Milling

MACHINE TOOLS
AND DIGITAL
MANUFACTURING
MODULE 5
For more visit : www.ktunotes.in

SYLLABUS

GRINDING
• Grinding is a metal cutting operation performed by means of a rotating
abrasive wheel that act as a cutting tool.
• Used for finishing work pieces which must show a high surface
quality, accuracy of shape and dimensions.
• It removes comparatively little metal usually 0.25 to 0.50 mm.
• Accuracy in the dimension in the order of 0.000025 mm.

KINDS OF GRINDING
• Rough Grinding : Snagging and off hand grinding.
• Precision grinding : External and Internal cylindrical grinding, Surface
grinding and form grinding.

GRINDING MACHINES
• According to the quality of surface finish classified into
• Rough Grinders
1. Floor stand and bench grinders,
2. Portable and flexible shaft grinders,
3. Swing frame grinders
4. Abrasive belt grinders.
•.Precision grinders
1. Cylindrical Grinders
a. Centre type (plain and universal)
b. Centreless
2. Internal Grinders
a. Chucking (plain and universal)
b. Planetary
c. Centreless
3. Surface Grinders
a. Reciprocating table (Horizontal and vertical table)
b. Rotary table (Horizontal and vertical table)
4. Tool and cutter grinder
a. Universal
b. Special
5. Special grinding machines
a. Crankshaft grinders
b. Piston grinders
c. Roll grinders
d. Cam grinders
e. Thread grinders
f. Way grinders
g. Tool post grinders
GRINDING MACHINES
Rough Grinders
• Whose chief work is the removal of stock without any reference t the
accuracy of the results.
Precision Grinders
• Precision grinders are those that finishing parts to a very accurate
dimensions.

GRINDING MACHINES : Rough Grinders
1. Floor stand and bench grinders

•.Mounted on a base or pedestal
•.Horizontal spindle with wheels usually at the both ends.
•.Belt drive from the motor.
•.Safety guard with eye shield.
•.Small size machine mounted on bench : Bench grinder.
•.These machines used for snagging and off hand grinding.

GRINDING MACHINES:Rough Grinders
2. Portable and flexible shaft grinders

• Portable grinders Resembles with portable or electric hand drill.
• Flexible shaft grinders has the grinding wheel on the end of a long
flexible shaft driven by a motor on a relatively stationary stand.
3. Swing frame grinders
• It has horizontal frame about 2 to 3 m long suspended at its centre of
gravity so as to move freely within the area of operation.
• Used for snugging particularly for the large castings.
• This machine is moved around with a jib crane suspended from
columns.

4. Abrasive belt grinders

• A strip of abrasive cloth of correct length and width is formed into an
endless belt b cementing the ends together, and slipped over two
drums.
• One of the drum is driven at high speed.
• Smooth rear side of the belt is slides over a heavy metal plate.
• Work may be applied commonly by hand.
• Heavy stock removal or light polishing works.

GRINDING MACHINES : Precision Grinders
1. Cylindrical grinders
•.These machines are used to produce external cylindrical surfaces.
•.This machine has a head stock and a tail stock.
•.The work piece is mounted between centers.
•.The grinding wheel and work piece move in the opposite direction.
•.The depth of the cut is given by the moving the wheel towards the work
piece.
•.In cylindrical grinding, two types of grinding are carried out: Traverse
grinding and Plunge grinding
•.General range of work speed for cylindrical grinding is from 20 to 30
s.m.p.m.
•.Wheel speed ranges from 1500 to 2000 s.m.p.m
Traverse grinding
• In traverse grinding, the work reciprocates as the wheel rotates.
• Here, work pieces of a large size can be ground with grinding wheels
that are less thick.

Plunge grinding
• In plunge grinding, the wheel is fed into the rotating work piece but
there is no reciprocating motion.
• This method is used for relatively short work pieces and especially in
form grinding where some profile on the work piece is to be ground.

