GRINDING AND OTHER ABRASIVE PROCESSES

Abrasive machining : It involves material removal by the action of hard, abrasive particles that
are usually in the form of a bonded wheel. The abrasive machining processes are generally used
as finishing operations, although some abrasive processes are capable of high material removal
rates rivaling those of conventional machining operations.

Grinding: It is a material removal process accomplished by abrasive particles that are contained
in a bonded grinding wheel rotating at very high surface speeds. The grinding wheel is usually
disk-shaped, and is precisely balanced for high rotational speeds.

Mechanism: The rotating grinding wheel consists of many cutting teeth (the abrasive particles),
and the work is fed relative to the wheel to accomplish material removal.

Similarity with Milling: Grinding can be likened to the milling process similar to peripheral and
face milling.

Differences with Milling: Despite these similarities, there are significant differences between
grinding and milling:

(a) The abrasive grains in the wheel are much smaller and more numerous than the teeth on a
milling cutter

(b) Cutting speeds in grinding are much higher than in milling

(c) A grinding wheel is self-sharpening—as the wheel wears, the abrasive particles become dull
and either fracture to create fresh cutting edges.
THE GRINDING WHEEL
A grinding wheel consists of abrasive particles and bonding material. The bonding material holds
the particles in place and establishes the shape and structure of the wheel.

The five basic parameters of a grinding wheel are:

(1) Abrasive material

(2) Grain size

(3) Bonding material

(4) Wheel grade

(5) Wheel structure.

To achieve the desired performance in a given application, each of the parameters must be
carefully selected.

a) Abrasive Material: General properties of an abrasive material used in grinding wheels

include

 High hardness

 High wear resistance

 High toughness

 High friability

Hardness, wear resistance, and toughness are desirable properties of any cutting-tool material.

Friability refers to the capacity of the abrasive material to fracture when the cutting edge of the
grain becomes dull, thereby exposing a new sharp edge.

Abrasive materials: Aluminum oxide, Silicon carbide, Cubic boron nitride and Diamond
b) Grain Size: The grain size of the abrasive particle is important in determining surface
finish and material removal rate.

 Small grit sizes produce better finishes

 Larger grain sizes permit larger material removal rates

The selection of grit size also depends to some extent on the hardness of the work material.

 Harder work materials require smaller grain sizes to cut effectively

 Softer materials require larger grit sizes.

c) Bonding Materials

 Strength and Toughness

 Hardness and Temperature resistance

d) Wheel Structure

Wheel structure refers to the relative spacing of the abrasive grains in the wheel. In addition to the
abrasive grains and bond material, grinding wheels contain air gaps or pores. Wheel structure is
measured on a scale that ranges between ‘‘open’’ and ‘‘dense.’
e) Wheel Grade: Wheel grade indicates the grinding wheel’s bond strength in retaining the
abrasive grits during cutting.

GRINDING OPERATIONS AND GRINDING MACHINES

Grinding is traditionally used to finish parts whose geometries have already been created by other
operations. Accordingly, grinding machines have been developed to grind plain flat surfaces,
external and internal cylinders, and contour shapes such as threads. The contour shapes are often
created by special formed wheels.

Four types of
surface grinding:

(a) horizontal
spindle with
reciprocating
worktable
(b) horizontal
spindle with
rotating worktable,
(c) vertical spindle
with reciprocating
worktable, and

(d) vertical spindle

with rotating
worktable.

Types of Grinding Operation

Following types of grinding operation are there:

(1) surface grinding, (2) cylindrical grinding, (3) centerless grinding, (4)
creep feed grinding, and (5) other grinding operations.

1 Surface Grinding Surface grinding is normally used to grind plain flat surfaces. These possible
combinations of wheel orientations and workpart motions provide the four types of surface
grinding machines illustrated in figure above.
Surface grinder
with horizontal
spindle and
reciprocating
worktable

2. Cylindrical Grinding: As its name suggests, cylindrical grinding is used or rotational parts.
These grinding operations divide into two basic types: (a) external cylindrical grinding and (b)
internal cylindrical grinding.

a) External cylindrical grinding is performed much like a turning operation.

b) Internal cylindrical grinding operates somewhat like a boring operation.

Two types of
cylindrical
grinding: (a)
external, and (b)
internal.

2. Center less Grinding: Center less grinding is an alternative process for grinding external and
internal cylindrical surfaces. As its name suggests, the work piece is not held between centers.
This results in a reduction in work handling time; hence, center less grinding is often used for
high-production work. The setup for external center less grinding, consists of two wheels: the
grinding wheel and a regulating wheel.

External centerless
grinding

Internal centerless
grinding
RELATED ABRASIVE PROCESSES

HONING

Honing is an abrasive process performed by a set of bonded abrasive sticks. A common

application is to finish the bores of internal combustion engines. Other applications include
bearings, hydraulic cylinders, and gun barrels.

The honing
process:
a)the honing tool
used for internal
bore surface, and
b)cross-hatched
surface pattern
created by the
action of the
honing tool.

LAPPING
Lapping is an abrasive process used to produce surface finishes of extreme accuracy and
smoothness. It is used in the production of optical lenses, bearing surfaces, gages, and other parts
requiring very good finishes. The lapping tool is called a lap. To accomplish the process, the lap is
pressed against the work and moved back and forth over the surface. Lapping is sometimes
performed by hand, but lapping machines accomplish the process with greater consistency and
efficiency.

SUPERFINISHING
Superfinishing is an abrasive process similar to honing. Both processes use a bonded abrasive
stick moved with a reciprocating motion and pressed against the surface to be finished.
Superfinishing differs from honing in the following respects:
(1) The strokes are shorter.
(2) Higher frequencies are used, up to 1500 strokes per minute;
(3) Lower pressures are applied between the tool and the surface
(4) Grit sizes are generally smaller. Superfinishing can be used to finish flat and external
cylindrical surfaces.
Superfinishing on
an
external cylindrical
surface.

POLISHING AND BUFFING

Polishing is used to remove scratches and burrs and to smooth rough surfaces by means of
abrasive grains attached to a polishing wheel rotating at high speed, around 2300 m/min. The
wheels are made of canvas, leather and even paper; thus, the wheels are somewhat flexible.
Polishing operations are often accomplished manually.

Buffing is similar to polishing in appearance, but its function is different. Buffing is used to
provide attractive surfaces with high luster. Buffing wheels are made of materials similar to those
used for polishing wheels—leather and cotton, etc.—but buffing wheels are generally softer.
Buffing is usually done manually, although machines have been designed to perform the process
automatically. Speeds are generally 2400 to 5200 m/min.