IIT BHU

Metal machining and

machine tools

Effect of Depth of Cut on MRR in Surface

Grinding
13/01/2016

NAME : Shubham Khatri

ROLL NO. : 14135077
CLASS : B. TECH. PART II, Semester IV
MECHANICAL ENGG.

SUBMITTED TO DR. MOHD. ZAHEER

Effect of Depth of Cut on MRR in Surface Grinding

What is Machining?
Machining is a manufacturing term encompassing a broad range of technologies and
techniques. It can be roughly defined as the process of removing material from a
workpiece using power-driven machine tools to shape it into an intended design. Most
metal components and parts require some form of machining during the
manufacturing process. Other materials, such as plastics, rubbers, and paper goods,
are also commonly fabricated through machining processes.

Types of Machining Process

Boring Process: In machining, boring is the process of enlarging a hole that has
already been drilled (or cast), by means of a single-point cutting tool (or of a
boring head containing several such tools), for example as in boring a gun
barrel or an engine cylinder. Boring is used to achieve greater accuracy of the
diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed
as the internal-diameter counterpart to turning, which cuts external diameters.

Cutting process: Cutting is a collection of processes wherein material is

brought to a specified geometry by removing excess material using various kinds
of tooling to leave a finished part that meets specifications. The net result of
cutting is two products, the waste or excess material, and the finished part.

Drilling process: Drilling is a cutting process that uses a drill bit to cut or
enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary
cutting tool, often multipoint. The bit is pressed against the workpiece and
rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the workpiece, cutting off chips (swarf) from
the hole as it is drilled.

Grinding process: Grinding practice is a large and diverse area

of manufacturing and tool making. It can produce very fine finishes and very
accurate dimensions; yet in mass production contexts it can also rough out
large volumes of metal quite rapidly. It is usually better suited to the machining
of very hard materials than is "regular" machining (that is, cutting larger chips

with cutting tools such as tool bits or milling cutters), and until recent decades
it was the only practical way to machine such materials as hardened steels.

Milling process: Milling is the machining process of using rotary cutters to

remove material from a workpiece advancing (or feeding) in a direction at an
angle with the axis of the tool. It covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty gang
milling operations. It is one of the most commonly used processes in industry
and machine shops today for machining parts to precise sizes and shapes.

Turning process: Turning is a machining process in which a cutting tool,

typically a non-rotary tool bit, describes a helical toolpath by moving more or less
linearly while the workpiece rotates. The tool's axes of movement may be
literally a straight line, or they may be along some set of curves or angles, but
they are essentially linear (in the nonmathematical sense).

Grinding Process:
Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish
obtained through grinding can be up to ten times better than with either turning or
milling.
Grinding employs an abrasive product, usually a rotating wheel brought into controlled
contact with a work surface. The grinding wheel is composed of abrasive grains held
together in a binder. These abrasive grains act as cutting tools, removing tiny chips of
material from the work. As these abrasive grains wear and become dull, the added
resistance leads to fracture of the grains or weakening of their bond. The dull pieces
break away, revealing sharp new grains that continue cutting. The requirements for
efficient grinding include:

Abrasive components which are harder than the work

Shock- and heat-resistant abrasive wheels
Abrasives that are friable. That is, they are capable of controlled fracturing.

Types of Grinding:
There are many forms of grinding, but the four major industrial grinding processes are:

Cylindrical grinding
Internal grinding

Centerless grinding
Surface grinding

Grinding wheel
A grinding wheel is an expendable wheel used for
various grinding and abrasive machining
operations. It is generally made from a matrix of
coarse abrasive particles pressed and bonded
together to form a solid, circular shape, various
profiles and cross sections are available
depending on the intended usage for the wheel.
Grinding wheels may also be made from a solid
steel or aluminium disc with particles bonded to
the surface.

Grinding Theory
The nature and intensity of the applied stresses on the particles affect the particle
size reduction process. In comminution the following three main breakage mechanisms
have been identified.

Abrasion occurs when stress is applied on

particles along the tangential axis(shear). Particle
breakage in this cases gives a bimodal particle size
distribution comprising fine particles that are
released from the surface of the initial particle and
particles with a size close to that the initial particles.

Cleavage of particles occurs when intense

stresses are slowly applied on a particle(compression).
This produces fragments of sizes 5080 vol. % smaller
than the initial particles.

Fracture occurs through rapidly applying

intense stresses(impact). The particle size
distribution in this case will range between 20 and 70
vol. % of the size of the initial particle.

Surface Grinding:
Surface Grinding is a manufacturing process which moves or grinding wheel relative a
surface in a plane while a grinding wheel contacts the surface and removes a minute
amount of material, such that a flat surface is created. The term surface grinding
designates any process which accurately processes or grinds a surface.
Parts may require surface grinding for several reasons. The following are a few of the
more common reasons:

Produce a very flat surface.

Very accurate thickness tolerance specified.

A very smooth surface roughness Ra is specified/required.

Cutting tool sharpening.

Reciprocating Table Surface Grinder

With reciprocating table grinding, the
grinding wheel remains stationary while
table on which the workpiece is fixed
moves "backwards and forwards" at
right angles to the reference edge
the resulting motion is described as
being "reciprocating". This method is
seen as the oldest variant of surface
grinding and is characterised by low
cutting depths (just 0.005 to 0.2 mm)
and high table speeds (15 to 30 m/min).
The technique impresses as a costeffective method for materials which
are easy to grind, small batch sizes and
low amounts of material removal, as
well in cases of relatively low machine
investment. However, the cost
benefits of this method come at the price of a number of disadvantages. Low cutting
depths prevent clean chip formation, and this can cause flattening of the grain tips
and hence high levels of friction during the grinding process. This friction generates

excess heat, which in turn can lead to thermal damage and grinding cracks. Combined
with relatively hard grinding wheels and low machine ridigity, low cutting depths often
lead to vibrations and therefore chatter marks on the surface of the workpiece.

Process Parameter:
1. Wheel parameters:
Abrasives
Grain size
Grade,
Structure
Binder
Shape and Dimension.
2. Work piece parameters:
Fracture mode
Mechanical properties
Chemical composition
3. Process parameters:
Wheel speed
Depth of cut
Table speed
Dressing condition.

Result and Discussion:

As it can be seen through observations that with increase in Depth Of Cut or Down
Feed the Metal Removal Rate(MRR) increases.
This can be clearly visualized as the Depth Of Cut increase more metal is removed in
one pass, and the time for which workpiece is subjected to grinding remains constant
due to constant transverse feed. This implies Metal Removal Rate(MRR) is directly
proportional to Down Feed