Project on

Grinding Burn

MID SEM PRESENTATION FOR PS-3

AT

BAJAJ MOTORS LTD, MANESAR

Submitted To : Submitted By:

Dr. Surya Prakash (Faculty Mentor) Vikash Kumar (15B00087)
Mr. M.S. Rao (A.V.P. Bajaj Motors) vikash.kumar.15mec@bml.edu.in
Crankpin
• A crankpin or crank journal is a journal in an
engine or mechanical device. That is, the part of
a shaft or axle that rests on bearings. In a
reciprocating engine, the crankpin is the part of a
crankshaft where the lower end of a connecting
rod attaches.
• Bajaj Motors manufactures crankpin model no :
P-17 for , Hero MotoCorp Ltd, one of their many
precious customers.
Process flow
diagram
Figure represents the process
flow diagram for the
manufacturing of the crankpin
p-17.

Where operations circled red

represent the operations
which involve grinding process
and is monitored during the
project.
Grinding
Grinding is a manufacturing process for finishing hardened surfaces and hard
or brittle materials that cannot be formed in other methods. It is classified as
a two-body abrasion process in which an abrasive material rubs against a
work piece and removes small pieces of the material of work piece
In manufacturing of crankpin, grinding is one of many processes for material
removal and it contributes to the quality of the product directly, a non
conformity or substandard product is not at all desired, hence importance of
quality improvement in this process is ranked above other priorities.
The result of a proper grinding process is a workpiece surface which is free of
tensile residual stresses and has retained its original microstructure in the
surface
Centerless Grinding (Throughfeed)
Centerless grinding is the process of removing material from
the outside diameter of a work piece using an abrasive
wheel. In its simplest form, a centerless grinder consists of the
machine base, grinding wheel, regulating wheel and work
blade. With centerless grinding, the work piece is not
mechanically held to drive the part.

The work piece is located on its outside diameter and

supported by the work blade which is between the regulating
wheel and the grinding wheel. The regulating wheel drives the
part and the grinding wheel removes the material.

Throughfeed grinding (also known as thrufeed grinding) is the process of feeding the part through the regulating
wheel and the grinding wheel. Throughfeed grinding is used for simple cylindrical parts. The regulating wheel is
angled to the grinding wheel, with the inlet side having a larger opening. The part is placed onto a conveyor and the
conveyor guides feed the part into the wheels. The part is then pulled through the wheels by the rotation of the
regulating wheel and the grinding wheel and exits on the opposite side.
Palmary PC-1810S
Machines used
Grinding Burns
The main problems in grinding are caused by the heat that is generated
in the grinding process. In grinding, the heat flow is much higher
compared to other manufacturing methods like cutting and also the
poor heat transfer properties of aluminum oxide wheels have to be
considered to have an effect.
Several forms of damages may occur due to these high localized
temperatures between the grinding wheel and the workpiece. The
formation of grinding burns is the most common type of thermal
damages.
Effects of grinding burns
Softening and the formation of temper burns, formation of rehardening
burns, formation of unfavorable residual stresses and formation of cracks are
the major effects on which burn and severity is categorized.
Temper burn is formed when the surface temperature exceeds the original
tempering temperature of the work piece. The formed softer layer, called
over-tempered martensite, consists of coarsened cementite carbides.
The softening of the surface layer occurs due to carbon diffusion at the
surface.
Also other alterations in the surface of ground part may occur: residual
stresses may form or the beneficial compression stresses gained from the
case hardening may decrease due to the thermal phase transformations,
thermal or plastic deformation or mechanical plastic deformation.
Non Conformities observed

Some visual and testing results of non conforming workpiece.

Project objective & action plan
• To collect the data of all the possible parameters having an effect on
the quality of finished product.
• Detect and reduce the grinding burn by tweaking the coolant flow
and reducing the heat generated in the process.
• To find out the optimum speed of the grinding wheel & control wheel
and dressing frequency.
• Necessary measures to discover the root cause and eliminating them.
• Devising necessary strategy to prevent the non conformities.
Work progress
• Currently operations to monitor have been identified and the data is
being collected.
• Degree of burn and categorization is under progress.
• Some of the parameters causing the grinding burn have been
identified and other possibilities are being taken into consideration.
• Discovering the major and minor causes for the problem is being
researched using pareto analysis.
Thank You