GRINDING

 Abrasive process
 Metal is removed with the help of ROTATING
GRINDING WHEEL
 Wheels are made of fine grains of abrasive
materials held together by a bonding material
called a BOND
Types of operations performed in cylindrical
grinding

1. TRAVERSE GRINDING

2. PLUNGE GRINDING
 GRINDING MACHINES

Conventional grinding machines can be broadly

classified as:

(a) Surface grinding machine

(b) Cylindrical grinding machine

(c) Internal grinding machine

(d) Tool and cutter grinding machine

HORIZONTAL GRINDING
• Full depth and stock is
removed with one or two passes
at low work speed
• Very high forces are generated
• High rigidity and power
CYLINDRICAL GRINDING
SURFACE GRINDING
CENRELESS GRINDING
 Surface grinding machine

Machine may be similar to a milling machine

used mainly to grind flat surface
Basically there are four different types of surface
grinding machines characterized by the movement of their
tables and the orientation of grinding wheel spindles

• Horizontal spindle and reciprocating table

• Vertical spindle and reciprocating table
• Horizontal spindle and rotary table
• Vertical spindle and rotary table
Horizontal spindle reciprocating table surface
grinder
Surface grinding (a) traverse grinding (b)
plunge grinding
Vertical spindle reciprocating Surface grinding in Vertical spindle
reciprocating table surface grinder
table surface grinder
 Cylindrical grinding machine
This machine is used to produce external cylindrical
surface.
Surfaces may be straight, tapered, steps or profiled.
Broadly there are three different types of cylindrical
grinding machine as follows:
1. Plain centre type cylindrical grinder
2. Universal cylindrical surface grinder
3. Centreless cylindrical surface grinder
Plain centre type cylindrical grinder
Classification of Grinding Machines
TYPES OF GRINDING
WHEELS
 Straight Wheel

These are generally used for cylindrical, internal, centreless and surface
grinding operations. These wheels vary in size, diameter and width of the
face.
 It is also a straight wheel but
its free is slightly tapered to
facilitate the grinding of
threads an gear teeth.

Type 5. It is used for surface grinding, i.e. production of flat surfaces.

Grinding takes place with the help of face of the wheel.

Type 6. It is used for grinding flat surfaces with the help of face of
grinding wheel.
Type 7 used in grinding of tools in tool room.

Type 8. It is used for sharpening of circular or band saw.

Type 9. These are normally on vertical spindle, rotary type
and reciprocating type surface grinders

Type 10. It is also used for grinding of tools in tool room. It is

capable to grind very narrow places due to its thinners.
Coding of a Grinding Wheel
Indian Standard Coding system of grinding wheel is IS : 551-1954. It
provides uniform system of coding of grinding wheels to designate their
various characteristics. It gives a general indication of the hardness and
grit size of any wheel as compared with another. Coding of a grinding
wheel consists of six symbols as described below
Generally abrasive properties like hardness, toughness and
resistance to fracture uniformly abrasives are classified into
two principal groups :

(a)Natural abrasives, and

(b)Artificial abrasives.
Natural Abrasives

Sand stone (solid quartz) These are relatively soft.

These cannot be used for grinding of hard material and
at faster speed.

Emery is a natural aluminium oxide containing 55 to 65%

alumina, rest are iron oxide and impurities.

Corundum : If percentage of aluminium oxide is more,

ranging from 75 to 95% then it is called corundum.

Diamond is not recommended to use as abrasive due to its

cost in effectiveness.
 Artificial Abrasives
Silicon Carbide
It is also called carbornudum. It is manufactured from 56 parts of silica
sand, 34 parts of powdered cake, 2 pats of salt, 12 parts of saw dust in a
long rectangular electric furnace of resistance type
There are two types of silicon carbide
abrasive, green grit with approximately 97%
silicon carbide black grit with approximately
95% silicon carbide.

It is less harder than diamond and less tough than aluminium oxide.
It is used for grinding of material of low tensile strength like cemented
carbide, stone and ceramic, gray cast iron, brass, bronze, aluminium
vulcanized rubber, etc.
 Aluminium Oxide
It is prepared by heating mineral bauxite, a hydrated
aluminum oxide clay containing silica, iron oxide, titanium
oxide mixed with ground coke and iron borings in a arc type
electric furnace.

Preferred for grinding of materials of higher tensile

strengths like steel; high carbon and high speed steel
and tough bronze
Grits: The grain or grit number indicates in a general way the size of the
abrasive grains used in making a wheel, or the size of the cutting teeth,
since grinding is a true cutting operation.

Coarse 10 12 14 16 20 24 -

Medium 30 36 46 54 60 - -

Fine 80 100 120 150 180 - -

Very Fine 220 240 280 320 400 500 600

 Grain size is denoted by a number indicating the number of meshes per
liner inch (25.4 mm) of the screen through which the grains pass when
they are graded after crushing.

The following list ranging from very coarse to very fine includes all the
ordinary grain sizes commonly used in the manufacture of grinding
wheels.
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 denoting the softest and the letter Z denoting 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
the one which holds the grains more securely is called hard.
The grades are denoted below.
Structure: Abrasive grains are not packed tightly in the
wheel but are disturbed 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 grains.
The primary purpose of structure is to provide clearance of chip and
it may be open or dense. The structure commonly used is denoted
by numbers as follows.
Bonds
A bond is an adhesive material used to held
abrasive particals together; relatively stable that
constitute a grinding wheel. Different types of
bonds are :

(a)Vitrified bond,
(b)Silicate bond,
(c)Shellac bond,
(d)Resinoid bond,
(e)Rubber bond, and
(f)Oxychloride bond.
Vitrified Bond

• This bond consists of mixture of clay and water.

