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Grinding Process

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018)

 Grinding

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• It is a process of removing very less quantity of

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material from the workpiece surface with the help

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of a grinding wheel which is made up of abrasive

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grains.

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• It is used for:

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– Machining of very hard materials such as tool and dies steel and hardened
materials.
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– Close dimensional accuracy of the order of 0.3-0.5 µm.
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– Surface finish Ra= 0.15-1.25 µm.
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– for example, the accuracy and fine surface finish required on ball and roller
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bearings, pistons, valves, cylinders, cams, gears, dies, and numerous precision
components used in instrumentation.
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 2

 Composition of Grinding Wheel

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• Composed of abrasives and suitable bond.

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Abrasive :

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• An abrasive is a small, hard particle having sharp

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edges and an irregular shape.

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• It is capable of removing small amounts of material

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from a surface through a cutting process that
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produces tiny chips (debris).
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 3

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Types of Abrasives

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Abrasives that are used most commonly in abrasive-

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machining operations are :

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Conventional abrasives:

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• Aluminium oxide (Al2O3)

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• Silicon carbide (SiC)
Superabrasives
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• Cubic boron nitride (CBN)

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• Diamond.
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Comparison

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Al2O3 SiC CBN Diamond

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In addition to the hardness, other important

property is friability.
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 5

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Friabilty

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Friability is defined as the ability of abrasive grains to

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fracture (break down) into smaller pieces.

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• It gives abrasives their self-sharpening characteristics

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during the actual use.

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• High friability means low strength or low fracture resistance

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of the abrasive. io
• Highly friable abrasive grain fragments more rapidly under
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grinding forces than one with low friability.

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• Alumina abrasives has lower friability than SiC abrasives.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 6

 Abrasive shape and grain Size

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• Blocky grains may be analogous to negative-rake
angle cutting tool and are less friable (strong) as

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compared to platelike (flattened) grains.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 7

 Abrasive shape …………contd.

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• As the size is decreased the probability of defects

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are less in smaller grains. They are stronger and less

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friable than larger grains.

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• The size of an abrasive grain is identified by a

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grit number (ISO), which is a function of sieve size.

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• The smaller the grain size, the larger the grit

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number.
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• Several standards have been setup for abrasive size.
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– US Std. CAMI (Coated Abrasive Manufacturers Institute)

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– European Std. FEPA (Federation of European Producers of Abrasives) "P" grade.

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– The FEPA system is the same as the ISO 6344 standard.

– Japanese Industrial Standards Committee (JIS)
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 8

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• MacroGrits

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– P16-P220

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• MicroGrits

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– P240-P2500 io
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P1500 800 1200 12.6

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P2000 1000 1500 10.3

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) P2500 2000 8.4
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Abrasive-Workpiece-Material Compatibility

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• The affinity (chemical reactivity) of an abrasive

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grain to the workpiece material is an important

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consideration.

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• Less reactivity corresponds to less wear and dulling

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of abrasive grains.
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• Diamond cannot be used for grinding steels.
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• Diamond dissolves in iron at the high temperatures

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encountered in grinding.
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 10

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Generally, the following recommendations are made

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with regard to selecting abrasives:

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Aluminum oxide: Carbon steels, ferrous alloys, and alloy steels.

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Silicon carbide: Nonferrous metals, cast irons, carbides, ceramics,

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glass, and marble.
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Cubic boron nitride: Steels and cast irons above 50 HRC hardness
and high temperature alloys.
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Diamond: Ceramics, cemented carbides, and some hardened steels.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 11

 Grinding Wheel

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• An individual abrasive grain can remove very small of
material from workpiece surface.

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• High rates of material removal can be obtained by

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bonding several abrasives grain together in the form of a

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wheel.
• Abrasive grains are distributed and oriented randomly in

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grinding wheel.
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Physical model of a grinding wheel showing its wear and failure

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018)
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• In bonded abrasives, porosity is essential in order to

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provide clearance for the chips being produced and
to provide cooling.

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• No porosity means simply no room for chips to

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form.

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• Porosity can be observed by looking closely at the

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surface of any grinding wheel.

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Grinding Wheel Specifications

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 14

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Standard marking system for Aluminium oxide and Silicon carbide bonded abrasives
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 15

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Standard marking system for CBN and Diamond bonded abrasives

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018)

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Abrasives

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 17

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Bond Types

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• Vitrified : also known as ceramic bond (brittle).

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– Consists of feldspar(crystalline mineral) & clay.

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– The ingredients are mixed with abrasives and

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compressed under high pressure to give a wheel shape.
– Curing is done at 1250 °C to fuse and develop strength.

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– Bond is strong and resistive to oil, acid and water.
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Feldspars (KAlSi3O8 – NaAlSi3O8 – CaAl2Si2O8)

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 18

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• Resinoid: are thermosetting resins (organic bond).
• Formed by mixing of abrasives, phenolic resins and

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additives.

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• Pressing the mixture into wheel shape and curing at

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175 °C to develop the strength.
• Resinoid wheels are flexible than vitrified wheels.

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• Sometimes polyamide resin is used in place of
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phenolic which is more tougher and resistant to
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temperatures.
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 19

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• Reinforced wheels:

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• Consists of one or more layer of fibreglass mats of
various mesh sizes .

