CHAPTER 25

Abrasive Machining and Finishing Operations

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-1

Examples of Bonded Abrasives

Figure 25.1 A variety of bonded abrasives used in abrasive machining processes. Source: Courtesy of Norton Company.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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General Characteristics of Abrasive Machining Processes and Machines

TABLE 25.1 Process Surface Characteristics Flat surfaces on most materials; production rate depends on table size and automation; labor skill depends on part; production rate is high on vertical-spindle rotary-table type. Round workpieces with stepped diameters; low production rate unless automated; labor skill depends on part shape. Maximum dimension (m)* Reciprocating table L : 6 Rotary table D : 3 Workpiece D : 0.8 Roll grinders D : 1.8 Universal grinders D : 2.5 Workpiece D : 0.8 Hole D : 2 Spindle D : 1.2 Table D : 3.7

Cylindrical

Centerless Round workpieces; high production rate; low to medium labor skill. Internal Bores in workpiece; low production rate; low to medium labor skill. Honing Bores and holes in workpiece; low production rate; low labor skill. Lapping Flat surfaces; high production rate; low labor skill. Ultrasonic Holes and cavities of various shapes, particularly in hard and brittle machining nonconducting materials. *Larger capacities are available for special applications. L=length; D=diameter.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-3

Workpiece Geometries

Figure 25.2 The types of workpieces and operations typical of grinding: (a) cylindrical surfaces, (b) conical surfaces, (c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or slotting with thin wheels, and (g) internal grinding. See also the illustrations in Section 25.6.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-4

Knoop Hardness for Various Materials and Abrasives

TABLE 25.2

Common glass Flint, quartz Zirconium oxide Hardened steels Tungsten carbide Aluminum oxide

350500 8001100 1000 7001300 18002400 20003000

Titanium nitride Titanium carbide Silicon carbide Boron carbide Cubic boron nitride Diamond

2000 18003200 21003000 2800 40005000 70008000

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Grinding Wheel
Figure 25.3 Schematic illustration of a physical model of a grinding wheel, showing its structure and wear and fracture patterns.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Common Grinding Wheels

Figure 25.4 Common types of grinding wheels made with conventional abrasives. Note that each wheel has a specific grinding face; grinding on other surfaces is improper and unsafe.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-7

Superabrasive Wheel Configurations

Figure 25.5 Examples of superabrasive wheel configurations. The annular regions (rim) are superabrasive grinding surfaces, and the wheel itself (core) is generally made of metal or composites. The bonding materials for the superabrasives are (a), (d), and (e) resinoid, metal, or vitrified, (b) metal, (c) vitrified, and (f) resinoid.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-8

Marking System for Aluminum-Oxide and Silicon-Carbide Bonded Abrasives

Figure 25.6 Standard marking system for aluminum-oxide and silicon-carbide bonded abrasives.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Standard Marking System for Cubic Boron Nitride and Diamond Bonded Abrasives
Figure 25.7 Standard marking system for cubic boron nitride and diamond bonded abrasives.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-10

Grinding Chips
(a) (b)

Figure 25.8 (a) Grinding chip being produced by a single abrasive grain. (A) chip, (B) workpiece, (C) abrasive grain. Note the large negative rake angle of the grain. The inscribed circle is 0.065 mm (0.0025 in.) in diameter. Source: M. E. Merchant. (b) Schematic illustration of chip formation by an abrasive grain with a wear flat. Note the negative rake angle of the grain and the small shear angle.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-11

Grinding Wheel Surface

Figure 25.9 The surface of a grinding wheel (A46-J8V) showing abrasive grains, wheel porosity, wear flats on grains, and metal chips from the workpiece adhering to the grians. Note the random distribution and shape of abrasive grains. Magnification: 50X. Source: S. Kalpakjian.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-12

Surface Grinding and Plowing

Figure 25.10 Schematic illustration of the surface grinding process, showing various process variables. The figure depicts conventional (up) grinding.

Figure 25.11 Chip formation and plowing of the workpiece surface by an abrasive grain. This action is similar to abrasive wear. (See Fig. 32.6).
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 25-13

Approximate Specific Energy Requirements for Surface Grinding

TABLE 25.3 Specific energy Workpiece material Aluminum Cast iron (class 40) Low-carbon steel (1020) Titanium alloy Tool steel (T15) Hardness 150 HB 215 HB 110 HB 300 HB 67 HRC W-s/mm 727 1260 1468 1655 1882
3 3

hp-min/in. 2.510 4.522 525 620 6.530

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-14

Shaping Using Computer Control

Figure 25.12 Shaping the grinding face of a wheel by dressing it with computer control. Note that the diamond dressing tool is normal to the surface at point of contact with the wheel. Source: Okuma Machinery Works Ltd.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-15

Speed and Feed Ranges and Grinding Wheel Recommendations

TABLE 25.4 Typical Range of Speeds and Feeds for Abrasive Processes Conventional Creep-feed Process variable grinding grinding Buffing Wheel speed (m/min) 15003000 15003000 18003600 Work speed (m/min) 1060 0.11 Feed (mm/pass) 0.010.05 16
TABLE 25.5 Typical Recommendations for Grinding Wheels for Use with Various Materials Material Type of grinding wheel Aluminum C46K6V Brass C46K6V Bronze A54K6V Cast iron C60L6V, A60M6V Carbides C60I9V, D150R75B Ceramics D150N50M Copper C60J8V Nickel alloys B150H100V Nylon A36L8V Steels A60M6V Titanium A60K8V Tool steels ( > 50 HRC) B120WB Note: These recommendations vary significantly, depending on material composition, the particular grinding operation, and grinding fluids used.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 25-16

