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Grinding Training Presentation

This document provides an overview of cylindrical grinding processes and the basics of grinding wheels. It discusses cylindrical grinding techniques like plunge grinding and traverse grinding. It also covers the machine requirements for cylindrical grinding, including rigidity, spindle power and balancing. The document reviews abrasive types like aluminum oxide and CBN as well as bonds and wheel construction. It discusses coolant delivery and truing and dressing of grinding wheels.

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Karthik Nerella
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388 views62 pages

Grinding Training Presentation

This document provides an overview of cylindrical grinding processes and the basics of grinding wheels. It discusses cylindrical grinding techniques like plunge grinding and traverse grinding. It also covers the machine requirements for cylindrical grinding, including rigidity, spindle power and balancing. The document reviews abrasive types like aluminum oxide and CBN as well as bonds and wheel construction. It discusses coolant delivery and truing and dressing of grinding wheels.

Uploaded by

Karthik Nerella
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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GRINDING BASICS

Presented By:
Dale Savington

Tooling & Accessories Group

PRESENTATION OUTLINE

Cylindrical Grinding Processes


Machine Requirements (Utilizing CBN) Abrasives

Properties of Abrasives

PRESENTATION OUTLINE

Superabrasives Bonds

Mechanics of Grinding
Coolant Truing & Dressing

CYLINDRICAL PROCESSES
(GRINDING BETWEEN CENTERS)

Conventional Plunge / Face Grinding


Down-Feed (face bump grind) Q (Prime) 2.14 (0.2) + Wheel Velocity S.F.P.M. 8,500 + m/sec. 43 + Work Velocity

75 to 125:1 of wheel velocity


High volume of coolant to get into grinding zone

Conventional Traverse Grinding


Cross Feed (Traverse) only Stock Removal (in-feed depth) 0.0 to 0.0178 mm (0.0007)
10% of abrasive / pass

Traverse rate
10 25% of wheel width per rotation of part Wheel Velocity S.F.P.M. 8,500 + m/sec. 43 + Work Velocity 75 to 125:1 Wheel Velocity

Finish Grinding

Peel Grinding
Multiple grinding functions Multiple diameters Multiple shoulder / Faces Q (Prime) 53 (5) + (Up to 100 mm3/mm/sec.) Traverse feed expressed as mm or inches per revolution of part. Wheel Velocity S.F.P.M. 20,000 + m/sec. 100 + Work Velocity 10 to 30:1 wheel velocity Easier coolant delivery into grinding zone (narrow contact area)

What is Q (Prime)?
Cylindrical Grinding Plunge
Q = work piece diameter (dw) x 3.14 () x in-feed rate (vf)

Example: Work piece diameter 25.4mm (1) In-feed rate = 0.67mm/sec.(0.159/minute) Q = 5.37mm3/mmsec. (0.5 in3/inmin.)

What is Q (Prime)?
Cylindrical Grinding Traverse
Q = work piece diameter (dw) x 3.14 () x depth/pass (a) x work speed (nw)

Example: Work piece diameter = 25.4mm (1) Depth per pass = 0.0127mm (0.0005) Work speed = 5.4 (rpm/60) (325rpm) Q = 5.47 mm3/mmsec. (0.51 in3/inmin.)

MACHINE REQUIREMENTS

Machine Rigidity
Spindles
Head Stock Slides Centers Tail Stock

Base

Parts will Mirror Machines Rigidity

Wheel Spindle POWER!

Wheel spindle power per 25.4mm (1) of wheel to work contact

Kilowatts!

Conventional Abrasives = 3.75 Kw (5 H.P.)


CBN Abrasives = 7.5 Kw (10 H.P.) (HEDG) = 18.75 Kw (25 H.P.) Peel depends on contact area, material and stock removal

Spindle Integrity

Run-Out

Out of Balance

Wheel Balance
(Dynamic vs Static)

Static Balance

Dynamic Balance real time

Portable Dynamic Balance

Wheel Balance
(Dynamic vs Static)

Static Balance allows balance in stationary position off the spindle.

Dynamic Balance is continuous balance on the spindle at working rotating speeds.

Acoustic Sensors
Dressing: Sound of dresser touching wheel through coolant.
Complete contact = dressed wheel

Other uses: Picture of grinding process Gap Sensor

Machine Requirements
(Minimum for Utilizing CBN)

Rigidity Spindle power Wheel Velocity Rotary Dresser Dynamic Balancing

Coolant Flow

Smooth Transitional Plumbing


Coolant Tank Capacity Coolant with lubricity

Acoustic Sensors

ABRASIVES

What affects Abrasive Decision?


