Académique Documents
Professionnel Documents
Culture Documents
By S K Mondal
Features
Uses wheels, accurate sizing, finishing, low MRR; can be done at high speeds . Uses wheels with long cutting arc, very slow feed rate and large depth of cut High MRR, to obtain desired shapes and approximate sizes Water jets with velocities up to 1000 m/sec carry abrasive particles (silica and garnet) "Stones" containing fine abrasives; primarily a hole - finishing process Fine particles embedded in soft metal or cloth; primarily a surface-finishing process
Video
Grinding
Grinding is the most common form of abrasive machining. It is a material cutting process which engages an abrasive tool whose cutting elements are grains of abrasive material known as grit. These grits are characterized by sharp cutting points, high hot hardness, and chemical stability and wear resistance. The grits are held together by a suitable bonding material to give shape of an abrasive tool. Grinding can be compared with milling with an infinite number of cutting edge.
Advantages of Grinding
Dimensional accuracy
Applications of Grinding
Surface finishing
same
Video
Grinding
If each abrasive grain is viewed as a cutting tool then in
grinding operation.
High
Rake angle can be positive, zero, or negative ranging from
+45o to -60o, dull, rounded grits has large negative rake angle Cutting speed is very high Very high specific energy of cutting
Low
Low shear angle Low feed rate Low depth of cut
grinding wheel.
G Ratio
The grinding ratio or G ratio is defined as thee cubic mm
useful life.
As the wheel losses material, it must be reset or
Abrasive Material
Aluminium oxide
Silicon carbide
Diamond
IES 2009
2 marks
preferred to grind material having high tensile strength like steel. Moreover, Al2O3 shows higher chemical inertness than SiC towards steel leading to much improved wear resistance during grinding.
Grit size
The grain size affects material removal rate and the surface quality of workpiece in grinding. Large grit- big grinding capacity, rough workpiece surface Fine grit- small grinding capacity, smooth workpiece surface
Grade
The worn out grit must pull out from the bond and make room for fresh sharp grit in order to avoid excessive rise of grinding force and temperature. A soft wheel should be chosen for grinding hard material. A hard wheel should be chosen for grinding soft material.
Structure / concentration
The structure should be open for grinding wheels engaged in high material removal to provide chip accommodation space. The space between the grits also serves as pocket for holding grinding fluid. Dense structured wheels are used for longer wheel life, for holding precision forms and profiles.
Why is coarse grain and open structured wheel is preferred for stock removal grinding?
Coarse grit allows large grit protrusion and open structure provides large inter grit chip space. Thus in combination those two provide large space for chip
accommodation during stock removal grinding and risk of wheel loading is minimized.
Vitrified bonds Composed of clays and other ceramic substances, porous, strong, rigid, and unaffected by oils, water, or temperature. Brittle and can not be used for high wheel speed. Resinoid, or Plastic bond, replaced shellac and phenolic rubber wheels, not with alkaline resins grinding fluid. Shellac bond For flexible cut off wheels, replaced by resin bond.
Electroplated bond
Glazing
With continuous use a grinding wheel becomes dull with the sharp abrasive grains becoming rounded. This condition of a dull grinding wheel with worn out grains is termed as glazing.
Loading
Some grinding chips get lodged into the spaces between the grits resulting in a condition known as loaded wheel. Loading is generally caused during the grinding of soft and ductile materials. A loaded grinding wheel cannot cut properly and need dressing.
Dressing
Dressing is the conditioning of the wheel surface which ensures that grit cutting edges are exposed from the bond and thus able to penetrate into the workpiece material. In dressing attempts are made to splinter the abrasive grains to make them sharp and free cutting and also to remove any residue left by material being ground. Dressing therefore produces micro-geometry.
Truing
Truing is the act of regenerating the required geometry on the grinding wheel. Truing is also required on a new conventional wheel to ensure concentricity with specific mounting system. Truing and dressing are commonly combined into one operation for conventional abrasive grinding wheels, but are usually two distinctly separate operation for super abrasive wheel.
wheels must never be used unless they are in good balance. Grinding wheel must be balanced Statically and Dynamically. A slight imbalance will produce vibrations that will cause waviness in the work surface. It may cause a wheel to break, with the probability of serious damage and injury.