• Clay and abrasives are thoroughly mixed with water to
make a uniform mixture.
• The mixture is moulded to shape of a grinding wheel
and dried up to take it out from mould.
• Perfectly shaped wheel is heated in a kiln just like brick
making.
• It this way clay vitrifies and fuses to form a porcelain or
glass grains.
• High temperature also does annealing of abrasive.
This wheel posses a good strength and porosity to allow
high stock removal with coal cutting.

Disadvantage of this type of wheel are, it is sensitive for heat,

water, oil and acids. Their impact and bending strengths are
also low. This bond is denoted by symbol ‘V’ in
specification.
Silicate Bond

Silicate bonds are made by mixing abrasive

particals with silicate and soda or water glass. It is
moulded to required shape, allowed to dried up
and then taken out of mould. The raw moulded
wheel is baked in a furnace at more than 200°C
for several days. These wheel exhibits water
proofing properly so these can be used with
coolant. These wheels are denoted by ‘S’ in
specification.
Shellac Bond

These are prepared by mixing abrasive with shellac than

moulded by rolling and pressing and then by heating upto
150°C for several hours. This bond exhibit greater
elasticity than other bonds with appreciable strength.
Grinding wheels having shellac bond are recommended
for cool cutting on hardened steel and thin sections,
finishing of chilled iron, cast iron, steel rolls, hardened
steel cams and aluminium pistons. This bond is denoted
by ‘E’ in specifications
Resinoid Bond

These bonds are prepared by mixing abrasives with

synthetic resins like backelite and redmanol and
other compounds. Mixture is moulded to required
shape and baked upto 200°C to give a perfect
grinding wheel.

These wheels have good grinding capacity at higher

speed. These are used for precision grinding of cams,
rolls and other objects where high precision of surface
and dimension influence the performance of
operation. A resinoid bond is denoted by the letter
‘B’.
Rubber Bond

Rubber bonded wheels are made by mixing abrasives with

pure rubber and sulpher.

After that the mixture is rolled into sheet and wheels are
prepared by punching using die and punch.

The wheels are vulcanized by heating then in furnace for

short time.
• Rubber bonded wheels are more resilient and have
larger abrasive density.

• Used for precision grinding and good surface finish.

Rubber bond is also preferred for making thin wheels
with good strength and toughness.

• Associated disadvantage with rubber bond is, these are

lesser heat resistant.

• A rubber wheel bonded wheel is denoted by the letter

‘R’.
Oxychloride Bond
• These bonds are processed by mixing abrasives with
oxides and chlorides of magnesium.
• The mixture is moulded and baked in a furnace to give
shape of a grinding wheel.
• These grinding wheels are used for disc grinding
operations. An oxychloride bonded wheel is specified the
letter ‘O’.
 GLAZING AND LOADING, THEIR
EFFECTS, CAUSES AND
REMEDIES

When the surface of a grinding

wheel develops a smooth and
shining appearance, it is said to be
glazed.

This indicates the abrasive particles

on the wheel face are not sharp.
• Loading
When soft materials like aluminium, copper, lead, etc.
are ground the metal particles get clogged between the
abrasive particles. This condition is called loading.
The effects of a glazed or a loaded grinding wheel are
almost the same.
Dressing
Dressing removes loading and breaks away the
glazed surface so that sharp abrasive particles
are again presented to the work. This is done
with various type of dressers. A common type
of wheel dresser, known as the star-dresser,
• For precision and high finish grinding, small
industrial diamonds, known in the trade as bors, are
used.
• Diamond or group of diamonds is mounted in a
holder. The diamond should be kept pointed, since
only the point can be used for cutting.
• This is done by the holder down at a 15° angle and
using a new surface each time the wheel is dressed.
• Good supply of coolant should be used when
dressing with a diamond, as overheating can cause the
diamond to fracture or drop out of its setting. Very
light cuts only may be taken with diamond tools.
• Truing :

Truing is the process of changing the shape of

the grinding wheel as it becomes worn from
an original shape, owing to the breaking away
of the abrasive and bond.

This is done to make the wheel true and

concentric with the bore, or to change the
face contour for form grinding. Truing and
dressing are done with the same tools, but not
for the same purpose
The only satisfactory method of truing a wheel
is by the use of a diamond tool in a similar
manner as explained before. In turning a
wheel with a diamond, the feed rate must not
exceed 0.02 mm, otherwise grooves may be
cut into the wheel
CUTTING FLUIDS

Recommended cutting fluids

Soluble mineral oil and pure water are mixed in the ratio of
1:40 or 50 (depending upon the grinding wheel) and is used for
grinding the following materials.
oCast iron or hardened steel
oSoft steel
oConnected carbide tools (using silicon
wheel) In India we use IOC Servocut oils as
cutting fluid.
There is a special grade oil manufactured by IOC for grinding
alone. It is called Servocut - clear.
WHEEL BALANCING OF GRINDING WHEEL
SURFACE ROUHGNESS OBTAINABLE
SUPER FINISHING