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Surface Grinding Experiment

The document discusses performing a grinding operation on a specimen using a surface grinding machine. It describes the objectives, apparatus, introduction to grinding processes and machines, properties and types of abrasives, grinding wheels and their selection, cutting action of grinding wheels, classification of grinding operations, turning of grinding wheels, and calculation of grinding ratio.

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Shovan Karmakar
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96 views6 pages

Surface Grinding Experiment

The document discusses performing a grinding operation on a specimen using a surface grinding machine. It describes the objectives, apparatus, introduction to grinding processes and machines, properties and types of abrasives, grinding wheels and their selection, cutting action of grinding wheels, classification of grinding operations, turning of grinding wheels, and calculation of grinding ratio.

Uploaded by

Shovan Karmakar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Experiment-9

To Perform Grinding Operation on Specimen using Surface Grinding Machine

Objectives:
Becoming familiar with the surface grinding machine and its various operations.
 Study of different types of grinding wheels.
 To learn about proper safety measures and their applications while using the machine.
Apparatus:
 Grinding machine
 Grinding wheels
 Work piece
 Vice
Introduction to Grinding Process and Grinding Machine:
Grinding is basically an abrasive machining process. Abrasive machining is the basic process in
which chips are formed by very small cutting edges that is the integral part of the abrasive
particles. The results that can be obtained from abrasive machining like grinding range from the
finest and smoothest surfaces produced by any machining processes, in which very little material
is removed, to rough, coarse surfaces and accompany high material removal rate(MRR). The
abrasive particles may be (1) Free, (2) Mounted in resin on a belt, or (3) Close packed into
wheels or stones, with abrasives held together by bonding material called bonded product. The
metal removal process is basically the same in all three cases but with important differences due
to spacing of active grains and degree of fixation of grains. Different types of abrasive machining
includes:
 Grinding: It uses wheels as machining tool and provides accurate sizing, finishing and
low MRR.
 Abrasive Machining:Its MRR is high and used to obtain desired shapes and approximate
sizes.
 Snagging: High MRR, rough rapid technique to clean up castings, forgings.
 Honing: “Stones” containing fine abrasives are uses as tool, primarily a hole finishing
process.
 Lapping: Fine particles embedded in soft metal or cloth; primarily a surface-finishing
process.
An abrasive is a hard and tough substance. It has many sharp edges. An abrasive cuts or wears
away materials that are softer than it. So in abrasive machining abrasives are used as cutting
tools or materials. The following figure shows an illustration of a typical grinding machine. The
main parts of the machine are
1. Base/Bed
2. Column

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3. Saddle
4. Table

Figure 9.1: Schematic illustration of grinding machine


5. Wheel guard
6. Wheel head
Properties of Abrasives:
 Penetration Hardness: This property refers to tire ability of the scratch or cut a softer
material.
 Fracture Resistance: This property refers to the abilityof an abrasive material to resist
breaking or cracking under load.
 Wear Resistance: It refers to the ability of the abrasive grain to maintain sharpness.
Wear resistance is largely related to penetration hardness and tensile strength of the
abrasive.
Types of Abrasives:
 Natural Abrasives: Natural abrasives are obtained from nature. They are being replaced
by artificial ones, Except for diamond, the natural abrasives are relatively soft in
comparison to artificial abrasives. Some of the natural abrasives are:
1. Crocus: Reddish-brown oxide of iron and may be natural or synthetic.
2. Emery: Composed of corundrum (A1203) and 40% iron oxide and other impurities.
3. Diamond: The hardest material known, is used in the form of grains bonded together to
form an abrasive stick or grinding wheel.

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 Artificial Abrasives: They are harder and have greater impact toughness than any
natural abrasives except diamond. The commonly used artificial abrasives are Silicon
Carbide, Aluminum Oxide, Boron Carbide, Synthetic diamond etc.

Grinding Wheels and Their Selection:


A grinding wheel is made of abrasive grains held together by a bond. These grains cut like teeth
when the wheel is revolved at high speed and is brought to bear against a work piece. The
properties of a wheel that determine how it acts are the kind and size of abrasive, how closely
the grains are packed together and amount of the bonding material.

Figure 9.2: Common types of grinding wheels


Cutting Action of Grinding Wheel:
Each abrasive grain in a grinding wheel is a cutting tool. Each has sharp cutting edge which
cutoff tiny particles from the metal being ground. The following figure shows a schematic view
of cutting action by grinding wheel.

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Figure 9.3: Cutting action of wheel

Classification of Grinding Operations:


 Rough Machining Operations: On abrasive-machining operations, metal is removed more
rapidly than on finish-grinding operations. It involves depth of cut 1.5mm or more.
 Finish Grinding: On finish-grinding operations, grinding wheels remove metal relatively
slowly in comparison with other cutting tools. Finish grinding usually follows other rough-
machining slowly in comparison with other cutting tools. It usually follows rough-machining
operations, and generally involves machining to very close tolerance.Three types of precision
grinding exists
 External cylindrical grinding
 Internal cylindrical grinding
 Surface grinding
Surface grinding:It is most common of the grinding operations. A rotating wheel is used
in the grinding of flat surfaces. Types of surface grinding are vertical spindle and rotary
tables.

Figure 9.4: Different types of grinding operations


Cylindrical grinding is also called center-type grinding and is used in the removing the
cylindrical surfaces and shoulders of the workpiece. Both the tool and the workpiece are
rotated by separate motors and at different speeds. The axes of rotation tool can be
adjusted to produce a variety of shapes.

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Figure 9.5:
Examples of various
cylindrical grinding
operations. (a)
Traverse grinding,
(b) plunge grinding,
and (c) profile
grinding.

Internal grinding is used to grind the inside diameter of the workpiece. Tapered holes
can be ground with the use of internal grinders that can swivel on the horizontal.

Figure 9.6: Schematic of Internal Grinding

Turing of Grinding Wheels:


A grinding wheel should be trued each time it is put on the spindle. It should be dressed
whenever it becomes dull, loaded or grazed with use. Turing refers to correcting an out of round
condition of the wheel. A dressing tool is used to remove particles of the abrasive from the high
part of wheel. Turing also refers to remove particles of the abrasive from the high part of the
wheel. Turing also refers to forming the wheel to a particular shape, such as concave or convex.
To be in good condition, the wheel must be sharp and run true on both the periphery and the
sides.
Dressing produces a sharp grinding surface. A diamond tool is used to remove the dull or loaded
surface of the wheel. Dressing is necessary whenever the wheel cuts poorly, usually resulting in
burning the work.

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Calculation of Grinding Ratio:

Figure 9.7
Where,
D=Grinding wheel diameter
d= Wheel depth of cut
V= Tangential velocity
v= Workpiece velocity
t= Undeformed thickness (grain depth of cut)
Grinding ratio, G=Volume of material removed/Volume of wheel wear

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