‘This machine differs from the plain cylindrical grinders due to the following points but their remaining construction details are same. (1) Head-stock is provided with swivel mechanism, hence it can be swivelled by + 80° angle in horizontal plane. (2) Its upper table can be swivelled by small angle with respect to vertical axis, hence lengthy tapered surfaces can be obtained. + = Centreless Grinder : Constructional Features : In the construction of this machine bed, wheel head, wheel housing, wheel rest, regulating wheel and two slides are included. Bed supports the remaining parts. The upper slide is made of wheel drive and wheel truing unit, while the other slide is gripping the work-rest and upper-slide. Slides are attached on swivel plate. The axial movement of the workpiece is obtained by keeping regulating wheel slightly inclined. WORKPIECE ‘eel? (@) THROUGH FEED, 1 Fe Fig, 7.16 Methods of Centreless Grinding Working Principle Working principles of external & internal centreless grindings are same. The material removed by abrasive cutting action by grinding wheel supported by regulating wheel and by providing support+ & Mantacturlng Enginetiog, piece Thi p ean be 1 feos ax shown in fig 7.16 eof the work rest €2) te feed and ¢3) Applieation + This machine is used Lo ge time & centering Hime is saved du piston, val cal cylindrical & tapered eurtocen, ety, tos that this machine can bo used in mans production 19 progey cylinders. *® = Surface Grinder Constructional Features t of base, table, whcel head and mechanism 8 the workpiece and pi carta the mechnnistn providian. verte} table mavement & spindle mx machine con be divides Baateally all surface genders are mn motion ts wheel & workpiece in desired dl feed. Wheel head provides joer to the gra & crass moewment to the wheel, As p os typer of surface grinders are shown a fig. 716 into four types TH | | | | @ aw SPINOLE. RECEIPROCATING (0) VoRned, SPNOLE RECOPROCATING TYPE SURFACE GRINDER TARE TRE SURFACE CANDOR Fig. 7.16 Surface Grinders Horiznatal spindle, reciprocating table 1 2 Horirontal spindle, retary table 4. Vertical spindle, rotary table 4. Vertical apindle, reciprocating table Working Principle : By holding workpiece on table, by the surface or perimeter of rotating grinding wheel, materia! can be removed by the abrasive grinding action is used in surface grinders. Application : This machine is used to ground flat eurfaors and somotimes irregular, convex & concave curved surfsoes, mainly usod in the tool rom. Splineshaft, Bar, Flat & Piston rings can be ground +f jt.fipeolal Geindorn : Hume of the grinders dre demgned far specific work ‘They arm yivesi nase including the nase uf work for whieh they are mount, Some of the special yrinders are ax wwtler 1 Tonk & cutter grinders 2 Porm grinders 8 Holl grantor 4 Crunkestut grinders 5 Cam grinders 6 Way grinders 7 Thread grindorn Toul & Cutter Grinds: joa in design of this type of grinders are seen. Hut each design is meant to carryout tail stock, work holding deviow, table, base and ta shown In fig. 7.17. Special Many va the aume work, Their design ini fottachments The construction of toad & cutter geil « achieved by using different © Diagram of Tool & Cutter Grinder 1 Gear milling cutter grinding attachment Reamer rehef grinding attachment 4 Twist drills grinding attachment 4 Eni relieve dise cutter attachment 8 Radius truing attachment . Application : For sharpening the cutting ediea of milling cutters, roamers, drilla ete. then tools & cutters become bhint.¥ aren WD) Crank-Shalt Grinder + Arkeally this is one type of cplindreal grinder, in which the principle fl plang-eat inks, in used. His weed to groaned the crank shafted Automshile engines, Aircraft engines, €291 enya an cemmgreseces (8) Camm Grinder ¢ Ti is epoca tye of oylindral grinder aud fur grinding the cama of the cam-sied, Fhe bod stock de tail stocks are eu arranged that they can cecillate, A shorthand, harden rps, is provided om ite head stack This templet rvtates with the wurk and moves Oppcstie to Seto Workpiece slowly rotates between centres a3 uly which cxotinuwmsly oscillates the head oz cacTintes. AT mamemerts in this machine ix automatic G) Piston Grinder : ‘The pistons of Righwpeed LC. engines are act completely oplindrical but they are elie asd sometioes kept slightly tapered. Piston grinder bas 2 mechanism, automatically operated thas pivcan atarnetely come suarer & away from the grinding wheel to cbsain its ellipsleal shy Proving the satee the plston is mozved sloaly away from its longitadinal movement +o tha: requ taper s2 alte sktsined. (5) Boll Grinder < Te eomparisen to other grinders this machine is very large, heavy and te grind Bigger roe, shade, spindles eee Doe to is rigility, the surface quality chtain oa wc which table can be moved and risating wie semain eiationary. On this 22 rol-dsive end attachneat sopporting rlls are provided. Sa actives ace waed io grocad scal diemeter rolls having shorter length. Other trpe of cactan are csed Sor barge size rolls In th rell-drive, roll supporting device and comaz provided co bed wy move the rjaticg wheel are provided. A combering mechanism is used ec ol gender, wk the fly of it eternal and imercel roll profiles in required oontour & acemay = beet id. They are eg (6) Way Grinder = | Te fs aisle osed to ground bed ways of machines. Way cesed i= this grinder are of oxp, ring and sermented types. i ‘Wheels ace fined on vertical spindle. Way grinder is provided | wh an ermngemens fer tiking the wheel spindle. How machine | | @ Porm Grinder : — To chtain excoth and accurate surface of the filler, Fig. 7.18 Way Grinder wend, Eregular shaye, thread etc. by the form grinder or profile grinder. In fact it is the sc cplindrical, internal or special grinding machine but the wheel used on it is made of required = grinders are very lerge in size and heavy. The grinding wheels i= fi 3 ted-ways ate preond is shown fiz. 7.18. t ‘Thruad grinding & gear grisding is also the types of form grinding.