MP GTU Study Material E-Notes Unit-8 06042020034658PM
MP GTU Study Material E-Notes Unit-8 06042020034658PM
MP GTU Study Material E-Notes Unit-8 06042020034658PM
During the operation, to cover the required grinding area the motor revolves the wheel and the frame is swung
by the operator about its suspension point.
The motor drives the grinding wheel by using a belt drive.
This is used for snagging, particularly for casting that is too large for the operator to hold up to the wheel.
Fig. 8.9 shows the block diagram of the centreless grinder with its main parts and controls.
It contains a heavy base and two-wheel heads i.e. grinding wheel (bigger one) and regulating wheel (smaller
one).
Each wheel head carries a separate truing mechanism for the wheel it carries.
The workpiece rests on the work rest blade between these two wheels.
The grinding operation is performed by the grinding wheel only whereas; the regulating wheel provides
support to the workpiece when it is pushed away by the cutting pressure of the grinding wheel
Also, bottom support is provided by the work rest as the workpiece during rotation rests on the work rest
blade.
Due to this, the workpiece remains in contact with the grinding wheel.
The direction of rotation of the grinding wheel and regulating wheel is the same
The common methods used for feeding the workpiece are as follows :
a) Through feed
b) linefeed
c) End feed
1. Through feed grinding:
In this method, the workpiece is supported and rotated as described earlier, but it is simultaneously given an
axial movement also by the regulating wheel and guides.
For this purpose, the axis of the regulating wheel can be inclined from 2° to 10° (α) with the vertical. Refer
to Fig' 8.8.
The amount of actual feed is determined by using the following relation :
1. Reciprocating table :
a. Horizontal spindle
b. Vertical spindle
2. Rotary table:
a. Horizontal spindle
b. Vertical spindle
a. Horizontal spindle rotary table surface b. Vertical spindle rotary table surface
grinder grinder
In both of the machines, the direction of rotation of the wheel and table is the opposite.
In a horizontal spindle grinder, the crossfeed is given by the horizontal movement of the wheel spindle
whereas in vertical spindle grinder it is by sliding a table on a slide.
These machines are also capable of doing light cylindrical, surface and internal grinding operations.
Tool and cutter grinder is a machine that supports the cutter while a rotating abrasive wheel is applied to the
cuffing edge for the purpose of sharpening it.
According to the purpose of grinding, they are classified into two groups :
1. Universal tool and cutter grinders
2. Single-purpose tool and cutter grinders
8.11.1 Abrasives
Abrasives are extremely hard materials consisting of very small particles called grains.
The grains carry a number of sharp cutting edges and corners.
There are two types of abrasives :
1 Natural
2 Artificial or manufactured
1. Natural abrasives
They are obtained from mines directly.
The most commonly used natural abrasives are sandstone, emery, quartz, corundum, and diamond.
Out of these, diamond is used for dressing of grinding wheels and is considered as an abrasive for grinding
hard materials.
Solid quartz is one of the natural abrasive stones from which grindstones are shaped.
Emery is a natural aluminum oxide that contains 60 to 70 % alumina and remaining is iron oxide and other
impurities.
Corundum is also natural aluminum oxide which contains 70 to 90 % aluminum oxide and remaining is
other impurities.
2. Artificial abrasives
They are manufactured in closed electric furnaces under controlled conditions, to avoid the introduction of
impurities and to achieve the required temperature for the chemical reactions to take place.
The most commonly used artificial abrasives are as follows :
a) Aluminum oxide Al2O3,
b) Silicon carbide (SiC)
c) Artificial diamonds.
8.12 Bonds
Bond material of the grinding wheel acts as a binder to hold the abrasive grains together.
It is necessary that the grains of abrasive material should be held firmly together to form a series of cutting
edges.
The principle bond materials are as follows ;
a. Vitrified bond b. Silicate bond
c. Oxychloride bond d. Resinoid bond
e. Shellac bond f. Rubber bond
a. Vitrified bond
It is a clay bond that is reddish-brown in color.
The base material is felspar which is fusible clay.
Proper proportions of refractories and flux are added to felspar and mixed thoroughly.
This mixture together with abrasive grains is fed into revolving drums that contain water to form a paste.
Most of the grinding wheel possesses this type of bond.
Vitrified bond is denoted by the letter'V'. Refer to Table g.2.
Disadvantages
The manufacturing process is slow.
wheels having a diameter of more than 750 mm cannot be easily produced.
The high temperature of the process makes the abrasive grains weak.
During the process, cracks may develop in large wheels.
b. Silicate bond
The base material is a silicate of soda.