Polishing 15002400

Surface Grinding Operations

Figure 25.13 Schematic illustrations of various surface grinding operations. (a) Traverse grinding with a horizontal-spindle surface grinder. (b) Plunge grinding with a horizontal-spindle surface grinder, producing a groove in the workpiece. (c) A vertical-spindle rotary-table grinder (also known as the Blanchard type).

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Surface Grinding
Figure 25.14 Schematic illustration of a horizontal-spindle surface grinder.

Figure 25.15 (a) Rough grinding of steel balls on a vertical-spindle grinder; the balls are guided by a special rotary fixture. (b) Finish grinding of balls in a multiple-groove fixture. The balls are ground to within 0.013 mm (0.0005 in.) of their final size. Source: American Machinist.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 25-18

Cylindrical Grinding Operations

Figure 25.16 Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge grinding, and (c) profile grinding. Source: Okuma Machinery Works Ltd.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-19

Plunge and Noncylindrical Grinding

Figure 25.17 Plunge grinding of a workpiece on a cylindrical grinder with the wheel dressed to a stepped shape. See also Fig. 25.12.

Figure 25.18 Schematic illustration of grinding a noncylindrical part on a cylindrical grinder with computer controls to produce the shape. The part rotation and the distance x between centers is varied and synchronized to grind the particular workpiece shape.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 25-20

Thread and Internal Grinding

Figure 25.19 Thread grinding by (a) traverse, and (b) plunge grinding.

Figure 25.21 Schematic illustrations of internal grinding operations.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Cycle Patterns in Cylindrical Grinding

Figure 25.20

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Centerless Grinding

(c)

Figure 25.22 Schematic illustrations of centerless grinding operations: (a) through feed grinding. (b) Plunge grinding. (c) A computer numerical control cylindrical grinding machine. Source: Courtesy of Cincinnati Milacron, Inc.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-23

Creep-Feed Grinding
(a) (b) (c)

Figure 25.23 (a) Schematic illustration of the creep-feed grinding process. Note the large wheel depth of cut, d. (b) A shaped groove produced on a flat surface by creep-feed grinding in one pass. Groove depth is typically on the order of a few mm. (c) An example of creep-feed grinding with a shaped wheel. This operation can also be performed by some of the processes described in Chapter 26. Source: Courtesy of Blohm, Inc., and Manufacturing Engineering Magazine, Society of Manufacturing Engineers.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-24

General Recommendations for Grinding Fluids

TABLE 25.6 Material Grinding fluid E, EP Aluminum CSN, E, MO FO Copper D, MO Magnesium CSN, EP Nickel EP Refractory metals CSN, E Steels CSN, E Titanium D: dry; E: emulsion; EP: Extreme pressure; CSN: chemicals and synthetics; MO: mineral oil; FO: fatty oil.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-25

Ultrasonic Machining and Coated Abrasives

Figure 25.24 (a) Schematic illustration of the ultrasonic machining process. (b) and (c) Types of parts made by this process. Note the small size of holes produced.

Figure 25.25 Schematic illustration of the structure of a coated abrasive. Sandpaper, developed in the 16th century, and emery cloth are common examples of coated abrasives.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-26

Belt Grinding
Figure 25.26 Example: Belt Grinding of Turbine Nozzle Vanes.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Honing and Superfinishing

Figure 25.27 Schematic illustration of a honing tool used to improve the surface finish of bored or ground holes.

Figure 25.28 Schematic illustrations of the superfinishing process for a cylindrical part. (a) Cylindrical mircohoning, (b) Centerless microhoning.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-28

Lapping
Figure 25.29 (a) Schematic illustration of the lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on cylindrical surfaces.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-29

Polishing Using Magnetic Fields

Figure 25.30 Schematic illustration of polishing of balls and rollers using magnetic fields. (a) Magnetic float polishing of ceramic balls. (b) Magnetic-field-assisted polishing of rollers. Source: R. Komanduri, M. Doc, and M. Fox.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-30

Abrasive-Flow Machining
Figure 25.31 Schematic illustration of abrasive flow machining to deburr a turbine impeller. The arrows indicate movement of the abrasive media. Note the special fixture, which is usually different for each part design. Source: Extrude Hone Corp.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-31

Robotic Deburring
Figure 25.32 A deburring operation on a robot-held die-cast part for an outboard motor housing, using a grinding wheel. Abrasive belts (Fig. 25.26) or flexible abrasive radialwheel brushes can also be used for such operations. Source: Courtesy of Acme Manufacturing Company and Manufacturing Engineering Magazine, Society of Manufacturing Engineers.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 25-32

Economics of Grinding and Finishing Operations

Figure 25.33 Increase in the cost of machining and finishing a part as a function of the surface finish required. This is the main reason that the surface finish specified on parts should not be any finer than necessary for the part to function properly.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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