‘This is the process like thread milling. Aw angalar thread grvmes are formed on the grinding’ the process of forming wed wanaratiog tyes, ally viteifiad bond & wheel containitg skrat OP) grits are used for thread winding. Special type of grinding machine ia required for thread pote. Tee types of thread grinding: are L Transverse grinding 2% Plange-cut grinding () Transverse Grinding = Whee! ia arranged on foll thread, depth and work fs | | passed or traverse on the rotating grinding wheel. Table | | is comerolled by the master lead-serew. Change- | t | i t aren: pars ere chosen ea per the pitch of the thread. First thread yom Tanase ef the wheel is grounded more due to maximum metal is | pip c19 (ay 7, eel pecred fom it Remaining thread carcyoat Ginishing work | Grinding @) Plange-cut Grinding : Wheel is introduced upto the full depth of theead ints | He work. When work completes one revolution, wheel advances pisb distance, so that its wear is uniform. This process i suiteble for short length. Thread grinding can be done on tard & soft work and as it cuts threada on solid work surface, eds are not discorted after hardening. * OiHand Grinding : It is the non-precision grinding done on bench & floor mods! tool grinder. The grinding of 3H chiesel, centre-puneh, Lathe and shaper tool-bits are grounded by holding them in hand Some ‘Ss work grinding device is also used. Advantages & Disadvantages of Grinding : * Advantages : Follewing advantages of grinding can be obtained by combine effort of proper machine, suitable Feckg wheel & skilled cperator. 1 Best accuracy 2% Close tolerances %. Rapid production. Over & above this @ Grinding of hard or soft material can be done b. Broad range of workpisce shape & size can be included ©& Cylindrical tapered workpiece can be ground speedily, accurately and at low cost in comparison to the turning operation. Fig. 7.19 (b) Plunge-cm Threed Grinding 1Manufactu 9 Engine in comparicon to the beri Holea can be made easily & speedily by drilling in cast iron & rough alloy-steel. & There are less scratch mark left in flat surfaces produced by grinding, Disadvantages ; Ita metal removal rate is vory low. Grinding is mainly a finishing process. Rigid condition of machine is necessary. Grinding operation needa spocific type of skill, ‘Teuing & dressing facility required for wheels that become out of ahape. "Use of fixture is necessary. Large quantity of coolant is required. Special care and safety level is to be maintained. per finishing operation is to be used in mae SRA Ree eee The process is not complete & final, a 7.2.2 Basic Specification : Specification of Surface Grinding Machine : (1) Maximum Table Size (mm) 2) Maximum Longitudinal Travel (mm) (3) Maximum Cross ‘Transverse (mm) () Maximum Spindle Centre height (above table) (mm) (@) Maximum Table Speed (m/min) (6) Power Corse Transverse (m/min) (1) Verticle Feed Head Lonst Count (mm) (8) Size of Grinding Wheel (mm) () Spindle Motor Power (HP or kW (10) Grinding Sindle Speed (rpm) (41) Chuck or without Chuck (12) Maximum Weight of Job (13) Operating System 7.2.3 Methods of Mounting Workpiece on Cylindrical Grinding Machines (Including Chett and Mandrel) : _ Chucking type cylindrical grinders are uscd to grind external dinmetera on workpieces whi! are relatively short, having no centre holes and no convenient surface for driving. ‘Tho work ba! © of the chucking grinder includes a rotnting spindle on which chuck ig mounted. When the machi?| Grinding Processes 169 GN OC jg provided with an automatic chuck and leadera, it becomes an extremely productive grinding machine. If the length of the job in more, the job can be supported hy a centre at the tail stock end. The roundness of the job ground on a chucking grinder in inherently limited by the quality of the workhead spindle bearings. Work holding on a Cylindrical Grinder : 1. In eylindrical grinding, the workpiece ia held between contees and ia rotated on its axis as shown in fig. 7.20. 2, Whenever possible the work head (head- stock) centre should be kept dead. The reason being that the centre can be ground in place and because it saves wear and tear on the spindle, Fig. 7.20 Work Between Centres 3, Long slender work in addition to being hold by the machine centres, is supported by work-rest-an shown in fig, 7.21. The usual procedure ia to place work rests at intervals of about 6 to 8 times the work diameter, They support the work from the back and bottam and have positions for keeping the jaws or shoes adjusted to the work, 7.2.3.1 Method of Mounting Workpiece in a Chuck + Fig. 7.21 Spring Type Back Rest ‘The workpiece with a length L.< 4D may be mounted in a chuck without the need of additional support of the free end, Threc and four—Jaw ehucks, screwed on the spindle, If the spindle is having aflange, then the chuck is bolted on that flange directly. Three jaw univernal chuck is widely used. ‘The three jaws of thia chuck moves together towards or away from the centre of the chuck. In adJaw chuck, each of the four jawa ia moved by its own screw independent of the other jaws along radial slots of the chuek-bady. This chuck can be used for mounting complex and non symmetrical workpieces. 