MANUFACTURING TECHNOLOGY – II

UNIT 1 SURFACE FINISH PROCESS

Introduction:
In industrial activities, any solid metal surface to be finished means the primary process is grinding operation. After
getting casting from mould, further operation such as sizing, rough turning, and fine-turning being done before
getting the operation of grinding. Grinding is an operation which is done by abrasion through grinding wheel
nearing to the required surface finish. To achieve further more finish, super finishing processes will be done, such as
Gear polishing, buffing, metal spraying, galvanizing and electroplating.

Grinding process:
Grinding operation performed by means of a rotating abrasive wheel that acts as a cutting tool. Such wheels are
made of fine grains of abrasive materials held together by bonding material, called a bond. These abrasive
materials are having high hardness and a high heat resistance.Grinding provides very good surface finish with high
accuracy. Therefore it is used for finishing operation.

The grinding machines may be classified as

1. Types of operation
(a) Tool grinders
(b) Cut off grinders
2. Quality of surface finish
(a) Precision grinders
(b) Rough grinders
3. Types of surface generated
(a) Cylindrical grinders
(b) Internal grinders
(c) Surface grinders
(d) Tool grinders
(e) Special purpose grinding machines
(f) Surface finishing grinders
1. Rough grinders
(a) Floor stand grinders
(b) Bench grinders
(c) Portable grinders
(d) Abrasive belt grinders
(e) Swing frame grinders
2. Precision grinders
(a) Cylindrical grinders
i. Centre type plain grinders
ii. Centre type universal grinders
iii. Centreless grinders
(b) Internal grinders
i. Chucking type grinders
ii. Planetary type grinders
iii. Centerless grinders
(c) Surface grinders
i. Horizontal spindle- Reciprocating table
ii Horizontal spindle-Rotary table
iii Vertical spindle-Reciprocating table
iv Vertical spindle-Rotary table
(d) Tool and Cutter grinders
(e) Special grinders
 ROUGH GRINDERS

Cylindrical grinding machine

Base: The base is the main casting that rests on the floor and supports the parts mounted on it.
Table: There are two table-upper table and lower table. The lower table slides on the guide ways of the bed and
provides traverse feed of the work piece. The upper table is mounted on the lower table and it carries head
stock and tail stock.
Head stock: Head stock, which is mounted on the upper bed, is to rotate the workpiece by means of dog and driving
pin.
Tail stock: the tail stock can be adjusted and clamped to accommodate different length of work piece. The work
piece is held in between the centre of headstock and tailstock.
Wheel head: The wheel head carries a grinding wheel, which is placed over the bed at its backside. This can be
moved perpendicular to the table ways by hand or power.

Centreless grinding machine

Centreless grinding is performed on work pieces which do not have centers, such as pistons, valves, rings, tubes,
balls, wrist pins, drills, bushings shafts etc.Centreless grinding can be done on both external and internal cylindrical
 surfaces.The principle of external centreless grinding is shown in fig. The grinder has two wheels, a larger grinding
wheel revolving at a high speed and a small regulating wheel revolving slow speed. Work rest is located in between
the wheels. The work is placed on the work rest. The regulating wheel is fed forward forcing the work against the
grinding wheel. So the work on the work rest is pressed against the grinding wheel surface. By friction, the
regulating wheel makes the work piece to rotate. The rotating work piece is pressed between the two wheels. So the
grinding wheel grinds the work piece. The regulating wheel does not remove the metal as it rotates slowly.

Work piece is placed in a floating condition between the grinding wheel and regulating wheel. So this is called
Centreless grinding.

Work Holding Devices

For centreless grinding machine:

The regulating roller controls the rotation of the part. The feed-through action is precipitated by slightly skewing the guide blade
axis in relation to the regulating roller, causing the regulating roller to pull the part across the face of the grinding wheel. The
workpiece is held against the guide blade and roller by gravity. Traversing the wheel toward or away from the guide blade and
regulating roller controls diameters precisely. Once the high spots are ground on a round, the diameter can be reduced precisely
to the desired range. The process is relatively simple to set up, and although the parts may need to be fed through the grinder
multiple times to achieve the roundness required, it is very economical, especially as volumes increase.

For cylindrical grinding machine:

Collets and chucks are used for grinding workpieces that are either too small for center points or require one end to be featured
or profiled. Chuck and collets systems are dynamic work holding systems. Unlike centerless and between-centers setups, where
the setup is stationary, the workpiece moves with the chuck or the collet. This means in addition to any inaccuracies they suffer,
the quality, wear, and balance of the drive system is critical to maintaining the overall stability of workpiece holding.