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• Fibreglass reinforcement retards the fracture of

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wheel rather than improving the strength.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 20

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• Rubber :

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– Most flexible matrix as compared to other bonds.

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– Fabricated by mixing crude rubber, sulphur and

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abrasives.

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– The mixture is rolled into thin sheets, cutting out disks

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of various diameters.

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– Finally heated to perform the vulcanization.

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– Cut-off wheels are formed for cutting operations
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 21

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• Metal :

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– Diamond and CBN abrasive grains are bonded to the
periphery of metal wheel by powder metallurgy.

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– The depth of the abrasives is generally 6 mm or less.

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– The metal wheel is made of Al, bronze, steel,

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ceramics or composites depending upon the
requirement.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 22

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Examples

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 23

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 24

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Types of Grinding

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Surface Grinding

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Wheel Balancing

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• Static Balancing

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• Dynamic Balancing

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Calculation of Chip Thickness in Surface Grinding

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• The material removed by a single abrasive grain

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In triangle OCF :

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(1)

(2)

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(3)
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(4)
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(5)
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(6)
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• The shape of the chip can be approximated as

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• Where

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(8)

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Grinding Ratio

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• It is the ratio of volume of work material removed

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to the volume of grinding wheel worn in the

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process.

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• Gr = Vw/Vg

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Where Vw = volume of work material removed

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Vg = volume of grinding wheel removed in the process
• Region 1: Grains are sharp but wheel
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wear is accelerated by grain fracturing.
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• Region 2: Wear rate is constant, linear

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relationship, attritious wear exists with

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grain and bond fracture.

• Region 3: grains become dull, plowing and

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rubbing is observed, re-sharpening is required. Typical curve of wheel wear

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• Typical values of Gr range between 95 and 125.

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• The grinding ratio has the most significance in the linear
wear region (region 3).

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• Grinding ratio is generally increased by increasing wheel

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speed v.

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• The size of the chip formed by each grit is smaller with
higher speeds, so the amount of grain fracture is

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reduced. io
• High speed also improve the
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surface finish.
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• Too much speed decreases

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surface finish.
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High speed is advantageous

 Glazing & Wheel loading

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• When wheel develops a smooth shining surface, it
is said to be glazed.

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• It occurs in the third region of wheel wear curve.

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• When some of the chips become clogged in the

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pores of the wheel. This is called wheel loading.

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• It inhibits the cutting action and leads to higher
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heat and work surface temperatures.
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or
 Dressing and Truing

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• When the wheel is in the third region, it must be
sharpened again.

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• The process of sharpening the glazed wheel with

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the help of a dressing stick (made of abrasives) is

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called dressing.

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• After prolong usage, grinding wheel looses its
shape. na
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• The process of restoring the cylindrical shape of

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grinding wheel with the help of a diamond tip is

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called as truing.
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Wheel Dressing Wheel Truing

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Superfinishing Operations

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• High surface finish is required along with

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geometrical and dimensional accuracy ???

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• Role of surface finish :

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– Wear Resistance

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– Corrosion Resistance
– Fatigue io
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– Power Loss
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 30

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Honing

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• It is a low abrading process using a hone tool.

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• Tool is given combined rotary and reciprocating

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motion.

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• Tool rotates with surface speed of 45-90 m/min.

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• The flexible abrasive sticks (stones) apply radial
outward force.

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• Most honing is done on internal cylindrical surface,
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such as automobile cylindrical walls, gun barrel etc.
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• Error in roundness is reduced.

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• Taper is reduced.
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• Dimensional accuracy is achieved.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 31

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32
Cylindrical Honing Centreless Honing
 Lapping

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• Loose abrasives are used for finishing the surface.

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• Abrasives are mixed in oil and water to form slurry.

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• It is used for flat, cylindrical and curved surfaces.

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• Sometimes abrasives are embedded in a soft and
porous lap made of cast iron, copper, leather or

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cloth. io
• Mating parts are lapped, glass lenses are finished.
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• Lapping pressure 0.007-0.140 MPa is used.

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• Manual lapping is done by moving hand in 8 shape

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 33

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 34

 Polishing

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• It produces smooth and lustrous surface finish.

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• Mechanism : softening and smearing of surface layers

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by frictional heat generated during polishing along

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with very fine abrasive removal of the surface.

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• Shining surface is obtained due to smearing action.

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• Removal of oxide layer takes place.
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• It consists of a flexible wheel or belt made of cloth or
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leather and abrasives (Alumina or Diamond) are glued

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on its surface.
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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 35

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 36

 Buffing

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• It is performed after polishing with finer abrasives

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to further smoothen the surface with high lustre.

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• Abrasives are applied externally over a rotating

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wheel made of cloth.

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• The wheel consists of stacker layer of cloth or

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canvas.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 37

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Peening

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• Fine abrasives or steel balls impact over the

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surface.

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• Removal of dust and oxide layer.

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• It also improves fatigue life of the component by

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imparting compressive stresses.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 38

 Burnishing

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• It is the plastic deformation of a surface due to

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sliding contact with another object.

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Dr. Lalit Thakur, A.P., M.E.D....Ver. 01 (2018) 39