74.4.2 Method of Mounting Workpieee on a Mandrel : A mandre] is used to loeate and held a workpiece with a central hole such an gear blanks, pulleys ete, A mandrel is a solid hardened bar, with contres and Mats on cach end, The mandrel is usually tappered eo that tho work can be forced on it with a press fit and then removed after grinding. A mandrel is held botwoen centres and rotated with a lathe dog clamped on its flat. The taper is about 0,005 mm per cm length of the mandral. Fiat for Dog (Both ends) Fig. 7.22 Workpiece Mounted on A Mandrel MEL Eng f 22 4 2023 a peleae 5 tte Mifacteiring, Eval & Honing, Lapping and Othe por Binighing Peooesies Ny * «Surface Fluishing Mrovessos + nit ate te the aoticge of griving opovation, The defbots aco clatter holical (ype scratches, suvfice cracks, smear motel ote. aa wspenaible for WoRFINg Ot Of thy uy certain civcumstanees high sviethes quality is eoquited. Hence Gir womoving Grinding go obtain dosived surdwe Gnish and to improve tho geometrical shape Auiahing proteases ayy it includes honing, Lapping ant super finishing, Qvor and above polishing Buffing, Powyy ahot blasting like now-prevision processos are also ued Parts wor | bay 781 Honing + Hoe mado by bo required dimension and fi In this proceas abrasive atone is used, The dimension to an accuracy of 0.005 mm can be obtained by honing proces Tho grit size of 80-600 stone used for honing and aulphur, rasin and wax are added in the bonding material is obtained to ! | | “to nechieve good cutting action, Generally WD sig 128 Honing Toot ishing by honing. thero'in the honing is done manually but sometime special devices are used. Single spindle anc miilti-spindle honing machines nro used for honing process. During honing eutting fluid (paraffin) is invavinbly used. Honing spindle is shown in fp 7.28, Honing is the wet cutting process. 6 to 8 honing sticks are held in holder and metal is remond hy rotating or reciprocating the holder. Honing of external surfacoa can also be done in spe cases. Honing tool ia rotated at a speed of 0.6 - 2.5 ms and reciprocated at speed of 0.2 ~ 05 m/s. All the sticks in the holder can be expanded by the automatic mechanism. Less heat ia generoled in this process as it is slow. The cross hatch pattern ean be obtained in it-for storing the lubricating ‘oil. Hence following four objectives are achieved by honing. 1, Metal is removed. ‘ 2 Accurate dimension is obtained ‘ 8, Roundness & strnightnesa is obtained t 4, Required surface finish is obtained. ; Application : Honing of automobile cylinder block is done. The honing can also be ustd it ‘eeyiaie tick 7.3.2 Lapping : ! Following three objectives are fulfilled by the lapping process. 1. Accuracy of dimension 2. Removal of minor irregularities of the shape 3. Improvement in surface finishGrinding Processes Wt ‘This poncoon ja mainly dene on the rotting auefieees, Abrasive copnpon i iv yooit 2 HL Mave accuracy in obtained as haut & prasatico mew tow leew in lapping. Laping ¢ is made by mixing dinmond, wilicon carhide, aluminiin oxide in oil, greets or water There are many types of Iypplag. pene () Mond Lapping + In this mothe lapping compound is sprended an east iron plate and workplees le moved manually, @) Machine Lapping + In this method » rotating tnblo is uned in placo of the plate, Again the workpiece to be lapped is given rolury motion by a enge and ratntod on the surthee of the table, Rotating lap is weed above & below the workpieeo to produeo parallel surfaces. This process is shown in fig. Machine lapping is diMieult in came of eoft metals hut it cam be done on hard metals, It is n alow and costly 8, process. ChFEED CONTROL LEVER MigW OF LOWER LAP 7.24 Machine Lapping Application : Machine lapping procesa is carried ont for gaugo blocks, piston pin, ball bearing races and engine valves, + Lapping of Internal Cylindrical Suffaces : Solid or adjustable laps are used for lapping internal cylindrical workpieces. Lap tool is rotated by machine (Lathe) and the workpiece is provided reciprocating motion manually, For this process, large laps are of cast iron and small laps of steel or hard brass are used. The helical grooves are cut on the Jap, which are useful for providing clearanco between workpiece and lap. Split-sleeve arrangement is made in adjustable lap. Again replaceable copper sleeve is used. Tt is necessary that the complet imternal surface of the workpiece should remain in contact of the lp to achieve better result of internal eylindrical lapping. For this purpose length of lap is kept ‘somewhat morethan the length of cylindrical job.Manufacturing Engin 472 mu) 7.3.8 Supor Finishing : ‘This process is one type of honing, in which 1 speed, hope more compared to the honing loss pressure, hi Amount of lubricant ~ cookant of low viseasity contact nea between work & abrasive fact is kept: Lose heat is produced during super finishing and it Js generally done on external surfaces This process ix shown in fig . sandstone is rotated in backward direction, This walt #8 ia rotated. Objective of this process is to produce the sm nisin 7.84 Difference between Honing, Lapping & Super Fi ‘Lapping of abrasive Fig. 7.25 Super Finishing ih nbranve stone i fixed in AFM lade . vam bo fixed on Tate erose-slide wer wfnce. . im which se Processes: Supor Finishing |__ ‘Used in tho form of nbsayin) bonded-stone | Prosmure of 1 3 kefen? | necessary. Cutting speed kept ia 10 ~ 1. Used in the form of abrasive | Used ia the form sticks op. 7 een” Pressure of 0.1 = 0.7 pier” is noceasnry 2. 