GRINDING Process of producing good surface finish on the workpiece and exact or close to tolerance dimensions.

GRINDING WHEEL COMPOSITION:

Abrasive -Grain that grinds the workpiece. -Should be harder than the material being ground. -Strong enough to withstand grinding pressure. -Does not become dull at grinding temperature. -Friable (capable of fracturing) Bond - Material that holds the abrasive. - It determines the hardness and grade of the wheel. Porous - Space or gap between abrasives.

Process of sharpening tools. Examples: Sharpening High Speed Steel Tools, Endmills, Drill bits, Chisels, etc.
Applicable for cutting or slitting.

TYPES OF ABRASIVE:
Bond
1. ALUMINUM OXIDE
Generally, it is used for grinding high tensile materials Material to grind: Mild steel, high-carbon steel, high-speed steel. 2. SILICON CARBIDE It is harder than aluminium oxide. Generally, it is used for grinding low tensile materials and carbide. Material to grind: tungsten carbide, glass, plastics, stainless steel. brass, bronze, aluminium and cast iron. 3. CUBIC BORON NITRIDE High hardness and abrasive resistance. Material to grind: high alloy and tough steel such as tool steel cold working steel and HSS. 4. DIAMOND WHEEL Harder than CBN, Ability to grind carbide, ceramic materials, glass and porcelain, carbon graphite.

Abrasive

Air space

Chip

Workpiece
The wheel is made of abrasives held together by a bond.

It has air-spaces among the abrasives and bond.

Abrasive Grain Size

Factors affecting the selection of grain sizes

Factor Type of surface finish required Type of material being ground Amount of material to be removed Area of contact between the grinding wheel and the workpiece Coarse Grains Poor Finish Grinding soft materials Removing a large amount of material Grinding big area of contact Fine Grains Fine Finish Grinding hard materials Removing a small amount of material Grinding small area of contact

Selecting Grade
The grade of the bond determines the strength of the wheel. During the grinding operation the abrasive grains will break away easily if the bond is weak. Such a wheel is a soft grade.

Grinding wheels with a strong bond will hold the abrasive grains strongly during the grinding operations.
The grade is indicated by a letter from A (soft) to Z (hard).

Structure
The structure of a grinding wheel is the spacing of the abrasive grains.

Dense structure provides small chip clearance.

Open structure provides big chip clearance.

Factors affecting the selection of the grinding- wheel structure

Factor
Hardness of workpiece material Area of contact between the grinding wheel and the workpiece Type of surface finish desired

TYPES OF BOND:
1. VITRIFIED BOND A bonded wheel that is unaffected by heat or cold and are made in a great range of hardness than any other bond. Not affected by water, oil or acid. It can be used for wet or dry grinding operations. 2. SILICATE BOND Release the abrasive grains more readily than vitrified bond. It is not suitable for heavy duty grinding. 3. RESINOID BOND Strong and flexible. It is used at higher speeds than vitrified-bonded wheel. It is widely used in snagging wheels for grinding irregularities. Used in cutoff wheels. 4. RUBBER BOND Pure rubber is mixed with sulfur. It is extremely flexible at operating speed and permits the manufacture of grinding wheel as thin as .006in or .15mm for slitting. 5. Shellac Bond Shellac-bonded grinding wheels are used for producing high quality finished with light cut on workpieces.

Dense Structure Open Structure

Grinding hard material Grinding small area of contact Grinding soft material Grinding big area of contact

Giving a fine finish

Giving a poor finish

GRINDING WHEELS SHAPE AND APPLICATION:

GRINDING WHEELS SHAPE AND APPLICATION:
Straight Shape Cylinder Shape

Application Cylindrical, internal, cutter, surface, and offhand grinding.

Application Surface grinding, tool and cutter grinder.

Flaring Cup

Dish Shape

Application Tool and cutter grinder

Application Tool and cutter grinder

GRINDING WHEEL MARKINGS:

There is a standard marking system for identifying aluminium oxide and silicon carbide wheel. The marking is printed on the side of large grinding wheels as well as on the blotter washers The marking is found on the blotter of small grinding wheels.