1 (a) Plain centre type grinders

i. Base
ii. Tables : Lower table & Upper table
iii. Head stock.
iv. Tail stock.
v. Wheel head


i. Base
•.Main casting that rests on the floor.
•.Supports the parts mounted on it.
•.On the top of the base are precision horizontal ways.
•.Houses the table drive mechanism.
ii. Table
•.Lower table slides on ways on the bed and provides traverse of the
work past the grinding wheel.
•.It can be moved by either hand or power.
•1 (a) Plain centre type grinders

ii. Table (contd.)
• Upper table is pivoted at its centre is mounted on the sliding table.
• It has T slots for securing the headstock and tail stock.
• Upper table can be swiveled and clamped in position to provide adjustment for
grinding straight or tapered work(.
iii. Headstock
• Head stock supports the work piece by means of a dead centre and drives it by
means of a dog.
• It may hold and drive the work piece in a chuck.
iv. Headstock
• Adjusted and clamped in various position to accommodate diffrnt length of work
pieces. For more visit : www.ktunotes.in

v. Wheel head
• It carry grinding wheel and its motor is mounted on a slide at the top
and rear of the base.
• Wheel head may be moved perpendicularly to the table ways by hand
or power to feed the wheel to the work.

1 (a) Universal centre type grinders

• Head stock can be swiveled at an angle in a horizontal plane.
• Wheel head and slide can be swiveled and traversed at any angle.
• Universal grinders are widely used in tool rooms for grinding tools

1 (b) Centreless grinders

• Method of grinding exterior cylindrical, tapered and formed surfaces
on work piece that are not held and rotated on centres.

•1 (b) Centreless grinders

• Both the wheels are rotated in the same direction.
• Work rest is located in between the wheels and rests upon the work
rest.
• Work rest, together with the regulating wheel, s fed forward, forcing
the work against the grinding wheel.
• Axial movement of the work past the grinding wheel is obtained by
tilting the regulating wheel at a slight angle (0 from horizontal
• Centreless grinding may be done in one of the 3 ways
1. Through feed 2. Infeed 3. End feed

1 (b) Centreless grinders
• Through feed grinding: The work is passed completely through the
space between the grinding wheel and regulating wheel usually with
guides at both end.
• Infeed grinding: The work is placed on the work rest against an end
stop and then regulating wheel is advanced towards the grinding wheel.
No axial movement of work, only movement is rotating movement.
1 (b) Centreless grinders.

• End feed grinding: The work is fed lengthwise between the wheels
and is ground as it advances until it reaches the end stop.

Advantages of Centreless Grinding:
1. Chuck and centers are not required.
2. The work piece is rigidly supported during grinding, so there is no
change of direction of work piece.
3. This process is fast.
4. Less skilled operator can carry out operation.
5. Wide range of components can be ground.
6. Large grinding wheels can be used so as to minimize wheel wear.

2. Internal grinders
• Internal grinding operation means, grinding of internal holes or bores.
• Internal grinding is designed to grind the surface of bores; whether
plain or tapered with the help of a small grinding wheel mounted on a
long slender spindle which can enter in the bore.
• This operation is performed on specially designed internal grinding
machines. For internal grinding, a softer wheel is generally preferred.

3. Surface grinders
• Surface grinders are used to produce flat surfaces.
• The basic machine has a grinding wheel above the work area which
can be fed downward in very small increments into a work piece
which is being moved to the left and the right and in and out.
• This allows the wheel to contact all areas of the surface of the work
piece.
• The grinder is usually equipped with a magnetic plate used to hold the
work piece.

3. Surface grinders

3. Surface grinders
• There are two types of surface grinders
i. Reciprocating surface grinders
ii. Rotary surface grinders
i. Reciprocating Surface Grinders
• Reciprocating surface grinders are of two types:
(a) Horizontal wheel spindle and reciprocating table
(b) Vertical wheel spindle and reciprocating table
(a) Horizontal Wheel Spindle and Reciprocating Table
• These types of grinders have one reciprocating table and a horizontal spindle.
• The table can be given a reciprocating motion either manually by hand wheel or by
hydraulic power.
• Depth of cut is achieved by lowering the grinding wheel with the help of a hand wheel.
• Feed to the grinding wheel is given by rotating the hand wheel.
3. Surface grinders
(b) Vertical Wheel Spindle and Rotary Table
• These types of grinders are used in production type of work.
• In these machines, the wheel diameter should be more than the width
of surface to be machined.