10-30 kefem? pressure is applied dig 100 - 260 78-91 | Lapping sper aa/min. 3. Surface speed i mmin m/min, | size usod is 400 - ‘oon Gra is 50 - 800 used is 30 = 900 |Grain size used 5. Surface Gnivh of O01 — 0.8 [Surfuco finish obtained is 005 jim is obtained = OL um 6. Metal removal 01 rum — [sae Tomoval i 0,035 mm | Metal removal is 0,005 ~ oi mirror honing, 0,5 mm mm primary honing Lapping is done on valves, slip | Super finishing of crankshai| gange ete, Joint bearing cte. is done. Surfaco finish obtained is 0,0) = 0.2 um. 7. Honing of eylinder liners is done 7.8.5 Super Abrasive Grinding : In this process diamond and eubic boron nitrate (CBN) sre used instend af conventional abrasive like aluminium oxide and silicon carbide, Due to that grinding of very hard material Can bo det and hotter quality can be obtained, Advantages of using super abrasives are aw fallows, 1. Very hard and tough materials enn be cut. Lifo of tool made of super abrasives is more. Material from the work enn removed at high rate (274 m/min). Better surfieo quality can be obtained. Uniform quality of surfuee ean be obtained, is attained, Pe ww aGrinding Processes 173 Grinding ian complex process, ‘Tho continuous nnd oxtensivo ronsnrch in tho field of grinding is going on to fulfil tho requiromonta of tolorancea and surfaco finish of the fiolds like acro-enginooring, nuclear engineering and ta make their technology offective, Tho main aubjocts which are dealt with are the use of super abrasives & higher cutting speed, very small grinding wheels, tomporature control, automatic baloneing of apood, diapoan! arrangement for used grinding wheels, sogmontod grinding wheel otc. 74 Grinding Wheels : ‘The grinding wheels ne made of two types of materials called (i) Abrasive grains and Bonding material which keeps tho abrasive grains together and gives shapo to the wheel. ‘The components of grinding, wheel are as chown in fig. 7.26, Fig, 7.20 Components of the Grinding Wheel 741 Abrasive Grains + ‘A Inrge variety of abrasive geains are used ta manufneture grinding wheels, which are eatoring the varied need of industries, Tho variables nre brought about by the types of constituont matorinls or their proportion in the mix and by the sequence of manufacturing oporations, Most of the grinding wheels are made from the following abrasive materials. (Aluminium Oxide (i) Silicon Carbide (ii) Boron Nitride (iv) Boron Carbide 6) Diamond ‘The abrasive materials, ns listed abovo, vary in their hardness values and wear characteristics. For choosing # grinding whcol for any particular application, othor characteristics such ne porosity and Mesibility ote. arc also important besides the cast and tho mature of the grinding process, ‘The abrasive grains ave hard and of irregular shapo, which are eutting or scrapping the matorinls, For its better functioning, the following propertios of abrasive grains are necessary. @ Penetrating hardness (i) Resistance against elastie deformation (iil) Resistance against fracture (iv) Resistance to wear, which depends on its tensile strength (v) Mass density (vi) High temperature stability ‘Types of Abrasive Grains : Abrasive grains are of two types @ ~~ Natural abrasives (i) Artificial abrasives (i) Natural Abrasives : ‘This type of abrasives includes naturally available materials such as flint, garnet, emery, crocka” and diamond. The flint and garnet are used in wood working industries while the emery, crocksand diamond are used in metal industries. The application of natural abrasive is reduces day 5, day. (ii) Artificial Abrasives + ‘This type of abrasives includes silicon carbide (SiC), Aluminium Oxide (Al,Q;), Boron Carbit, and artificial diamond. The required properties can be obtained in this type of abrasives depending upon its manufacturing process. ‘The efficiency of abrasives is based on its type & size. Hence both the type and size of abrasives are mentioned in the specification of grinding wheels. 7.4.2 Bonding Materials : A variety of bonding materiale are used to import the desired cutting characteristics to thy grinding wheel. For example a slitting saw io a very thin grinding wheel. If a brittle bonding material is used for its manufacture, it would easily shatter on even a slight side thrust. Therefore, for such a flexible material which can allow slight deflection is used. If we are grinding a side face with the side of grinding wheel, any deflection in grinding wheel would give rive to inaccuracies in size heneo for such applications a strong and rigid bonding material is used. In industry a variety of grinding operations are encountored. To eater their needs, following bonding matorialy are wide used Vitrified bonds Mineral bonda Organic bonds ‘The functions of bonding materials are as follows : (a) Comenting together the abrasive grains, (&) Providing mechanical strength to the grinding wheel far preserving the shape & aize af the wheel. Helping in maintaining the vclf sharpening action of the wheel. © (4) Facilitating tho various grades of the grinding wheel. (i) Vitrified Bonds : It is tho most commonly used bond. ‘The process of wheel making consints of mixing abrasivt rains with ceramic elays or porcelains, shaping the mixture into wheol shape, drying and baking ‘at 1300°C for a long period. The vitrified bond ie not affected by acide or moisture. It is a very hard bond and leaves aufficiont spaces between grains, thus making the wheol more open. This bond ia hard and brittle, hence it can not be uscd for thin wheels. The vitrified bond gives an all purpose wheel for the grinding of atecla & Coat irons, It is not affected by the heat generated during the grinding process. This bond is strong and rigid and retain high strength at clevoled smooth finishes. It is not affected by water, oil tomporntures, Tt cnn remove stock and maintai and grinding fluids. Due to ite brittleness, ita resistance to shock is poor. Honce can not bo used whero mechanical impact and large thermal vibrations are likely to occur.Grinding Processes 475 Main characte of this bond are as under : 1. Strong & porous wheels can be made by this bond. 2, Various grinding coolants can be used as this bond is not affected by acids, oils & instant change of temperature. 