GRINDING

MACHINE
 GRINDING

• Grinding is the process of removing metal by the application of abrasives

which are bonded to form a rotating wheel.
• When the moving abrasive particles contact the work piece, they act as
tiny cutting tools, each particle cutting a tiny chip from the work piece.
• The grinding machine supports and rotates the grinding abrasive wheel
and often supports and positions the work piece in proper relation to the
wheel.
• It is basically a finishing process employed to produce high accuracy and
surface finish. The grinding wheel consists of sharp crystals called abrasives
held together by suitable bonding.
•
 The grinding machine is used for
1. Roughing and finishing flat, cylindrical, and
conical surfaces.
2. Finishing internal cylinders or bores.
3. Forming and sharpening cutting tools.
4. Snagging or removing rough projections
from castings and stampings.
5. Cleaning, polishing, and buffing surfaces.
 Specification of Grinding Wheel
• 51 A 60 K 5 V 05
51 – Manufacturer’s identification no. for exact kind of abrasive used
A – Type of abrasive
A – Al2O3, B – CBN, C – SiC, D – Diamond
60 – Average grit size
8-24 – Coarse; 30-60 – Medium; 80-180 – Fine; 220-600 – Very fine
K – Hardness of wheel → A – Softest to Z – Hardest
5 – Porosity of wheel → 1 to 15/20
1- Low porosity / Closed structure / More denser
15/20- High porosity / Open structure / Less denser
V – Bonding material
05 – Wheel manufacturer’s identifier
 Classification of Grinding Machines
1. Surface Grinding M/c: Similar to Milling
a) Horizontal Machine b) Vertical Machine
 Surface Grinding
• Surface grinding or grinding flat surfaces, is
characterized by a large contact area of the wheel with
the workpiece.
• The force of each abrasive grain against the work piece
is smaller than that applied to each grain in cylindrical
grinding.
• In surface grinding the grinding wheel should be
generally softer in grade and wider in structure than for
cylindrical grinding.
2. Utility Grinding Machine
• The utility grinding machine is intended for offhand
grinding where the work piece is supported in the hand
and brought to bear against the rotating grinding abrasive
wheel.
• The accuracy of this type of grinding machine depends on
the operator’s skill and knowledge of the machine’s
capabilities and the nature of the work.
• It consists of a horizontally mounted motor with a
grinding abrasive wheel attached to each end of the
motor shaft.
3. Cylindrical Grinding M/c: Similar to lathe. Can
perform both External and Internal Grinding.
• The axis of the regulating wheel and grinding wheel are
slightly misaligned, causing the part to travel slowly in
the axial direction.
3. Special Grinding M/c
a) Tool & Cutter grinder b) Thread Grinder
 GLAZING & LOADING
• When the surface of a grinding wheel develops a
smooth and shining appearance, it is said to be
glazed. This indicate the abrasive particles on the
wheel face are not sharp. These are worked down
to bond level.
• When soft materials like aluminium, copper, lead,
etc. are ground the metal particles get clogged
between the abrasive particles. This condition is
called loading.
 Dressing
• Dressing is the conditioning of the wheel
surface which ensures that grit cutting edges
are exposed from the bond and thus will be
able to penetrate into the work piece
material and substantially influence the
condition of the grinding wheel.
• Dressing refers to the removing of clogs and blunt
abrasive grains from the surface of the grinding
wheel.
• Dressing exposes the cutting edges which restore
the correct cutting action of the wheel.
• Dressing is done on a glazed or loaded wheel to
recondition it.
 Diamond Dresser
• The diamond dresser is the most efficient for truing
wheels for precision grinding, where accuracy and high
finish are required.
• When using a diamond dresser to dress or true a grinding
wheel, the wheel should be turning at, or slightly less
than, normal operating speed never at the higher speed.
• When starting the dressing or truing operation, be certain
that the point of the dressing tool touches the highest
spot of the wheel first, to prevent the point from digging
in.
• Feed the dresser tool point progressively, 0.001 inch at a
time, into the wheel until the sound indicates that the
wheel is perfectly true.
• The rate at which you move the point across the face of
the wheel depends upon the grain and the grade of the
wheel and the desired finish.
• A slow feed gives the wheel a fine finish, but if the feed is
too slow, the wheel may glaze.
• A fast feed makes the wheel free cutting, but if the
feed is too fast, the dresser will leave tool marks on
the wheel.
• The correct feed can only be found by trial, but a
uniform rate of feed should be maintained during
any one pass.
 Glazing
• Glazing of the wheel is nothing but abrasive
particles getting blunt. As they can be emoved by dressing, grinding
wheels are called self sharpening wheels.
• Loading / Clogging: It is the condition when pores of the grinding
wheel get filled/clogged with chips. This can occur due to grinding of
soft materials or by improper selection of grinding wheels or
improper process parameters or improper cutting fluids. Dressing will
remove the clogged layer.
 Truing
Truing is the act of regenerating the required
geometry on the wheel. Truing is required
whenever a new wheel is loaded to ensure
concentricity with machine spindle. It is done
with a diamond truing tool by removing the
outer layer and creating a concentric layer w.r.t
the spindle axis.
• Truing refers to the shaping of the wheel to make it run
concentric with the axis.
• When a new grinding wheel is mounted, it must be trued
before use to remove the run out.
• To improve dimension
control on cylindrical
parts, center less
grinders, which use long
cylindrical wheels, are
employed.
 NOTE
1. The specific energy requirement in Grinding (50 J/mm3)is more than that
required in turning (2 - 5 J/mm3). This is because of the large contact area
between the wheel and the work resulting due to the large no. of cutting edges.
2. The Grinding wheels have random geometry. The rake angle varies from +450
to -600 and more. The negative rake increases the cutting forces and promote
rubbing action affecting the cutting action. Hence high rotational speeds are
used for minimizing the effect of negative rake.
3. The ratio of thrust force to cutting force in Grinding is > 1. This is opposite in
turning (i.e < 1).
4. Soft wheels are used for hard materials as they break easily to release worn
out grains (High self sharpening capability). Hard wheels are used for soft
materials as wear out is less and they retain the grains for more time.
 Internal Grinding

• The internal grinding attachment is bolted to the wheel

head on the universal tool and cutter grinder.
• The RPM is increased by placing a large pulley on the
motor and a small pulley on the attachment.
• The workpiece should be set to rotate in the direction
opposite that of the grinding wheel.
• Since internal grinding uses small grinding wheels, the
spindle and quill must operate at a high speed to get the
required SFPM.
• Most internal grinding attachments come with several
sizes of quills. Use the largest one possible for the hole
being ground.
• The smaller quills tend to spring away from the work
easily and produce tapers and irregularities.