3. Surface grinders
ii. Rotary Surface Grinders
• These are also of two types–horizontal spindle and vertical spindle.
• In a horizontal spindle rotary table surface grinder, the work pieces are
arranged in concentric circles on the table. The table is made to rotate under
the revolving wheel. Both the wheel and the table rotate in opposite
directions.
• A vertical spindle rotary table surface grinder makes use of a cup shape
wheel for finishing operation.

3. Surface grinders
ii. Rotary Surface Grinders

4. Tool and cutter grinder

• Sharpening and reconditioning of varieties of tools and cutters.

Grinding wheel
• Multi tooth cutter made up of many hard particles known as abrasives.
• Which have been crushed to leave sharp edges which do the cutting.
• Abrasive grains are mixed with suitable bonds, which act as a matrix
or holder when wheel is in used.
• Wheel may consists of one piece or of segments of abrasive blocks
built up into a solid wheel.
• Abrasive wheel is usually mounted on some form of machine adapted
to a particular type of work.

Abrasives
• Substance used for grinding and polishing operations.
• It should be pure and have uniform physical properties of hardness,
toughness and resistance to fracture.
• Natural and artificial.
• Natural abrasives include sand stone, diamond, corundum and emery.
• Artificial abrasives include silicon carbide and aluminum oxide.

Abrasives
Natural abrasives
I. Sand stone or quartz
•.Relatively soft.
•.Materials harder than quartz cannot be grounded rapidly.
II. Emery
•.Natural aluminium oxide
•.Contains 55 to 65 per cent alumina and remainder consists of iron
oxide and other impurities.
•.Greater hardness and better abrasive action than quartz

Abrasives
Natural abrasives
III. Corundum
• Natural aluminium oxide
• Contains 75 to 95 percent aluminium oxide remainer contains
impurities.
• Greater hardness and better abrasive action than quartz
IV. Diamond
•.Diamonds of less than gem quality are crushed to produce abrasive
grains for making grinding wheels.
•.Used to grind cemented carbide tools and making lapping tools.

Abrasives
Artificial abrasives
I. Silicon carbide (SiC) (denoted by letter S)
•.Manufactured from 56 parts of silica sand, 34 parts of powdered coke, 2
parts of salt and 12 parts of saw dust.
•.Manufactured in along rectangular electric resistance type furnace that is
built up with of loose work.
•.Sand furnishes silicon, coke furnishes carbon, sawdust makes the charge
porous, salt helps to fuse it, and gases escape through the open joints in
the brick work.
•.2 types of SiC abrasives : Green grit(at least 97% SiC) and Black grit (at
least 95% SiC).
•.Green grit harder but weaker than black grit.
Abrasives
•Artificial
abrasives
I. Silicon carbide (SiC) (contd.)
• It is used for grinding materials of low tensile strength such as cemented
carbide, stone and ceramic materials, gray cast iron, brass, bronze, copper,
etc.
II. Aluminium oxide () (denoted by letter A)
• Heating mineral bauxite, a hydrated aluminium oxide clay containing
silica, iron oxide, titanium oxide, etc., with ground coke and iron borings in
arc type electric furnace.
• It is tough and not easily fractured.
• Used for grinding materials of high tensile strength (Steels, carbon steels,
annealed malleable iron, high speed steels, wrought iron and tough bronzes.
Abrasives
•Artificial
abrasives
III. Boron carbide
• It is harder than silicon carbide but not as diamond.
• It is produced from coke and boric acid at very high temperature in an
electric furnace.
IV. Cubic boron nitride (CBN)
• Harder than SiC & .
• CBN is produced by combination of intensive heat and pressure in the
presence of catalyst.
• High thermal resistance and second hardest material.
• Known as borazon
Bonds
• Bond is an adhesive substance that is employed to hold abrasive grains
together in the form of sharpening stones or grinding wheels.
1. Vitrified bond
2. Silicate bond
3. Shellac bond
4. Resinoid bond
5. Rubber bond
6. Oxychloride bond