3. It has uniform structure and having no hard spots. 4. It can hold abrasive particlos at high speeds henco the wheels made by using this bond can be run upto a speed of 50 m/sec. 6. [t cam preserve the shape of the wheel. 6. Thin wheels made using this bond can not take lateral load. 7, The possibility of crack formation during finishing process is likely to occur in large wheels having this bond. 8. This bond can be used upto a wheel size of 90 cm. 9, The wheels made using this bond are designated by 'V' symbol. 10. The process of wheel making with this bond is i) Mineral Bond : For making wheels with this bond; the abrasive grains are mixed with sodium silicate and cays. The mixture is moulded into wheel shape and baked at 260°C for about 20 hours. This bond is softer than the vitrified bond and gives a relatively mild grinding action. It also leaves fewer voids than the vitrified bond. This bond is not very flexible and hence not recommended for making thin wheels."The wheels with this band are used for sharpening fine edged tools and knives, The silicatq, of soda ia an important ingradient of this bond. This bond is used to limited extent in aperations where the heat generated by grinding is kept minimum, It is Jons sensitive to shock and side loads than vitrified bond. It is affected by dampness and alkaline solutions. The magnesia bond is becoming hard in open atmosphere, but it ia sensitive to moisture, therefore it can be used in dry grinding, The silicate bond wheels are not affected by water & hence they can be used for wot grinding, Mineral bond is mainly made from silicates, ‘The main characteristica of the mineral bond arc as under : 1. Its strength is less than the vitrified bond. 2, This bond is delicate hence leaves the abrasive grains easily. 4. Wheels made by this bond are soft, hence they are mostly used to sharpen the cutting edge of the tools. 4, Wheels upto 150 cm diameter can fee made using this bond. 6. The wheels having the minoral bond are designated by the symbol " 6. The .proceas of making wheel is relatively fast. (ill) Organic Bond : For making grinding wheels with organic bond, the abrasive grains are mixed with organic materials like shellac, phenolic resins, rubber ete. moulded into wheel shape and baked at 160°C, nies2 Manufacturing Enginecringy ‘The organic material gives a wheel of high strength and flexibility, These wheels are used for finish, cast iron rolls, for final finish grinding of steels, for cutting marble and granite as well as for grind; of cutlery. These wheels ore more flexible and resilient in comparison to rigid vitrified bond whey, Therefore they can withstand more bumping and side pressure than Vitrified bond wheels, Organ, bonds are cured at low temperatures, hence the materials like steel, nylon and fibreglass cap J, permanently bonded into this type of grinding wheel to reinforce it. The reinforcement strengthen, the wheel so that when it is broken, it does not fly off, Reinforced wheels are suitable for roo, grinding operations, as the resinoid bond is suitable to work at higher temperatures. The may characteristics of the organic bond are as under : 1, The shock resistance & strength of this bond ia moro. ‘The wheels made using this bond can be used for grooving, roughing work, cutting oy and polishing work, 3. The wheels with organic bond can be run at 70 m/sec ‘The wheels with organic bond can not be used beyond 300°C temperatures. ‘The wheels made by resinoid are designated by the symbol “B". In the circumstances like side loading condition than rubber and resinoid are added with natun) ‘and artificial febric & fibre, glass fibre and non-ferrous wire grills, 7.4.8 Types of Grinding Wheels : ‘The various types of grinding wheels based on different criteria are as follows : (A) Based on Bonding Material : 1. Vitvified grinding wheel 2. Silicate grinding whcel 3. Elastic grinding wheel 4. Resinoid grinding wheel 5, Wulcanised grinding wheel 6 Oxy-chloride grinding wheel (B) Based on Wheel's Grade + 1, Soft grade wheels 2, Medium grade wheels 3. Hard grade wheels In grinding wheels, the grade is the meastite of strength of bonding materials to bind the abrasive grains, which means the capacity ta withstand the stresses produced during grinding process, The wheel, whose grains are separated easily is called soft grade wheel. Similarly the wheels from which the grains are not separated easily are called hard grade wheels. The constructions of soft grade wheel and hard grade wht are shown in fig. 7.27, Hard grade wheel is used for soft metal like mild steel while the soft gr! wheel is used for hard metals like high speed steel,The whee! hardnoss in do Sa resents ; ; ila Agta Z are hard. (c) Based on Structure : 1, Open structure grinding wheel In the spaces etween grains, bonding material is filled. The construction so obtained raled the wheel structure. The wheel density iBeore when therd is [oss apace between Mine, Such construction of wheel is ealled erie or close structure. Similarly whools faving more epace between nbrasive grains has les density and their construction is ealled rueture. Both these structures are shown open st in fig. 7.28. ‘The open structure wheel is used for metal removal while the close structure wheel is used for precision shapes. (D) Based on Wheel Shape : ‘The grinding wheels are made in many shapes. Some of the shapes are standardised for the industrial application, and are casily available in the market, Non-standard wheels can be obtained as per necd by placing order. Some standard shapes of grinding wheels are shown in fig. 7.29. 