The process of manufacturing is similar to a vitrified bond, but at low temperature, which results in high
tensile strength.
Wheels possessing this type of bond are light grey in color.
Silicate bond is denoted by letter's'. Refer to Table 8.2.
Advantages
.The process of manufacturing is fast.
The low temperature of the process makes the abrasive grains strong.
Large wheels i.e. up to 1500 mm diameter can be easily produced.
The cutting action of the wheel is smoother and cooler.
Disadvantages
Extra hard wheels cannot be produced.
Harder grades of this bond do not provide a free cutting action.
c. Oxychloride bond
Oxychloride bond is a mixture of oxide and chloride of magnesium.
This type of bond provides a cost-cutting action, but grinding is generally done in dry conditions because it
is very susceptible to the action of conventional coolants.
Oxychloride bond is used for the making of disc-shaped wheels.
Oxychloride bond is denoted by the letter 'O'. Refer to Table 8.2.
d. Resinoid bond
Resinoid bonded wheels are manufactured from a mixture of abrasive grains synthetic resins and some
compounds.
This mixture is filled in molds and fed into the furnace and baked at a temperature of about 200 °C.
Due to heat, resin sets and binds the abrasive grains together.
A resinoid bond is a synthetic organic compound that is strong and flexible.
Resinoid bonded wheels are used for cutting bar stocks, fine grinding of cams, precision grinding of rolls,
etc.
Resinoid bond is denoted by the letter 'B'. Refer to Table 8.2.
e. Shellac bond
Shellac bonded wheels are produced by mixing the bond and abrasive grains in a steam-heated mixture
Shellac bonds wheel is used on hardened tool steel and thin section. They are also helpful in producing high
surface finish on the component like camshaft.
Shellac bond wheel re strong but possesses some elasticity.
Shellac bond is denoted by letter ‘E’ Refer Table8.2
f. Rubber bond
Rubber bond wheel is manufactured by passing a rubber and sulphur through the mixing rolls and adding
abrasive slowly. Abrasive grains are added until the required proportion is added.
The mixture is again passed through another set of rolls, to obtain the desired thickness
Medium 30 36 46 54 60
Coarse 10 12 14 16 20 24
Grade
Grade denotes the strength of a bond in a wheel i.e. the power of the abrasive particles to hold together and
resist disintegration under the cutting pressure.
If the proportion of bond for a specified quantify of abrasive particles is higher, then the wheel becomes
harder and lower proportion makes the wheel soft.
The selection of a particular grade of the wheel depends on the following factors :
a. Nature of workpiece
b. Composition of workpiece
c. Size and hardness of the workpiece
Softer wheels are considered for grinding hard materials and harder wheels for grinding soft materials.
Generally, all the wheel manufacturers provide a table of recommended grits and grades for specific
operations and materials to be machined.
It is advisable to follow the table for selecting a wheel for a particular job.
Prof. Paras G. Vegada Department of Mechanical Engineering
8.21
Manufacturing Process (3141908) | Unit-8 Grinding Machine and Abrasive
Table 8.4 shows the different grades of grinding wheel :
Soft A B C D E F G H
Medium I J K L M N O P
Hard Q R S T U V W X Y Z
Structure
The term structure indicates the spacing between the abrasive density grains or indicates the of the wheel
The structure of a wheel is mainly affected by the proportion of the bond.
A higher proportion of bonds is considered a close structure.
A higher proportion of bonds considers as an open structure, whereas a lower proportion as close structure.
The selection of particular structure depends on the following factors :
a. Hardness of workpiece
b. Type of grinding operation
c. Quality of surface finish required on the workpiece
For grinding brittle and hard materials dense structure is considered whereas for soft and tough materials
open structure is selected.
Table 8.5shows some standard numbers, which are categorized into dense and open structure
To obtain a good surface finish, to prevent vibration and to avoid undue wear on machine parts, it is
necessary that the grinding wheel should have a good balance before its use.
Hence, the wheel is properly tested for balance before its use. But, before testing it is trued.
Generally, small size wheels do not require any balancing but larger wheels operating at high speeds require
balancing.
Balancing is done in the static position of the wheel by shifting the position of weights on one of the
mounting flanges of the wheel.
The wheel is mounted on a suitable mandrel and placed on a balancing fixture for finding out the direction
in which the weights are to be shifted. Refer Fig. 8.21
8.19 References
1. Hajra & Choudhari. “Element of Workshop Technology Vol. II” Media Promoters and Pvt. Ltd
2. B.S.Raghuvanshi “A Course in Workshop technology Vol. II” Dhanpat Rai & Co,
3. R. K. Jain.”Production Technology” Khanna Publications