Grinding wheel and its specifications:

The Grinding Wheel:

A grinding wheel is a multi tooth cutter made up of many hard particles known as abrasives which have been crushed to
leave sharp edges which do the cutting. The abrasive grains are mixed with a suitable bond, which acts as a matrix or holder
when the wheel is in use. The wheel may consist of one piece or of segments of abrasive blocks built up into a solid wheel. The
abrasive wheel is usually mounted on some form of machine adapted to a particular type of work.
Abrasives:
An abrasive is an substance that is used for grinding and polishing operations. It should be pure and have uniform
physical properties of hardness, toughness and resistance to fracture to be useful in manufacturing wheels. Abrasives may be
classified in two principle groups: (a) natural and (b) artificial or manufactured
Bonds:
A bond is an adhesive substance that is employed to hold abrasive grains together in the form of sharpening stones or
grinding wheels. Bonding materials and processes are:
1. Vitrified bond used for making vitrified grinding wheels
2. Silicate bond forf making silicate wheels
3. Shellac bond for making elastic wheels.
4. Resinoid bond used for making resinoid wheels.
5. Rubber bond used for making vulcanized wheels.
6. Oxychloride bond for making Oxychloride wheels
Grits:
The grain or grit number indicates in a general way the size of the abrasive grains in making a wheel, or the size of the
cutting teeth, since the grinding is a true cutting operation. Grain size is denoted by a number indicating the number of meshes
per linear inch (25.4 mm) of the screan through which the grains pass when they are graded after crushing.
The size of the abrasive grain required in a grinding wheel depends on the amount of material to be removed, the finish
desired and the hardness of the material being ground. In general, coarse wheels are used for fast removal of materials. Fine
grained wheels are used where finish is an important consideration. Coarse wheels are may be used for soft, ductile materials
but generally a fine grain should be used to grind hard, brittle materials.
Grade:
The term ‘grade’ as applied to a grinding wheel refers to the tenacity or hardness with which the bond holds the cutting
points or abrasive grains in place. It does not refer to the hardness of the abrasive grain. The grade shall be indicated in all
bonds and processes by a letter of the English alphabet. ‘A’ denotes the softest and ‘Z’ the hardest grade. The term ‘soft’ or
‘hard’ refer to the resistance a bond offers to disruption of the abrasives. A wheel from which the abrasive grains can easily be
dislodged is called soft, whereas one which holds the grains more securely is called hard.

Structure:
Abrasive grains are not packed tightly in the wheel but are distributed through the bond. The relative spacing is referred
to as the structure and denoted by the number of cutting edges per unit area of wheel face as well as by number and size of void
spaces between the grains. The primary purpose of structure is to provide chip clearance and it may be open or dense. The
structure commonly used is denoted by numbers.

Wheel shapes and sizes:

Grinding wheels are made in many different shapes and sizes to adapt them for use in different types os grinding
machines and on different classes of work. They fall into the following broad groups: straight-side grinding wheels, cylinder
wheels, cup wheels and dish wheels. The shape of the grinding wheels have been standardized so that those commonly used in
production and tool room grinding may be designated by a number of name or both.
 MOUNTING THE GRINDING WHEEL

BALANCING THE GRINDING WHEEL

Grinding wheels are statically balanced if no balancing unit is present on the machine and balancing has to be performed
outside the machine on a balancing stand. The balancing process is performed with the grinding wheel upright.
Balancing stand
The balancing stand must be aligned with a spirit level and the grinding wheel must be dry. The balancing arbor, its
mounting and the contact surface must be clean. The balancing stand must also be positioned on a firm surface (no rubber
surfaces).
Procedure
• Remove all balancing elements.
• Place grinding wheel on the balancing stand and allow to come to rest.
• The heaviest point of the wheel is now at the bottom. Weight no. 1 is mounted exactly opposite this and is not moved
again.
• Distribute the other two weights, no. 2 and no. 3, symmetrically over approx. 120°.
• Now rotate the grinding wheel by 90° and stop it. If weight no. 1 pulls down, push the other two weights symmetrically
away from no. 1, or vice-versa towards no. 1.

FINE FINISHING PROCESSES

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

Super Finishing

Polishing
It is the most refined of the finishing process which removes the surface particles. Each type of
polishing abrasive acts on an extremely thin region of the substrate surface. Progress from the finest abrasive that
can remove scratches from the previous grinding process and completed when desired level of smoothness is
achieved. The final stage produces scratches so fine they are visible when greatly magnified.

Buffing

GALVANIZING
 Hot-dip galvanizing is the process of immersing iron or steel in a bath of molten zinc to produce a
corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal. While the steel is immersed in the zinc, a
metallurgical reaction occurs between the iron in the steel and the molten zinc. This reaction is a diffusion process, so the
coating forms perpendicular to all surfaces creating a uniform thickness throughout the part.

ELECTROPLATING

Electroplating is a process that uses electric current to reduce dissolved metal cations so that they form a
thin coherent metal coating on an electrode. The term is also used for electrical oxidation of anions onto a solid substrate,
as in the formation silver chloride on silver wire to make silver/silver-chloride electrodes. Electroplating is primarily used
to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic
qualities, etc.), but may also be used to build up thickness on undersized parts or to form objects by electroforming.

METAL SPRAYING

During metal spraying the melted spray additives are mostly sprayed by using compressed air, but also other
spraying gases or gas flow from the heat source. The parts meet the substrate surface with a very high kinetic
energy, they are deformed and the material to be sprayed is quickly cooled down on the relatively cold substrate.
This results in a layer made of metal, oxides and very small intermediate spaces.

Advantages of thermal spraying

 Almost any material can be coated/sprayed

 The metal to be coated is not thermally changed
 Almost any component size (independent of the basic material) can be coated
 Excellent automation of the thermal spraying process
 Flexible operation
 High dimension accuracy
 High quality standard