477 mated as oft, medium and hard. Wheel with hardness rating on .ze called soft, those having rating of J to P are medium and whvels with hardness rating 2 Closed structure grinding wheal Fig. 7.28 Types of Structure of Grinding Wheel TYPE NO.S RECESSED ONE SIDE (STRAGHT) atts TWPE NO.* TAPERED: TRE WO.2 CYUNDER a TYPE HO.6 STRNGHT CUP a TYPE NO.11 FLARING CUP SECUENTED WHEEL CS TWPE NO.13 SAUCER WOUNTED Poors Fig. 7.29 Standard Shapes of Grinding Wheels ‘Wheels bearing no. 1, 5 and 7 are mainly used for cylindrical, external centreless and surface grinding operations. MEail_Eng 123 1 2023Ave Manufacturing Engl Wheel no, - 2 is wed for grinding fint surfaces, * Wheel no, — 4 in used to grind threads & gear teeth, * Wheel no. = 6 is uaed for fint surface grinding. + Wheela na, = 11 & 12 are uned in toal-rona, * Wheel no. ~ 13 is used fo sharpen band saw tooth, + — Soqmental wheel in used on wurfnce grinders & way grindors. + Wheels with differont fucns & mounted pointé nre used for grinding contour & nawa, Mounto, points whecls are generally used by mounting them on tha portable grindern. Such wheels aro specified hy their internal and external dinmeters and their width, TAA Nomenclature of Grinding Wheels + ‘The grinding wheels are produced by different manufacturers, If thes munulucturara specify grinding wheels a per their need, than the selection of proper wheel becomes inconveniont. To make nelection of wheel convenient and to bring uniformity in specifying the grinding wheels B.L8, (fureay of Indian Standard) han developed n method like the inatitutions, The details for wpecifying grinding 1964 in explained in fig. 7.0. Abroslve Grainsize Grads Structures BOND TYPE Sufix K 5 Vv ” wheels on per 1S Sequence :Preffx w A 46 Nature af abrative Manufacturers! Manufacturer's Syinbo! tru identfication, Iraicting the exact sr fe the we fafore of the abratlve ie) (eptioned) Allaenture Osles - A V = Yi ed Silicone Caraids « C 1B - Nexinuiad Re» Rubber He Shellac Coane = Medium | Fine Dente | To Open Silat to Mo wo a M ton 4 46 130, I 4 io » ct im u 9 © Oxychloride 10 Ma Mayne Roti Medi Hand ABCDEFGHISKLMNOPQRSTUVWXYZ Ply. 7.30 Method of Grinding Whoa! Nomenclature ax Per 18 Reade tleale (1) Symbol of Munufoeturer + Thin is not compulaury, ‘The munulucturer «pecificn particular quality of abranivow by it —- OEn Grinding Processes ¢ 419 (2) Type of Abrasive : It in specified oo Finglish letters. ‘The aluminium cide in apecified by letter ‘A! and silicon eathide by letter °C", From which one can ascertain the type of abrasive grain wed by produce the wheel. (a) Grain Size + Grain size affeetn the quantity of material removed & murface quality obtained. The grain size selected is haved on product material, type of grinding process, required wurfaee finieh and material tobe removed from the job surface, The grain ais can be clansified na under, + Very eoarie grnina 6 4 10 ie “4 + Connie grain 16 ” a 0 + Medium grains Eo 16 54 % + Fine grain #0 99 309 iy Very fine grains 150 wo A Superfine geains 280) Cn + Special grain 1000 or finer Abrasive gritin aie for une in grinding wheel manufacture varies from 859 to 1500 mpm, Choice ofyrain niae depends upon the properticn af work material, surface finish required, rate of metal removal tte, Coarner grains (grit sive: 10 ta 24) yive fanter rate of metal removal, fine grits (grit nize 70-120) results inte fanter rates of metal romeval but yield a pvor surface, Whereas fine grita (grit nine 70-120) tre ueed fur Finishing operation but the rate of motal removal is slow. Coarne grain wheels are normally suitable for aoft and ductile: materials; for hard & brittle materials finer graine are preferred, 4) Grade : ‘The grade in referred to an the hardness of the wheel, The abrasive grains in the grinding whoel rire bound tguther by the bunding material, ‘The bond must hold the abrasive grain until it im completely w The 1 breaks off dug to ineresmed cutting forces, The force holding thy raion in place, denotes the hardnens of the wheel, It ix based on the type of bond, grinding whee} structure and on the ratio of the amount of abrasive yraina. The greater is the bond content, stronger tond material maken the wheel hardor, Hardor grade whuols are uned for heavy metal removal & for precie: grinding of nofter materials, When area of contact between work & wheel is ler, we eon uno the harder wh ufier grade wheels can be used for harder materials for light metal reimoval, ‘The hardnens of grinding wheels i cham denuted by latar A ta %, ed an very oft, woft, medium, hard, very hard and * Very Sof A B c D gE Fr G * Soft iW I J K * Medium L M N 0 * Hard Pp o R 5 © Mary heed v u Vv w x Y “| ing ~=F 480 Manufacturing Enpinectings (8) Structure : ‘The complete volume of the wheol is not occupied by the abrasive grains & bonding materi, Therefore porosity romains at some places inside the wheal, Duc to this type of construction grinding wheel structure can be divided into two types as open structure & close structure. The numben of abrasive grains per unit volume are less in open structure in comparison to the close structure, Open structure wheels are used to remove more amount of metal, while the close structure wheely are used for grinding precision farms and profiles, Structure is shown by the numbers from 0 tp 15. The structure is more close when structure number is less, Dense ——_—__> Open o 1 2 38 4 6 6 7 8 9 1 MH 138 MW 6 (6) Type of Bond : Which type of bonding material used is shown by its type. It is specified by the symbol fer ‘the bonding material used. eg. "V" ~ Vitnified and “R’ ~ Rubber ete. (7) Manufacturer's Mark to Identify the Wheel = ‘Thia is not compulsory. It is the, symbol given by the manufacturer of the wheel for its identification. It is generally shown by figures, Mlusteation : 51A36L5V23 grinding wheel has 51 : Symbol of manufacturer A. : ‘Type of abrasive (Aluminium oxide) 36: Grain size (Medium) L : Grade (Medium) 5 : Structure (Dense) V + Type of bond (Vitrified bond) 23: Mark of manufaeturer 7.4.5 Selection Criteria of Grinding Wheels : ‘The suécess of grinding process is based on wheel selection, The following factors are considered for selecting a grinding wheel. (A) Constant Faetors : 1, Material of the product 2 Quantity of metal to be removed from thé product. 