Bonds
1. Vitrified bond (denoted by V)
•.Are made with clay and water.
•.Clay and abrasive materials are mixed thoroughly with sufficient water
to make mixture uniform.
•.Mixture is poured into mould and allowed to dry.
•.When it is dried to a point where it can be handled, the material is cu
and trimmed to more perfect size and shape.
•.It is then heated in a kiln in much the same manner as brick or tile is
burnt.
•.When the burning proceeds, clay vitrifies ie; it fuses and forms
porcelain or glass like substance that surrounds and connects abrasives.
Bonds
•1. Vitrified bond (contd.)
•.It gives a wheel good strength as well as porosity to allow high stock
removal with cool cutting.
•.It is affected by heat, cold, acid, or oils.
•.Disadvantages of vitrified bond wheels are their low bending strength.
2. Silicate bond (denoted by letter S)
•.Mixing abrasive grains with silicate of soda or water glass.
•.Packed into moulds and allowed to dry.
•.Moulded shapes are then baked in a furnace at a temperature of 260 for
several days.
•.Water proof.
Bonds
•3. Shellac bond (denoted by letter E)
• Elastic bonded wheels (elasticity is more than other types) and has
considerable strength.
• Abrasives and shellac are mixed in heated containers and then rolled
or pressed in heated moulds.
• Later the shapes are baked for few hours at a temperature of
approximately 150
• Not intended for heavy duty.
• Cool cutting on hardened steel and thin sections and is used for
finishing chilled iron, cast iron and steel rolls, hardened steel cams and
aluminium pistons and in very thin sections.
Bonds
•4. Resinoid bond (denoted by letter B)
• Mixing abrasive grains with resins and other compounds.
• Mixture is placed in moulds and heated at about 200
• At tis temperature resin set the abrasive grains in the wheel form.
• Wheels bonded with synthetic resins ( Bakelite, Redmanol) are used
for the purposes which require a strong, free high speed wheel.
• Removes stocks very rapidly.
• Used for precision works.

Bonds
•5. Rubber bond (denoted by letter R)
• Mixing abrasive grains with pure rubber and sulphur.
• Mixture is rolled into sheets and wheels are punched out of the sheets
on a punch press
• Then wheels are vulcanised.
• Rubber bonded wheels are more resilient, les heat resistant and more
dense than resinoid bonds.
• Good finish purposes.
• They are strong and tough enough to make thin wheels.

Bonds
•6. Oxychloride bond (denoted by letter O)
• Mixing abrasive grains with oxide and chloride of magnesium.
• Mixing is same as in vitrified bonded wheel
• Used for making wheels and wheel segment for use in disc grinding
operations.

Grit /Grain size
• The size of abrasive grain is indicated in terms of the mesh(Screen
size)
• Number of meshes per inch of screen through which the grains pass
when they are graded after crushing.
• Coarser grains by low numbers and finer grains by high numbers.
• Coarse grits are in use for soft, ductile, stringy materials for fast stock
removal rough grinding, large contact area, high grinding pressure.
• Finer grits in use for obtaining smooth finish, hard & brittle materials,
small contact area and form holding of small & narrow corners.

Grade
• This indicates the strength with which the bonding material holds the
abrasive grains in the grinding wheel.
• A wheel from which the abrasive grains can easily dislodged is called
soft.
• Wheel which one holds the grains more securely is called hard.
• Soft wheels are recommended for hard materials.
• Hard wheels are recommended for soft materials.