State the basic advantage of a creep feed grinder over a conventional surface
Productivity is enhanced and life of the grinding wheel is extended.
Cylindrical Grinding
Center-type cylindrical grinding is commonly used far producing external cylindrical surfaces. The grinding wheel revolves at an ordinary cutting speed, and the workpiece rotates on centers at a much slower speed. Grinding machines are available in which the workpiece is held in a chuck for grinding both external and internal cylindrical surfaces.
Centerless Grinding
Centerless grinding makes it possible to grind both external and internal cylindrical surfaces without requiring the workpiece to be mounted between centers or in a chuck. This eliminates the requirement of center holes in some workpieces and the necessity for mounting the workpiece, thereby reducing the cycle time. Two wheels are used. The larger one operates at regular
grinding speeds and does the actual grinding. The smaller wheel is the regulating wheel. It is mounted at an angle to the plane of the grinding wheel.
Centerless Grinding
The regulating wheel controls the rotation and longitudinal motion of the workpiece and usually is a plastic- or rubber-bonded wheel with a fairly wide face. The workpiece is held against the work-rest blade by the cutting forces exerted by the grinding wheel and rotates at approximately the same surface speed as that of the regulating wheel.
Centerless Grinding
Video
Centerless Grinding
The axial feed is calculated by the equation F = dN sin where F = feed (mm/min) d = diameter of the regulating wheel (mm) N = revolutions per minute of the regulating wheel
grind flat surfaces. However formed, irregular surfaces can be produced on some types of surface grinders by use of a formed wheel. Four basic types of surface grinding machines are: 1. Horizontal spindle and reciprocating table 2. Vertical spindle and reciprocating table 3. Horizontal spindle and rotary table 4. Vertical spindle and rotary table
Video
Lapping
Lapping is basically an abrasive process in which loose abrasives function as cutting points finding momentary support from the laps. Material removal in lapping usually ranges from .003 to .03 mm but many reach 0.08 to 0.1mm in certain cases.
Video
Abrasives of lapping
Al2O3 and SiC, grain size 5 ~100 m
Rapeside oil
grease
lapping speed
Honing
Honing is a finishing process, in which a tool called hone carries out a combined rotary and reciprocating motion while the workpiece does not perform any working motion. Most honing is done on internal cylindrical surface, such as automobile cylindrical walls. The honing stones are held against the workpiece with controlled light pressure. The honing head is not guided externally but,
Honing
It is desired that
1. Honing stones should not leave the work surface 2. Stroke length must cover the entire work length. 3. In honing rotary and oscillatory motions are combined to produce a cross hatched lay pattern.
The honing stones are given a complex motion so as to prevent every single grit from repeating its path over the work surface.
Honing
Video
2. oscillation speed
3. length and position of the stroke
Buffing
Buffing is a polishing operation in which the workpiece is brought into contact with a revolving cloth wheel that has been charged with a fine abrasive, such as polishing rough. The wheels are made of disks of linen, cotton,
broadcloth, or canvas, and achieve the desired degree of firmness through the amount of stitching used to fasten the layers of cloth together. Negligible amount of material is removed in buffing while a very high luster is generated on the buffed surface. The dimensional accuracy of the parts is not affected by the buffing operation.
Video
Super Finishing
Fig. super finishing of end face of a cylindrical work piece in radial mode
In this both feeding and oscillation of the super finishing stone is given in the radial direction.
Super Finishing
In this case the abrasive stone covers the section of the workpiece requiring super finish. The abrasive stone is slowly fed in radial direction while its oscillation is imparted in the axial direction. It reduce surface roughness and increase bearing load capacity.