Ferrous Materials
Non-Ferrous Materials Fatigue Concerns
(Potential thermal damage)

Production Numbers

Dimensional Tolerances Process Controls

Types of Abrasives
Aluminum Oxide Silicon Carbide Cubic Boron Nitride (CBN)

Diamond

Abrasive Selection

Ferrous Materials
Cubic Boron Nitride (CBN) Aluminum Oxide

Non-Ferrous Materials
Diamond Silicon Carbide

PROPERTIES OF ABRASIVES

Aluminum Oxide (Al2O3)


For Grinding Ferrous Materials

Hardness on Knoop Scale (kg/mm2) = 1400 - 2100

Thermal Conductivity O (W/m K) = 29

Silicon Carbide (Si,C)


For Grinding Non-Ferrous Materials

Hardness on Knoop Scale (kg/mm2) = 2700

Thermal Conductivity O (W/m K) = 400

Cubic Boron Nitride (CBN) (B,N)


For Grinding Ferrous Materials

Hardness on Knoop Scale (kg/mm2) = 4500

Thermal Conductivity O (W/m K) = 1300

Diamond (C)
For Grinding Non-Ferrous Materials

Hardness on Knoop Scale (kg/mm2) = 8000

Thermal Conductivity O (W/m K) = 2000

Review
Knoop Hardness Aluminum Oxide
Silicon Carbide

Thermal Conductivity 29
400 1300 2000

1400-2100
2700

Cubic Boron Nitride (CBN) 4500 Diamond 8000

The Puzzle Why Not Diamond?

Diamond + Ferrous Material + Heat =

Note: Silicon Carbide has similar reaction

SUPERABRASIVES

What are Superabrasives?

Diamond Cubic Boron Nitride (CBN) Borazon

What makes Superabrasives Super?

Hardness (Resistance to wear) Thermal Conductivity (The ability to absorb heat) Flexibility (one wheel for many applications) Wheel Life (100 + times Conventional Abrasives)

Some Advantages
(For Superabrasives)

Decreased Cycle Time Reduced Dressing


Reduced Gaging

More Consistent Parts (Less Scrap) Reduced Time for Wheel Changes
Reduced Coolant Changes Reduced Filter Changes Reduced Coolant Disposal Costs Less Swarf Contamination

Conventional Abrasives Construction


Conventional Layer = full area of wheel Wheel Vitrified Bond Resin Bond

Rubber Bond
Shellac Bond

Superabrasive Construction
Superabrasive Layer = 3mm (1/8) to 6mm (1/4) Wheel Core

Resin Bond Metal Bond

Vitrified Bond

BONDS

Grinding Matrix Vitrified Wheel

Grain

Pore

Bond
Chip

Grinding Wheel Bond Systems


Resin , Metal & Bonds

Abrasive + Bond = Wheel

Grinding Wheel Bond Systems


Open Structure (Low fired) Vitrified Bonds

Abrasive + Bond + Pores = Wheel

Grinding Wheel Bond Systems

Plated Wheels (Single Layer)


Wheel body Cathode (-) Electrolyte (Nickle Solution)

Abrasive Anode (+)

Plated Wheel Cut-A-Way

Mechanics of Grinding

Abrasive wear
Bond

Abrasive Fracture wear Chip

Cut a way of wheel

Abrasive wear
Conventional Abrasive (one grain)

Attritious wear (Rubbing)

Work Piece

Abrasive wear
Conventional Abrasive (one grain)

Fracture wear Work Piece

Abrasive wear
Conventional Abrasive (one grain)

Fracture wear Work Piece

Abrasive wear
CBN Abrasive (one grain)

Attritious wear Work Piece

Standard Markings Conventional Abrasives


Abrasive Type A C SG30 A Abrasive Size 60 120 80 24 Abrasive
(combination)

Hardness (Grade) J K L R

Structure (Pore) 6 12 10

Bond

1 2

V V V B

Standard Markings Superabrasives


Abrasive Type BN D BN Abrasive Size 140 240 120 Hardness (Grade) J k L
Concentration

Bond B M V

100 75 150

Superabrasives are always combinations 120/140, 80/100 etc. Calculating concentration take number and divide by 4 Example 100 4 = 25% by volume of abrasive in wheel

COOLANT

Coolant Flow

Nozzle Designs
Centerless Surface grinding

Cam grinding

Coolant Condition

Tank Size & Coolant Temp.

Filtration & Particle Distribution

Chemistry (Lubricity)

TRUING & DRESSING

The Difference Between Truing & Dressing

Truing Resin & Metal Bonds

Dressing Resin & Metal Bonds

Truing & Dressing Plated Wheels

Truing & Dressing Vitrified Bonded


(CBN Wheels)

Examples of Rotary Dressers

Truing & Dressing


(Depth or In-Feed) Conventional Abrasives Aluminum Oxide
0.0178mm (0.0007) per pass

Ceramic Abrasives Seeded Gel (SG)


0.005mm (0.0002) per pass

CBN Abrasives
0.0025mm (0.0001) per pass

Truing & Dressing


(Traverse Rate)

Starting Parameters
0.1mm (0.004) per revolution of wheel Assuming 0.5mm (0.020) radius dresser

Faster traverse rate creates rougher finish


Slower traverse rate creates finer finish

CBN vs Conventional
(Surface Finish plunge grinding only)

Conventional Grinding Surface Finish = Grit Size CBN Grinding: Surface Finish = Diamond Overlap

the end

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