MANUFACTURERS SYMBOL Indicates the exact type of Abrasives (Use is optional)

Grinding Wheel marking

ABRASIVE
A Aluminum Oxide C Silicon Carbide B Diamond D Cubic Boron Nitride

GRIT SIZE
Coarse 10 12 14 16 20 24 Medium 30 36 Fine 70 80 90 100 120 150 180

46 54 60

Very Fine 220 240 280 320 400 500 600

Soft
A E

GRADE Medium
I M

Hard
Q V

B C
D

F G
H

J K
L

N O
P

R S
T U

W X
Y Z

STRUCTURE Dense
1 2 3 5 6 7 9 10 11 13 14 15
BOND TYPE

V = Vitrified S = Silicate
B = Resinoid R = Rubber E = Shellac

12

Open

COMMON GRINDING OPERATIONS:

1. Cylindrical Grinding
Grinding wheel

Work

MANUFACTURERS SYMBOL

Identifies wheel
(Use is optional)

COMMON GRINDING OPERATIONS:

COMMON GRINDING OPERATIONS:
2. Surface Grinding
Grinding Wheel

3. Centerless Grinding

Work

Control wheel

Work

Wheel

Workrest

COMMON GRINDING OPERATIONS:

4. Internal Grinding
Work Grinding wheel

COMMON GRINDING OPERATIONS:

5. Off-hand Grinding
Wheel

Tool

Tool Rest

GRINDING MACHINE and its OPERATIONS: CYLINDRICAL GRINDING

Electrical Control Workhead

GRINDING MACHINE and its OPERATIONS:

Wheelhead Wheel Footstock

CYLINDRICAL GRINDING Plain Cylindrical Grinder

Upper Table Table Traverse Handwheel Trip Dogs Infeed Handwheel

Generally, it is a production type of machine. The wheelhead and the upper table cannot be swivelled

Lower Table

Universal Cylindrical Grinder

The workhead, the wheelhead and the upper table can be swivelled to an angle for grinding tapered workpieces.

Base

GRINDING MACHINE and its OPERATIONS: CYLINDRICAL GRINDING

GRINDING MACHINE and its OPERATIONS: CYLINDRICAL GRINDING

Work Rotation

A. Parallel Shaft

B.

Step Shaft

Work

Work Axis

Longitudinal Feed Wheel Rotation

C. Arbor D. Dead Centre

In cylindrical grinding, a grinding wheel is used to reduce the diameter of the workpiece. The grinding wheel and workpiece are both rotating in the same direction

GRINDING MACHINE and its OPERATIONS: CYLINDRICAL GRINDING Base

It is made of cast iron. It supports other parts of the machine It has ways to guide the machine table.

GRINDING MACHINE and its OPERATIONS: CYLINDRICAL GRINDING

Upper Table

Upper table(swiveling table) It rests on the lower table, it can be swiveled for grinding tapers.

Lower table(sliding table)

It rests and reciprocates on the ways of the base.
Lower Table

GRINDING MACHINE and its OPERATIONS:

GRINDING MACHINE and its OPERATIONS:

CYLINDRICAL GRINDING
Wheelhead

CYLINDRICAL GRINDING
It is mounted on the left end of the table.

It is mounted on the cross-slide behind the table. It holds and drives the grinding wheel
It can be swiveled on Universal Grinders.

It holds the chuck or centre that drives the workpiece.

It provides different speeds for the work. It can be swiveled for grinding tapers.

Workhead

GRINDING MACHINE and its OPERATIONS: CYLINDRICAL GRINDING Footstock

It is mounted on the right end of the table.
Footstock

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

Wheel guard

Column Nozzle Magnetic chuck Table

Trip dogs

Spark guard Wheel

Table traverse handwheel Saddle

It holds a centre to support a long workpiece. It can be positioned anywhere along the length of the upper table.

