Group 4

11/16/05

David Reis
Jeremy Huckins
Alberto Barraza
Nick Mellady
The Process of grinding
 Grinding – a chip
removal process that
uses an individual
abrasive grain as the
cutting tool.
Work pieces

Cylindrical, conical, fillets, helical, concave, slotting,

internal grinding
Naturally Occurring Abrasives
 Emery, corundum, quartz, garnet,
diamond
Grinding Wheels

Structure, wear, and fracture patterns

Grinding Wheels
•The surface of
grinding wheels are
made up of these
grains.
•Grains have random
irregular shapes that
are located at the
edge of the grinding
wheels.
Common Grinding Wheels

Colored surfaces indicate grinding faces

Superabrasive wheels

Colored surfaces indicate grinding faces

Types of Bonds
 Vitrified (ceramic bond) – most common type
of bond. Resistant to water, oil, and acids.
Sometimes made with steel backing plates to
improve physical strength.
 Resinold (thermosetting resins) – Also known
as organic wheels. Resistant to extremely
high temperatures
 Reinforced Wheels – Made with layers of
fiberglass. If it did break it would not
disintegrate, it would just crack.
Types of Bonds
 Thermoplastic – sol-gel abrasives
bonded with thermo plastics
 Rubber – the most flexible bond.
 Metal – lowest cost. Used mainly in
small quantity production
Grinding Formula
L = (Dd)
Undeformed length = (Diameter)(depth)
 Chip Formation

•When a chip forms

ridges are formed
where the chip left
the material. This is
known as plowing.
Considerations while grinding
 Temperature
 If it gets too high it can:
 Affect surface properties, including metallurgical
change
 Cause residual stress on the work piece
 Cause distortions in the work piece, therefore
accuracy goes down
Wheel wear
 Once a wheel starts wearing it becomes
less accurate
 Grain wear – grains become flat and
dull
 Bond fracture – the bond breaks and
the grains come off the wheel
Grinding Ratio
 G = Volume of material removed
Volume of wheel wear

 These vary widely, ranging from 2 to 200+

 Using grinding fluids can increase the life
of a grinding wheel 10 fold.
 Shaping grinding wheels
•The edges of grinding
wheels are shaped with
diamond dressing tools
controlled by
computers.
•Shaping the wheel
sharpens it and restores
its accuracy.
 Grinding

 Almost any material can be ground -

aluminum, steel, ceramics, even diamond
or glass.
How Grinding Is Used
 Grinding is used whenever something
needs to be smoothed or shaped.
 Grinding is used to form countless types
of products such as automobile engines,
sharp edges on knives, ball bearings
and drills. The smooth, accurate surface
of the Hubble Telescope lens was
formed by a process of grinding and
polishing.
Types of grinding Machines
 Surface grinder

 Cylindrical grinder

 Universal Tool and Cutter Grinder

 Lapping and Polishing

• Cylindrical grinding
center

cylindrical
grinding centerless.
The bench grinder
Chemical Milling
• chemical milling/blanking is a
chemical process that dissolves material
from unmasked (unprotected) areas of
metallic parts immersed in a tank of
heated and agitated chemical
reagents. The term "blanking" denotes
small, thin workpieces, and "milling"
indicates relatively large workpieces.
(a) Schematic illustration of the
chemical machining process.
Note that no forces or machine
tools are involved in this
process.
(b) Stages in producing a
profiled cavity by chemical
machining; note the undercut.
• considerable
advantages compared
to punching, laser-
cutting and wire-
erosion

(top) Weight reduction of space launch vehicles

by chemical milling
aluminum-alloy plates. These panels are
chemically milled after the plates have first been
formed
into shape by processes such as roll forming or
stretch forming.
(left) Missile skin-panel section contoured by
chemical milling to improve the stiffness to-
weight ratio of the part.
 Chemical milling is
used to reduce the
overall weight and
other non desirable
factors of a
workpiece
 Process of Chem. Milling
1. Artwork and Negative Preparation

An image is printed by a program with a laser plotter directly to the film at any size
needed
2. Photoresist Application / Exposure / Develop

Apply Photoresist coating to make the metal sensitive to light.