Video
GATE - 1998
In machining using abrasive material, increasing abrasive grain size (a) Increases the material removal rate (b) Decreases the material removal rate (c) First decreases and then increases the material removal rate (d) First increases and then decreases the material removal rate
GATE - 2002
The hardness of a grinding wheel is determined by the (a) Hardness of abrasive grains (b) Ability of the bond to retain abrasives (c) Hardness of the bond (d) Ability of the grinding wheel to penetrate the work piece
GATE - 2006
If each abrasive grain is viewed as a cutting tool, then which of the following represents the cutting parameters in common grinding operations? (a) Large negative rake angle, low shear angle and high cutting speed (b) Large positive rake angle, low shear angle and high cutting speed (c) Large negative rake angle, high shear angle and low cutting speed (d) Zero rake angle, high shear angle and high cutting speed
IES - 2005
Consider the following statements in respect of grinding? 1. The pitch of the grit cutting edges is larger than the pitch of the milling cutter. 2. The cutting angles of the grits have a random geometry. 3. The size of the chip cuts is very small for grinding. Which of the statements given above are correct? (a) 1 and 2 (b) 2 and 3 (c) 1 and 3 (d) 1, 2 and 3
IES - 2001
Specific cutting energy is more in grinding process compared to turning because (a) Grinding (cutting) speed is higher (b) The wheel has multiple cutting edges (grains) (c) Plaguing force is significant due to small chip size (d) Grinding wheel undergoes continuous wear
IES - 1996
Specific energy requirements in a grinding process are more than those in turning for the same metal removal rate because of the (a) Specific pressures between wheel and work being high. (b) Size effect of the larger contact areas between wheel and work. (c) High cutting velocities (d) High heat produced during grinding.
IES - 1994
The ratio of thrust force to cutting force is nearly 2.5 in (a) Turning (b) Broaching (c) Grinding (d) Plain milling
IES 2010
In relation to the peripheral or surface speeds of the grinding wheel and that of the workpiece in cylindrical grinding of alloy steel workpieces, the grinding wheel speed is (a) Less than the speed of the workpiece (b) Same as the speed of the workpiece (c) Double the speed of the workpiece (d) 65 to 75 times the speed of the workpiece.
IES - 2000
The sequence of markings "S 14 K 14 S" on a grinding wheel represents respectively (a) Bond type, structure, grade, grain size and abrasive type (b) Abrasive type, grain size, grade, structure and bond type (c) Bond type, grade, structure, grain size and abrasive type (d) Abrasive type, structure, grade, grain size and bond type
IES - 1993
Tool life in the case of a grinding wheel is the time (a) Between two successive regrinds of the wheel (b) Taken for the wheel to be balanced (c) Taken between two successive wheel dressings (d) Taken for a wear of 1mm on its diameter
IES - 2007
Honing Process gives surface finish of what order? (a) 10 m (CLA) (b) 1.0 m (CLA) (c) 0.1 m (CLA) (d) 0.01 m (CLA)
IES - 2012
Statement (I): Honing is an abrading process to remove stock from metallic surfaces. Statement (II):Honing is commonly done on internal surfaces. (a) Both Statement (I) and Statement (II) are individually true and Statement (II) is the correct explanation of Statement (I) (b) Both Statement (I) and Statement (II) are individually true but Statement (II) is not the correct explanation of Statement (I) (c) Statement (I) is true but Statement (II) is false (d) Statement (I) is false but Statement (II) is true
IES - 1992
A surface finish of 0.025 0.1 micrometer CLA values is to by produced. Which machining process would you recommend? (a) Grinding (b) Rough turning (c) Lapping (d) Honing
IAS - 2001
Consider the following statements: The set-up for internal centreless grinding consists of a regulating wheel, a pressure roll and a support roll, between which the tubular workpiece is supported with the grinding wheel within the tube, wherein 1.The grinding wheel, workpiece and regulating wheel centers must lie on one line 2.The directions of rotation of workpiece and grinding wheel are same 3.The directions of rotation of pressure roll, support roll and regulating wheel are same 4.The directions of rotation of grinding wheel and regulating wheel are same Which of these statements are correct? (a) 1, 2 and 3 (b) 1, 3 and 4 (c) 2 and 3 (d) 3 and 4
IAS - 2001
Which one of the following grinding wheels (with Grade, Grit and Bond) is suitable for cutter grinding? (a) K 60 vitrified (b) K 320 vitrified (c) T 60 resinoid (d) T 320 resinoid
Q. No 1 2 3 4 5 6
Option A A A C A D