EFFECT OF GRINDING

PARAMETERS ON GRINDING
WHEEL PERFORMANCE

What Is Grinding
Grinding is an abrasive machining process that uses a grinding
wheel as the cutting tool. It is considered as a surface finishing
process and is accompanied by a certain amount of metal
removal. It is capable of yielding surface finish in the order of
12.5 to 0.75 CLA. Several processes like honing, lapping, etc. are
used.
Grinding Machine with variations
such as Hand-cranked knifesharpening stones (grindstones),
Handheld power tools such as
angle grinders and die grinders
etc. are used. Bench grinders
used in residential garages and
basements

WHAT IT CAN DO!!

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),

It was the only practical way to machine materials like

hardened steels. It is better suited to taking very shallow
cuts, like reducing a shafts diameter by half a thousandth
of an inch or 12.7M.

Grinding is one of the widely accepted finishing operations

because it removes material in very small size of chips 0.25
to 0.50 mm. It provides accuracy of the order of 0.000025
mm. Grinding of very hard material is also possible.

IMPORTANT TERMS IN GRINDING

Cutting Speed.
The cutting velocity V in
grinding
is very high. It is related to the
rotational speed of the wheel by V =
DN
Depth of Cut or In feed.
Depth of cut d is called in feed and is
defined as the distance between the
machined and work surfaces.
Width Of Cut or Cross feed
As the operation proceeds, the
grinding wheel is fed laterally across
the work surface on each pass by the
work part. The distance at which the
wheel is fed is called a cross feed.
The cross feed is actually the width
of cut w.
The cross feed multiplied by in feed
determines the cross-sectional area

Continued.
Feed Rate.
Feed
rate
is
a
significant
parameter in case of cylindrical
grinding and surface grinding.
Feed
rate
is
defined
as
longitudinal movement of the
work piece relative to axis of
grinding wheel per revolution of
grinding wheel.
Metal Removal Rate
The material removal rate, Known
as M.R.R, is defined by
M.R.R = VwxCSA

GRINDING PARAMETERS
Grinding Parameters have a severe effect on the performance
of the grinding wheel. G is the ratio of the amount of metal
removed to the amount of wheel wear. The important grinding
parameters are
Wheel Speed
Work Piece speed
In Feed
Transverse Feed
Grinding Fluids and the method of there application
Severity Of Dressing.

Grinding Wheel Speed

If we increase the
grinding
speed
the
uncut chip thickness
experienced by a grit
decreases. Hence the
forces coming on the
grit decrease. Naturally
the grit will remain on
the grinding wheel till
the
force
is
high
enough(
after
some
wear) to pull out the
grit.
Thus increasing
the
wheel
speed,
increases the grinding
ratio.

At Extremely High Speeds, grinding ratios as high as 400 have been

achieved though the normal values lie between 100 and 200. high
speed grinding brings In the problem of centrifugal stress in the
grinding wheel. The wheels have to be specially designed so that they
do not fracture due to rotational stresses.

The figure besides shows

the three modifications
on the existing designs
for strengthening the
wheel. A second problem
is of the application of
the coolant. Because of
the high speed of the
wheel,
a
rotating
boundary layer of air
around the wheel is
developed and it does
not let the coolant get to
the grinding zone. The
work piece surface may
get overheated and thus

WORK PIECE SPEED

Increase of the work piece speed increases the uncut chip
thickness that a grit cuts, and hence increases the force acting
on it. Its effect is opposite to that of the wheel speed. Increase
of work speed will make the wheel act soft.
A large work speed will result in more wheel wear

INFEED
The figure shows the
effect of the in feed on
the
grinding
ratio,
surface roughness and
power. The surface
finish
deteriorates
with increase in infeed in nearly linear
relationship.
The
power consumed also
increases linearly with
increase of in feed.
The
grinding
ratio
however goes through
a minima.

Feed Rate

where
T is the grinding time (min)
L is the required longitudinal travel in mm.
i is the number of passes required to cover whole width
S is the longitudinal feed rate (mm/rev.).
N is the rpm and
K is the coefficient depending on the specified grade of accuracy
and class of surface finish
for rough grinding K = 1 to 1.2 and for finish grinding K = 1.3 to
1.5.

Transverse feed
The effect of the transverse feed on the grinding wheel
performance is shown in the figure . Besides affecting the
distribution of wear along the width of the grinding wheel, it
adversely affects the grinding ratio. The surface roughness
increases and so does the power in the process

Grinding fluids
Grinding fluids or coolants affects the surface finish, the wheel
wear surface temperature and the surface integrity of the
ground surface. In rough grinding used for stock removal,
surface finish is not very important. With proper choice of the
bond of the wheel and the grinding parameters, the wheel may
act as a self sharpening wheel. The role of cutting fluids is to
remove the heat generated during the process and to cool the
wheel in order to reduce excessive wheel wear. It may also
reduce the surface damage of the work piece.
In the finish grinding the grits do not come out so readily and
thus develop wear flats. The rubbing actions of the wear slats
with work surface may produce excessive temperatures in the
work surface and thus damage the work surface. The role of the
cutting fluid is to lubricate the rubbing surfaces so as to reduce
friction and also produce a separating layer between the

Normally grinding fluids remove heat

from grinding zone and wash the clips
away
Generally two types of grinding fluids
are used
(a) Water based fluids, and
(b) Oils based fluids.
Water based fluids remove heat from
grinding zone but do not provide any
lubrication to grinding zone. However,
oil based fluids provides lubrication
properties
also.
Heat
removing
capability of oil base fluid is more due
to their high specific heat. Examples of
water based fluids are dissolved
chemicals into water like
sulfur
chlorine,
phosphorus,
etc.
Examples of oil based fluids are oils
originated from petroleum, animals
and
vegetables.
They
can
be

SEVERITY OF DRESSING
The severity of dressing has a great influence on the
performance of grinding wheel. If the dressing is too mild , the
grains have more flat areas and during grinding the
temperature of the grit becomes excessive which results in
rapid wheel wear. On the other hand if the dressing is too
severe, the working life of the wheel will be reduced by
premature pull out of grits. Therefore the dressing should be
just sufficient to bring out grits which are worn out and are
bonded to the wheel surface.
The temperature during grinding are less if the wear rate is
more. Also the bond strength is such that with dulling of the
grit, increased grinding force pulls it out. The right speed of
the dressing can be determined by dressing at different
speeds and determining the performance of the grinding
wheel.

Bibliography

Wikipedia
http://en.wikipedia.org/wiki/Grinding_%28abrasive_cutting%29

Grinding NPTEL
http://nptel.ac.in/courses/112105127/pdf/LM-28.pdf

University Of Notre Dam- http://www.nd.edu/

http://www3.nd.edu/~manufact/MPEM_pdf_files/Ch09.pdf

IGNOU
http://www.ignou.ac.in/upload/unit-2.pdf

Fundamentals of Metal Cutting and Machine Tools- B.L. Juneja & Nitin Seth

Production Engineering Science- P.C. Pandey & C.K. Singh

University Of Notre Dam

THANK YOU