3 Contact area 4 Type of Grinding MachineGrinding Processes (B) Variable Factors 1. Speed of the Grinding wheel 2. Speed of the job or product 3. Condition of the machine 4. Personal reasons (i) Material of the Product : ” Based on the product material, grinding wheel bond, abrasive, ee sie, ‘grade and seructure are chosen, Which are chown in the following tables. contact between wheel & job + Chilled Casting, C.I and hard steel “Hard material whose tensile strength is more than — 35 ke/cm? eg. Alloy steel, steel. + Soft material whose tensile strength is less than - 35 kg/cm? eg. Grey C.L, Brass, Bronze ete. ‘Ee Fatteling ‘Tool grinding + General rough work (off hand) + Cylindrical Centreless and crank shaft Internal = 1 1) Tool and cutter Surface grinding (segments) Surface grinding (cylinders or cups) meant kre as 1 1 AR ER zee ezno * Surface grinding (Straight wheels)182 Manufacturing Engineering Manufacturing Enaincering gy } Stock Removal i + For removing more stock : coarse grain, open structure + For removing less stock : Fine grain, close structure (3) Contact Area : ¥ Less contact area : Fine grain, close structure + More contact area : Coarse grain, open structure (4) Type of Grinding Machine : + Use soft’ grinding wheel on the machine having rigid construction and is more heavy, Now we will discuss about variable factors. (1). Grinding Wheel Speed : Wheel speed should be close to the speed specified by the manufacturer. If speed is less thay the consumption of grains increases. Similarly when speed is high than the possibility of whee breakage increases. Wheel speed plays major role in selection of grade and bond. The suitable speed: for various grinding operations are given in table 7.1. Table 7.1 : Wheel Speed for Various Grinding Operations Vitrified Bonded Wheel + Cylindrical grinding + Surface grinding 1500 — 2000 5000 — 6500 1200 — 1500 4000 — 5000 + Internal grinding 600 — 1800 2000 — 6000 . Tool & cutter grinding 1600 — 2000 5000 — 6500 + Centreless, snagging operation 1500 — 1800 5000 — 6000 Resinoid Bonded Wheel + Snagging operation 2000 - 3000 6500 — 9500 @) Speed of the Job or Product : The speed of the job io rolated to the wheel speed. If the job-speed is more then hard wheel to be used. Speed of the job or product is given in table 7.2. Table 7.2 : Wheel Speed for Different Materials Cast-Iron + Aluminium 30 60 + Soft-Steel : 9 15 * Hard steel 20 30finding Processes : i = {@ Condition of the Machine : Machine condition helps in selecting wheel grade. If the condition &' foundation of machine aye Hid than eof grinding wheel is to be used. (g Personal Reasons : ‘The value and result of the grinding process is based on the skill of the operator. 48 Application of Grinding Wheels : ‘qhe application of grinding wheel as-per IS : 1249 : 1958 is shown in table 7.3. The manufacturer ojtte wheels also gives guidelines for application of wheel in their guide ~ booklet. They arw shown low in the table 7.3, Table 7.3 Applic Type of Grinding Process Job or Work Material bere b P ion of Grinding Wheel as per IS : 1249 : 1968 Grinding Wheel A 60 LV ‘A 54 MV C46 KV A 46 KV A 46 MV C46 dV Cylindrical Grinding Hardened Steel Soft Steel Cast Iron * Hardened Steel Soft Steel Cast Iron Hardened Steel Soft Steel Cast Iron > ‘Internal Grinding +. Surface Grinding Applications of Grinding Wheels as per guidelines of the Carborandom Universal Linited are as undet. : L HSS. Billet ‘A 20-Q5-V30 V0 : Tool grinding 2 Brake drum (C.1) C 8641S-VG VG : Precision grinding (silicon carbide) 3. Broach Ab0-1S-V10 VIO : Precision grinding (Al,0,) 4, Concrete C-80-R-VG CR : Precision grinding and : certain cutting off operation. 5. Drill Off hand) ‘Ag0-N5—Va0 6 Plug-gauge AG0-K5-V10 5 7. Glass GC80-K5-VG & Marble C30-L5-VG §. Pla Ca0-N-BR 0. Rubber (Hard) Cutting Off C46-K-BRin) Of hand rough, ) OF hand fi 12 Tuo and Cutter grinder OCIG AS VG GC 16 YO = ta) Renigh 1-H MG (by Yinish A010 db VO Terms Associated with Grinding Wheel Operations Including Lowdiag Glaxing, Dressing and Truing + 1.8.) Leading, Glasing, Truing and Dressing 5 Hath these eanditions are resulting dus (a eperating faults, whicl tnepemsne the wheal dlaiasyy 1) Leadiog § When the openings or porwe uf dhe wheal-farn ie filled up with metal partir the sheel fren cutting frealy, The satersparnce betwen the alywsive the particles of miotal dun La that Ube cutting edyew da net jorjert out the wheel to do the grinding wrtion ‘Tho loading of the wheel ie 4 ans prenesy prin Aoessomans ebay iffivdently, whieh peeves wallowing reascee Popwing the cut teas faat or ta deep, which allen the clipe ta ba careied away by te what 2 By doing o grinding wheel to grind the efor wheal tie wae A. The eons grain and hand bonded wheel Me used on pl pertioular pmaterial verdad Chive the material for whi o oof wheel 4 Than Fight vsti: Rutd te nid weed A take the er deep rut fh Hteenivig the ahead of tre bard wm bend toy wlively fay am The incrrnen ja oehoad apes and sue cf wetter wilieel ean vivre the 2) Gtestag Whe the aigaatee graben hich fave fot their abs ped oy tha heal thaw HAs eplled Gewing 1A Mik crediting thie wheal bernie dull sist the fave or cutting edges tabs A plese ibe eppenraren The cutting ponte uf