Structure
• The relative grain spacing in a wheel.
• Denoted by number of cutting edges per unit area of wheel space as
well as by number and size of void space between grains.
• Dense spacing is denoted by low numbers and open spacing by high
numbers.
• Wheel structures are depending upon the material to be ground, rate of
stock removal, accuracy and surface finish required.
• Open structure: Soft, tough and ductile materials and heavy cuts.
• Dense structure: Hard and brittle materials and finish cuts

Marking system of grinding wheel
• The Indian standard marking system for grinding wheels has been prepared with a
view to establishing a uniform system of marking of grinding wheels to designate
their various characteristics.

FACTORS AFFECTING WHEEL
SELECTION
• In selecting grinding wheel there are 4 constant factors and 4 variable
factors.
• Constant Factors : Material to be ground
Amount of Stock to be removed
Area of contact
Type of grinding machine
• Variable Factors : Wheel speed
Work speed
Condition of the machine
Personal factor

1.
SELECTION
Material to be ground
•.ABRASIVE : Aluminum oxide for steel and steel alloys.
Silicon carbide for cast iron, non-ferrous and non-
metallics.
•.GRIT SIZE : Fine grit for brittle materials. Coarse grit for ductile
materials.
•.GRADE : Hard grade for soft materials. Soft grade for hard materials.

2.
SELECTION
Amount of stock to be removed
• GRIT SIZE : Coarse grit for rapid stock removal as in
rough grinding.
Fine grit for high finishing.
• BOND : Vitrified for precision cutting. Resinoid and
Rubber for high speed cutting.
3. Area of contact
•.Fine and close grain spacing are useful where area of contact involved
is small.
•.Coarse and wide grain spacing are useful where area of contact
involved is large.

4.
SELECTION
Type of grinding machine
•.Type of grinding machine determine the extent the grade of the wheel.
•.Heavy rigidly constructed machines take softer wheels than the lighter
and more flexible types.
5. Wheel speed
•.BOND : Standard vitrified wheels are not exceeding 2,000mpm. Standard
organic bonded wheels(Resinoid, Rubber) are used of most applications
over 2,000mpm up to 6,000mpm.
6. Work speed
•.Higher the work speed in relation to the wheel speed, harder the wheel
should be.

•7.
SELECTION
Condition of grinding machine
•.Condition of grinding machine has a bearing on the grade of the wheel
to be selected.
•.Spindle loose in their bearing and insecure or shaky foundations
would necessitate the use of harder wheels.
8. Personal factor
•. Skill of workman
•.It can vary the grinding costs as much as 100 on same work in the
same factory.

WHEEL SHAPES
• Grinding wheels are made in a wide variety of shapes to suit the
immense range of work and special features of machine tools on
which the wheels shall be put to use.
• Wheels from (a) to (h) are disc wheels and grinding is to be done on
the periphery of the wheel.

WHEEL SHAPES
• Wheels (j) to (l) are mostly used on cup wheel grinders. Wheels (m),
(n) and (p) are used for tool and cutters grinding.
• The thin wheel shown at (r) is used on abrasive cutters for slitting and
parting off.

Mounting the grinding wheels
• Great care must be taken in mounting the grinding wheels on the
spindle because of the high cutting speed of the grinding wheels.
• Following points are important in connection with mounting of the
wheel.

1. All wheels should be closely inspected just before mounting to make
sure that they have not damaged in transit, storage or other wise. The
wheel must first subjected to ringing test (applicable for vitrified and
silicate wheels) : Grinding wheel is put on arbor while it is subjected
to slight hammer blows. A clear, ringing, vibrating sound must be
heard.
2. Abrasive wheel should have an easy fit on their spindles or locating
spigots. They should not be forced on.
3. The hole of grinding wheel mostly in lined with lead. The lead liner
bushes should not project beyond the side of wheels.

4. There must be a flange on each side of the wheel. The mounting
flanges must be large enough to hold the wheel properly, at least the
flange diameter must be equal to the half of the grinding wheel
diameter. Both the flanges should be of the same diameter.
5. The sides of the wheel and the flanges which clamp them should be
flat.
6. All flanges must be relieved in the centre so that the flanges contact
the wheel only with the annular clamping area. If they are not properly
relieved the pressure of the flanges is concentrated on the sides of the
hole.

