Grinding A

Grinding Grinding
Illegitimi non carborundum g

ver. 1 ver. 1
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
1
Overview Overview
Processes
Analysis Analysis
2
3
Horizontal Grinding
4
5
Horizontal grinding
Vertical grinding
6
Centered grinding Centered grinding
Centerless grinding
7
Creep Feed Grinding Creep Feed Grinding
8
9
10
11
12
Grinding Wheels Grinding Wheels
13
Grinding Wheels Grinding Wheels
14
Grinding Wheel Information
15
Correctly Mounted Wheel
16
Grinding Wheel Surface Grinding Wheel Surface
17
Grind Wheel Dressing Grind Wheel Dressing
ME 6222: Manufacturing Processes and
Systems Prof. J .S. Colton GIT 2009
18
Grinding Wheel Dressing Grinding Wheel Dressing
ME 6222: Manufacturing Processes and
Systems Prof. J .S. Colton GIT 2009
19
Grinding Chips Grinding Chips
20
Chip formation geometry Chip formation geometry
w
l
D
t
l
V
d
t

l
v
21
Chip geometry Chip geometry
As with rolling contact length, the chip length, As with rolling contact length, the chip length,
l
D = wheel diameter, d = depth of cut
d D l =
Material removal rate, MRR
v = workpiece velocity, d = depth of cut, b = width p y p
of cut
b d v MRR =
22
Material removal rate Material removal rate
Th hi h t i l The chips have a triangular cross-
section, and ratio (r) of chip thickness (t)
t hi idth ( )
w
to chip width (w)
20 10t
w
w
So, the average volume per chip
20 10to
t
r =
t
l
So, the average volume per chip
wtl l t w Vol
chip
4
1
2
1
2
1
= =
23
chip
4 2 2
Chips Chips
The number of chips removed per unit The number of chips removed per unit
time (n), where c = number of cutting
edges (grains) per unit area (typ 0 1 to edges (grains) per unit area (typ. 0.1 to
10 per mm
2
, and V = peripheral wheel
velocity velocity
c b V n =
24
Combining Combining
Vol n b d v MRR = =
chip
Vol n b d v MRR = =
1
wtl Vbc b d v
4
1
=
t r w =
d D l =
d D t t r b c V b d v =
4
1
25
4
Chip thickness Chip thickness
d v 4
d D r c V
d v
t

=
4
2
or
D
d
V
v
t =
4
D r c V
26
Specific grinding energy u Specific grinding energy, u
Consist of chip formation, plowing, and
slidingg
u u u u + + =
sliding plowing chip
u u u u + + =
27
Total grinding force Total grinding force
Get force frompower Get force from power
MRR u Power = MRR u Power
b d v u V F = b d v u V F
grinding
=
b d v
u F

=
V
u F
grinding
=
28
F i i l lt t d From empirical results, as t decreases,
the friction component of u increases
t
u
1
t
K u
1
1
=
or
t
substituting
b d 1
V
b d v
t
K F
grinding

=
1
1
29
Substituting for t
V
b d v
d
K F
grinding

=
4
1
1
V
D
d
r c V
v

4
i rearranging
v r c d
d D
V
v r c d
b K F
grinding

=
4
1
30
Force on a grain Force on a grain
The force per grain can be calculated The force per grain can be calculated
Area u F
grain
=
g
wt u F
grain
2
1
=
rt w =
and
K u
1
=
grain
2
t
K u
1
=
1 1
t t r
t
K F
grain
=
2
1 1
1
31
Force on a grain Force on a grain
substituting for t, and rearranging
d v
r
K
F
i
=
4
1
D r c V
r F
grain
2
D
d
c V
r v
K F
grain
=
1
32
Grinding temperature Grinding temperature
Temperature rise goes with energy
delivered per unit area
input Energy
K T
area
p gy
K T =
2
d l b u 1
d
t
K K
l b
d l b u
K T =

=
1
1 2 2
1
D
d
Vcr
v
d K K T
4
1
2 1
=
33
D Vcr
Grinding temperature Grinding temperature
Rearranging
d D
v
r c V
K K T

=
4
2 1
Temperatures can be up to 1600
o
C, but
for a short time.
34
Grinding Ex. 1-1 g
You are grinding a steel, which has a specific
grinding energy (u) of 35 W-s/mm
3
.
The grinding wheel rotates at 3600 rpm, has a
diameter (D) of 150 mm thickness (b) of 25 mm and diameter (D) of 150 mm, thickness (b) of 25 mm, and
(c) 5 grains per mm
2
(c). The motor has a power of 2
kW.
The work piece moves (v) at 1.5 m/min. The chip
thickness ratio (r) is 10.
Determine the grinding force and force per grain Determine the grinding force and force per grain.
Determine the temperature (K
2
is 0.2
o
K-m/N). Room
temperature is 20
o
C.
35
Grinding Ex 1 2 Grinding Ex. 1-2
First we need to calculate the depth of p
cut. We can do this from the power.
b d v u MRR u Power = =
min
2
mm m s W
sec 60
min
10 25
min
5 . 1 35 2000
2
6
3

=
m
mm
mm d
m
mm
s W
W
m d
6
10 4 . 91

=
36
Now for the total grinding force g g
V
b d v
u F
grinding

=
V
grinding
mm mm
mm
s W
F
d
25 10 4 . 91
min
1500
35
3

=

mm
m
rev
mm rev
mm
F
grinding
1000
150
min
3600
35
3

=
N F
grinding
7 . 70 =
37
Next, the force per grain
wt u F
grain
2
1
=
rt w =
and
t t r u F
grain
=
2
1
we need t we need t
mm
mm
d v
t
10 4 . 91
min
1500 4
4
3
mm
mm
grains mm
D r c V
t
150
10 5
min
150 3600
min
2

=

=
mm t
3
10 32 1


38
mm t 10 32 . 1 =
Substituting Substituting
( )
2
3
10 32 . 1 10
2
1
35
2
1

= = t t r u F
grain
( )
2 2
grain
N F
4
10 05 3

N F
grain
10 05 . 3 =
39
For the temperature, we need K
1
and p ,
1
K
2
. K
2
is given, so we need to calculate
K
1
.
1
t r K t t r
t
K t t r u F
grain
= = =
2
1
2
1 1
2
1
1 1
t 2 2 2
m K N
6
1
4
10 32 . 1 10
2
1
10 05 . 3

=
2
m
N
K 2 . 46
1
=
40
Grinding Ex 1 7
substituting
Grinding Ex. 1-7
substituting
d K K T =
1
N m K 1
6
d
t
K K T =
1 2
K m
m
m
N
N
m K
T =
640 10 4 . 91
10 32 . 1
1
2 . 46 2 . 0
6
6
C T T T
initial
= + = + = 660 640 20
41
Summary Summary
Overview of processes
Analysis of process Analysis of process
Example problem
42
43

Grinding A

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Grinding A

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Grinding Grinding

Illegitimi non carborundum g

ME 6222: Manufacturing Processes and Systems

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