Expose coated metal to UV light source which applies the image from the art work to the metal part.
Treat exposed metal part with a developing solution which removes the soft portion of the Photoresist.

3. Etching / Resist Removal

Process the metal through chemical etcher which dissolves all metal not protected by the hardened
photoresist coating.
Electrochemical Machining (ECM)

 uses an electrolyte
at a high rate from
the tool piece to
wash away the
metal ions from the
workpiece
 the tool is usually
solid or tubular form
 Material removal
rate is 1.5 – 4mm³
 ECM was developed in 1929
 Not as widely used as other processes
 Generally used to make complex
cavities and shapes
 Finishes parts burr-free and bright
surfaces
 Never has any thermal damage to part
or wear on the tools
Parts From Electrochemical Mill
Replacement Knees
Design Considerations for ECM
 ECM is not suitable for producing sharp
edges or flat sufaces
 Flow of electrolyte can become difficult
 Designs should make provision for a
small taper for holes to be machined
 Electrochemical Grinding
(ECG)
• Process that combines electrochemical
machining with conventional grinding
• Grinder wheel is embeded with abrasive
particles of dimond or aluminum oxide
  Abrassives on the spindle have two
functions
 To act as insulators between the wheel and
workpiece
 To remove electrolytic products from the work
area
• Majority of material is removed by the
electrolytic action, less than 5% is removed by
the wheel
 The ECG process is similar to that of
milling, and grinding
 Much better than traditional grinding
where wheel wear is high
Electrical discharge machining
 Erosion of metals by
spark discharge
 Capacitor discharge
is between 50 and
380 V
 EDM can be used on
any material that is
an electrical
conductor
• Uses an
electrode that
sends out the
sparks which
erodes the
metal
• Uses dielectric
fluids for cooling
and flushing of
the material
• EDM wire
• Wire is brass,
copper or tungsten
• With wire edm you
can basically cut out
any design
 Laser-Beam Machining
 Focuses optical energy on the work piece
 The high focus high density energy melts the
material
 Rough surface and has heat affected areas
 Oxygen maybe added to the laser for
increase of energy, doing this leave a oxide
free edge which improves welding
 Lasers are also used for etching
 Design consideration with LBM
 Sharp corners should be avoided
 Deep holes will have tapered walls
 Don’t use highly reflective material
Electron-Beam Machining
 The energy source in EBM is high-
velocity electrons that move from 50%
to 80% the speed of light!
 It is a lot like Laser beam Machining but
needs a vacuum because it puts of
harmful x-rays, so is only used by
trained personnel
Electron Beam Machine
• Plasma arc cutting is a type of EBM its
temp. gets from 9400 C to 17,000 C
Which makes the process much faster
the LBM and EDM with better products
• EBM have limited machining because of
the vacuum capacity
 Water Jet Machining
• Cut a variety of metal and nonmetal material up
to 6-ft. x 12-ft. x 12-in. thick
• Reduce machining time by as much as 70%
• Provide a burr-free finished edge
• Leave no heat-affected zone (HAZ)
• Reduce waste material
• Eliminate costly set-up time
 Water jet cutters
have no start holes
 The jets have an
extremely high
velocity
 No heat during
cutting
 Very intricate designs
 The water jet is the most versatile machine
on the market today
 The water leaving the nozzle is from 400 MPa
to 1400 MPa
 The diameter of the spray is .05mm - 1mm
 It is used in lots of industries from wood, to
food processing, metal working
 The material is wet very little
 It is environmentally safe process
Abrasive water jet machining
 The same thing is water jet but with
added abrasive particle, such as silicon
carbide or aluminum oxide
 This increases the material rate removal
of the product
 The machine is a little more
complicated cause it needs to mix the
contents
References
 www.nd.edu/~manufact/pdfs/Ch26.pd
f - Supplemental Result
 Kalpakjian • Schmid Manufacturing
Engineering and Technology © 2006
 www.storkvecousa.com/
technology/2_etch.htm