7. Washers of compressible materials such as cardboard, leather, rubber,
etc. not over 1.5mm thick should be fitted between wheel and flanges.
In this way any unevenness of the wheel surface can be avoided.
Diameter of the washer is equal to the diameter of the flanges.
8. Inner fixed flange should be keyed or fastened to the spindle, whereas
outer flange should have an easy sliding fit on the spindle so that it can
adjust itself slightly to give a uniform bearing wheel and the
compressible washers.
9. The nut should be tightened to hold the wheel firmly.
10. The wheel guard should placed and tightened before the machine is
started for work.

• After mounting the wheel, the grinding machine is started .the
grinding wheel should be allowed to idle for a period of 10 to 15
minutes.
• Grinding wheels must be dressed and trued which are out of true,
before any work can be started.

Glazing In Wheels
• Glazing of the wheel is a condition in which the face or cutting edge
takes a glass like appearance.
• Cutting points of the abrasives have become dull and worn down to
the bond.
• Which increases the smoothness and decreases the cutting capacity.
• Glazing takes place when a wheel is too hard or revolves at too fast a
speed.
• Remedy for glazing is to decrease the speed or to use a softer wheel.

Loading In Wheels
• Particles of the metal being ground adhering to the wheel.
• The openings and pores of the wheel face have been filled with metal
thus preventing the wheel from cutting freely.
• Loading may be caused by grinding a softer metal / by using a wheel
of too hard and running it slowly.
• It may also be caused by taking cuts that are too deep and by not using
the right cutting fluid.
• Remedy for loading is to increase the speed of the wheel or use softeer
wheel.

Dressing Grinding wheels
• The remedies of glazing and loading is dressing of grinding wheels.
• Dressing removes the loading and breaks away the glazed surface so
that sharp abrasive particles can be formed again ready for grinding.
• Different type of dressing operations are done on a grinding wheel.
One of them is the dressing with the help of star dresser.
• It consists of a number of hardened steel wheels with sharp points on
their periphery. The total is held against the face of revolving wheel
and moved across the face to dress the whole surface.
• Another type of wheel dresser consists of a steel tube filled with a
bonded abrasive. The end of the tube is held against the wheel and
moved across the face.

Truing Grinding wheels
• Truing is the process of restoring the shape of grinding wheel when it
becomes worn and break away at different points.
• Truing makes the wheel true and concentric with the bore.
• By using a diamond tool.
• Most popular is form truing with a crush roll: A roll shaped to the
desired profile is forced against the revolving wheel, crushing the
corresponding shape into it.
• Rolls are two types : Idle and Power driven.
• Idle : In which the wheel drives the roll
• Power driven : Small motor drives the roll which in turn rotates the
wheel by frictional contact.
LAPPING
• Lapping is regarded as the oldest method of obtaining a fine finish.
• 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.

LAPPING
Characteristics of lapping process
• Use of loose abrasive between lap and the work piece
• Usually lap and work piece are not positively driven but are guided in
contact with each other
• Relative motion between the lap and the work should change
continuously so that path of the abrasive grains of the lap is not
repeated on the work piece.
• Lapping is performed either manually or by machine.
• Hand lapping is done with abrasive powder as lapping medium,
whereas machine lapping is done either with abrasive powder or with
bonded abrasive wheel.

LAPPING
• Cast iron is the mostly used lap material. However, soft steel, copper,
brass, hardwood as well as hardened steel and glass are also used.
• The abrasive mixture is characterized by the properties of the
abrasives and the properties of the mixture or the cutting fluid,
• Aluminum oxide and silicon carbide are commonly used for lapping
steel, cast iron, nonferrous metals
• Boron carbide is mostly used for lapping sintered carbides; diamond
dust is used for hardened steel and sintered carbides; chromium
oxide is used for obtaining the highest surface quality of steel and
copper alloy surfaces.