The spindle is spring loaded.

Diamond Dresser

A diamond dresser can be mounted on it for dressing the wheel.

Crossfeed handwheel Downfeed handwheel Base

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

In surface grinding, the work is passed under a rotating wheel to produce flat or irregular surfaces.

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

Base
Saddle

Saddle
It is mounted on top of the base.
It is moved in or out across the ways by hand or by automatic feed.

It is made of cast iron. It usually houses the hydraulic pump to operate the table and the power feed.

Base

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

Table
Spark guard Magnetic chuck It is mounted on top of the saddle.

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

Wheelhead

Wheelhead
It reciprocates across the upper ways of the saddle.
It is mounted on the column.

It holds the grinding wheel. It can be raised or lowered for setting the depth of cut

Column

Work table

Grinding wheel

GRINDING MACHINE and its OPERATIONS:

GRINDING WHEELS:
High Spot

SURFACE GRINDING
Purpose of Truing

Truing

is the operation of removing any high spots on the grinding wheel. Dressing
is the operation of removing the blunt abrasives and metal particles from the grinding wheel face.

Wheel

A trued grinding wheel will rotate concentric with the machine spindle.

Blunt Abrasive Grains

A trued grinding wheel will also reduce or eliminate vibrations.

Wheel Face Has Glassy Appearance

GRINDING MACHINE and its OPERATIONS: SURFACE GRINDING

Dressing Dressing is the operation of removing the blunt abrasives and metal particles from the grinding wheel face. The blunt abrasive grains and the metal particles in the airspace reduce the cutting action of the grinding wheel.
Improper balanced grinding wheels will affect the workpiece. The workpiece will have inaccurate dimensions. Grinding wheels that are unbalance will create unwanted vibrations. Vibrations will damage the spindle bearings of the grinding machines.

The workpiece will have poor surface finish. Excessive vibrations may cause the wheel to break.

There are two types of static balancing unit : The beveled knife edge type. The disc type.

Grinding Wheel

Mandrel

Disc

Touching
Wheel

True the grinding wheel

Wheel

Levelling gauge

Prepare the bevelled knife edge static balancing unit on a surface plate Use the levelling gauge to level the knife edge plate.

Mandrel Remove the grinding wheel from the machine.

Balancing unit

Mount the grinding wheel on a mandrel.

Place 2 balancing weights on the flange.

The balancing weights should be diametrically opposite to each other

Balancing unit

Mandrel

Place the grinding wheel assembly on the balancing unit.

Allow the grinding wheel to rotate slowly.

Wait for the grinding wheel to stop. Lightest point will be at the top of the wheel

Wheel Balancing weights

Chalk

Chalk mark

Put a chalk mark at the top (Lightest point) of the wheel

Re-adjust the 2 balancing weights diametrically at 90 degree to the chalk mark.

Chalk mark

Move the balancing weights equally towards the chalk mark about 3 mm at a time.
Check the grinding wheel balance in the 4 positions. Continue to move the balancing weights towards the chalk mark until the grinding wheel remains still in any position

Balancing weights

Grinding wheels may have been damaged during transportation or storage.

Chipped Edge

Look for the following defects :

Cracks Broken Edges Damaged bushing
Bush

They must be carefully inspected before use. Damaged grinding wheels are dangerous to use
Blotter Washer

Damaged blotter washers

Sometimes cracks cannot be seen by the naked eye Use ring test to check the grinding wheel for such cracks.

Support the grinding wheel with a finger through the bushing

Tap the wheel lightly with a screwdriver handle

Points to Note

Grinding wheels must be dry and clean before testing.

Wet and dirty grinding wheels may not produce clear ringing sound

Important : A clear ringing sound shows that the grinding wheel is not cracked.
A cracked grinding wheel will give a dull sound.

Place the grinding wheel vertically on a piece of wood.

Use your hand to support the grinding wheel lightly. Tap the grinding wheel with a wooden or plastic mallet.