the al fooermne ohh de ernment erm tha ters The further wan of glased wheel bnevennne the wntedttievnnn nl the fen! leit rachocing ie rutting emparty ‘The raunes of ginriny are ma under 4 Tae setae i toes Sard fw the wert Th whaal in ronan ol fant epsed than nacinenes firm particular work } Ts wea bermpend is ory bow ‘The wheel which reqiites Wimening A veering ie used a a a 4Gaading Processes 6 The work motarial ia 6 The sheenc: oF defcuency of ettiny fluid. Tha ducrranc in wheel wpecd cor te wae 6 eotier whan) wan decreoue the potog uf the photog (ay Trving sd Drwssing : que ix cutled the prvauen of changing the shape of tie wheel, whats pending toe be ha baw orional shaper shen the rinsing wheel ww wiawre an w vend WF biweiay weny of tn sheasire aris Ae bend “Phe Aradiene te dora toy sinlen the had toe wad aimmmclen wile Ka hie fe wheal ranter for Gorn gaining ean ba whined Ie teen The dressing Of grinding whwnd te dose ts peayre the boeing apd tos baewaninny Mae geste partese of the ohn, Wy Dring oat He sharp alyrosiva peatitan fav yripdiny ie word pha uing wed Aseseing bo the Lalewing seasune 1 Te remain the whinge he ebfictaney of thew wheel 2 TH geduce the heat qenanted batwwen work borhan a te 6d chad 4 Ta tinprenes the warfare quality uf the wary The ruin and dewenitig can be waaily undavetiodd boy wtirdying the fg Th The toed mand fae Ciing Be Adeemuing be called “Dywwopt "Tha Atwesepe ate if the Wher St | Matal erusiions ptt ae en 1 Abeasien atiche/whente Ler 6) Wi TAN nay ot testo & ve Nhe wt aah es Hein Waeannd Areaser th) Single wot ana fe) Metary wed ean ry diamend vette th Cow ie ralle Up Metal Crualor 6 Wh be amedd dae reseatiinng ogee wd Him lees leery no “Hap drwaney” “Phas opps ot Sincant Wa tated ws the welvesl face bey eopeirig Me aleiny at 1 tes MM tas Whe mtiesl aria Thee dirvenay senior al el the wend he ill gricios trove ets om 1G) Abrasive MilrkaWheela \ re waead tor the wrindinng hun! veel tox grindome curd wed cotta v teading and lacing of the Aianend wheel The alanmen wheete see cael bo emg aed Aye wf the dieminnd and suhie heron nuteiding hnela ‘The tdack of gree eee taht i tunel in tlie typo if dewaner The dinrimter off the mbemnive while kgs 16 is LA Dame Be dlaimater uf grinding hoot fe tink be EL106 wey The single point for precision operat grinding. 1 ix kept nt Ht 1 oli ATO LocANOH OF HERA, Lowen Toot fron SET 1 Tikes surtiew eiivinng, eylidedeml gerintiny Vo angle to the whool xia nw Jarge & wide wheel dressing without fading, Crushers are used for profile drenaing bit now a diy rotary and form dinmond rolla are wed in ite place, which can provide better geometrical shay to the wheol. There are two mothods of truing & dressing. They are (1) grinding nnd (2) Crushicg In crushing alow flow ia given to tho rollars against the rotating grinding wheel, Duc ts this of brasive breake ond leave the wheel fice, In crushing the rise of temperature ix lows but Ht gonornts tore rough eurface in comparison to the diamond dressing, In both these method sufficient mx of coolant is necessarily used. Grinding Fluid : Main functiona of the Muids used in grinding operations are as follows : 1. To prevent the rise of temperature of the work. 2, To take awny the chips formed by grinding and the abrasive grai foe, ‘Tha advantages of uaing grinding Auids are nx under, 1. The surface finish of the job can he maintained. leaving the wed 2 ‘The service life of grinding wheel is inercases. 3. Higher temperature produced between work and grinding wheel 7.8.2 Self Sharpening Action of Grinding Wheol : ‘The forces acting on contact arce of wheel and work is shown in fig. 7.33. When the grinding wheel it used than with its use the abrasive grains edgca becomes blunt, due to that the fore | acting on them increases. When thea furcon heenme capable of breaking the bold holding of the abrasive grain than the grains are coming out of the wheel in the form of free particles. In place of these grains new grains are eming wat on the surface of the wheel as shown in the Gg. 71 in be controlled. a a en1 pigeon of there now yrning works im 1 arp edgon. ‘Thin procean ‘and (ected Uh 201 whinrpen ] ofthe crinding wheel. I description it in clear th | sharpening nection in loan yely thw lind wheel, Therefore, owned iy Ine Th Fig, 7.94 Sot 8 Job apc e of Gelading Wi riinive gent to effect the wolf whiurponing of Uh @ Short Qu tion and Aniwors 1 Eaplnin : Controless Grin Aion, In contre toan geinding, tho werk work-roat, ‘Thorofore fixture in bs sure rotated in the eumw direction. provided to the work hy keoping the small regulating: wer speed thin grinding whool, ‘The work is prersed by motnl, After completion of the grinding nak aerangoment, whent Both the wh atdifferomt wheel slightly wloppinig a run the feed wheel teow th nding wheel for removal of tt of the wheel-fice is filled up with motal . than it provente ew botween the abrasive ¢raine become clogged with due to that the cutting edges do not project out sufficiently, which prevents he londing of the whool in eaued due to the following renron When the apeninie or por the wheel from cutting: freoly. ‘The interap: the particles of m tewheel to do the gi 1 Forcing the cuit too fast or toa deop, which allows the chipa to be cartied away by the wheel, 2 By using a grinding wheel to grind the softer material than tho material for which it should be used, da The"course grain and hard banded wheel if used in place of whecl moant to Partiewlar material, 4. The right cutting Muid ix not used to take the too deep eut. 5. Running the wheel ef too hard a bond too slowly than tho specd with witeh it should be used. Tho incrense in wheel specd and uso of softer wheel can cure the problem of loading. > | ee ie