LAPPING
• Compound: The compound to be mixed with the abrasives should ensure
sufficiently the following properties:
Holding the abrasives in a uniform suspension during the lapping operation
Should not evaporate easily
Be noncorrosive and nontoxic
Easily removable by normal cleaning
Adheres to the lap and, therefore, minimizes the waste of the machining
compound
• Lubricating compounds include grease, tallow, stearin, and wax.
• In some cases, colloidal graphite is added to improve the lubricating properties.
• Machine oil, rape oil, and paraffin are mainly used as lapping fluids where the
abrasive dust is suspended.

LAPPING : Hand Lapping
• Hand lapping of flat surface is carried out by rubbing the component
over accurately finished flat surface of master lap usually made of a
thick soft close-grained cast iron block.
• Abrading action is accomplished by very fine abrasive powder held in
a vehicle.
• Manual lapping requires high personal skill because the lapping
pressure and speed have to be controlled manually.
• Laps in the form of ring made of closed grain cast iron are used for
manual lapping of external cylindrical surface.
• The bore of the ring is very close to size of the workpiece however,
precision adjustment in size is possible with the use of a set screw

LAPPING : Hand Lapping

LAPPING : Lapping machine
• Machine lapping is meant for economic lapping of batch qualities.
• In machine lapping, where high accuracy is demanded, metal laps and
abrasive powder held in suitable vehicles are used.
• Bonded abrasives in the form wheel are chosen for commercial lapping.
• Machine lapping can also employ abrasive paper or abrasive cloth as
the lapping medium.
• Two laps : Upper lap and lower lap.
• Lower lap rotates at low speed of about 50 -70 rpm.
• Upper lap is stationary and it rests and floats on the work piece and
supplies pressure for abrading action.

LAPPING : Lapping machine

HONING
• Honing is a finishing process, in which a tool called hone carries out a
combined rotary and reciprocating motion while the work piece 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
work piece with controlled light pressure.
• The honing head is not guided externally but, instead, floats in the
hole, being guided by the work surface

HONING
• Honing is an abrasing process used for finishing internal cylindrical
surfaces like drilled or bored holes.
• Honing stones are manufactured by bonding abrasives like aluminum
oxide or silicon carbide. Materials like sulphur, resin or wax are added
to improve the cutting action.
• Honing can be done manually or by machines. The preferred method
is by using machines. The stones are held in a honing head. This head
is directed to move in and out of the hole for carrying out operation.
Honing is both a sizing and finishing operation and is generally used
for removing the scratch marks produced by grinding. The material
removal is less than 0.125 mm.

HONING TOOL
• Honing stones are made from common abrasive stones called hones.
• Hones are made from common abrasive and bonding materials
impregnated with Sulphur, resin or wax to improve cutting action and
lengthen tool life.
• Honing stones may be loosely held in holders, cemented directly in
holder or cast into plastics tabs which are held in holders.
• The quality of the surface finish produced by honing can be controlled
by the type and size of abrasive used, the pressure applied, and speed. A
fluid is used to remove chips and to keep temperatures low. If not
performed properly, honing can produce holes that are neither straight
nor cylindrical, but rather in shapes that are bell mouthed, wavy, barrel
shaped, or tapered.

HONING TOOL

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For more visit : www.ktunotes.in

For more visit : www.ktunotes.in

For more visit : www.ktunotes.in

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1. Floor stand and bench grinders

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2. Portable and flexible shaft grinders

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4. Abrasive belt grinders

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1 (a) Plain centre type grinders

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1 (a) Plain centre type grinders

•1 (a) Plain centre type grinders

1 (a) Plain centre type grinders

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1 (a) Universal centre type grinders

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1 (b) Centreless grinders

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•1 (b) Centreless grinders

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1 (b) Centreless grinders.

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4. Tool and cutter grinder

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For more visit : www.ktunotes.in

For more visit : www.ktunotes.in

For more visit : www.ktunotes.in