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GRINDING AND
OTHER ABRASIVE PROCESSES

1
Material Removal Processes
A family of shaping operations, the common feature of which
is removal of material from a starting workpart so the
remaining part has the desired geometry.

Machining – material
removal by a sharp
cutting tool, e.g., turning,
milling, drilling.

Material Removal

Nontraditional processes various energy forms other than
sharp cutting tool to remove
material, e.g. electrochemical and
thermal energy processes.
Manufacturing Processes
Prof Simin Nasseri

Abrasive
processes –
material removal by
hard, abrasive
particles, e.g.,
grinding.
Machining Processes
Traditional Chip Removal

•
•
•
•
•
•

Turning
Milling
Drilling
Boring
Reaming
Shaping

Manufacturing Processes
Prof Simin Nasseri



Sawing
Broaching



Planing



Grinding
Honing
Lapping






Nontraditional Machining










Ultrasonic
Electrical Discharge
Electro-arc
Optical Lasers
Electrochemical
Chem-milling
Abrasive Jet Cutting
Electron Beam Machining
Plasma Arc Machining
Abrasive Machining
 Material removal by action of hard, abrasive particles
usually in the form of a bonded wheel

 Generally used as finishing operations after part
geometry has been established by conventional
machining
 Grinding is most important abrasive process

 Other abrasive processes: honing, lapping,
superfinishing, polishing, and buffing

Manufacturing Processes
Prof Simin Nasseri
Why Abrasive Processes are Important
 Can be used on all types of materials
 Some can produce extremely fine surface finishes,
to 0.025 m (1 -in)
 Some can hold dimensions to extremely close
tolerances

Manufacturing Processes
Prof Simin Nasseri
Grinding
Material removal process in which abrasive
particles are contained in a wheel that
operates at very high surface speeds.

Manufacturing Processes
Prof Simin Nasseri
Wheel Structure
The grinding wheel:
is usually disk-shaped and precisely balanced for high
rotational speeds.
Consists of abrasive particles and bonding material.
• Abrasive particles accomplish cutting.
• Bonding material holds particles in place and
establishes shape and structure of wheel.

Figure 25.1 Typical structure of a grinding wheel.
Manufacturing Processes
Prof Simin Nasseri
Abrasive Material Properties





High hardness
Wear resistance
Toughness
Friability - capacity to fracture when cutting edge dulls,
so a new sharp edge is exposed

Manufacturing Processes
Prof Simin Nasseri
Traditional Abrasive Materials
Aluminum oxide
(Al2O3) - most common
abrasive

Silicon carbide
(SiC) - harder than
Al2O3 but not as tough

Used to grind steel
and other ferrous
high-strength alloys

Used on aluminum,
brass, stainless steel,
some cast irons and
certain ceramics

Manufacturing Processes
Prof Simin Nasseri
Hardness of Abrasive Materials
Abrasive material
Aluminum oxide
Silicon carbide
Cubic boron nitride
Diamond (synthetic)

Manufacturing Processes
Prof Simin Nasseri

Knoop hardness
2100
2500
5000
7000
Surface Finish
Most grinding is performed to achieve good surface
finish
Best surface finish is achieved by:
 Small grain sizes
 Higher wheel speeds
 Denser wheel structure = more grits per wheel
area

Two main categories of grinding:
 Surface grinding
 Cylindrical grinding
Manufacturing Processes
Prof Simin Nasseri
Four Types of Surface Grinding

Figure 25.7 (a) Horizontal spindle with reciprocating worktable,
(b) horizontal spindle with rotating worktable, (c) vertical spindle
with reciprocating worktable, (d) vertical spindle with rotating
worktable.
Manufacturing Processes
Prof Simin Nasseri
Surface Grinder

Figure 25.8 Surface grinder with horizontal spindle and
reciprocating worktable (most common grinder type).
Manufacturing Processes
Prof Simin Nasseri
Cylindrical Grinding

Figure 25.9 Two types of cylindrical grinding: (a)
external, and (b) internal.

Manufacturing Processes
Prof Simin Nasseri
Other Abrasive Processes
 Honing
 Lapping
 Superfinishing

Manufacturing Processes
Prof Simin Nasseri
Honing
Abrasive process performed
by a set of bonded
abrasive sticks using a
combination of rotational
and oscillatory motions.
Creates a characteristic
cross-hatched surface that
retains lubrication.
Grit sizes range between 30 and
600.
Figure 25.16 The honing
process: (a) the honing tool
used for internal bore surface.

Manufacturing Processes
Prof Simin Nasseri

Surface finishes of 0.12 m (5 -in)
or better.
Honing
Common application is to finish the bores
of internal combustion engines.

Manufacturing Processes
Prof Simin Nasseri
Lapping
Uses fluid suspension of very small abrasive particles
between workpiece and lap (tool).
Lapping compound - fluid with abrasives, general
appearance of a chalky paste.

Applications: optical lenses, metallic bearing surfaces,
gages.

Figure 25.17 The lapping process in lens-making.
Manufacturing Processes
Prof Simin Nasseri
Superfinishing
Similar to honing - uses bonded abrasive stick
pressed against surface and reciprocating
motion
Differences with honing:
* Shorter strokes
* Higher frequencies
* Lower pressures
between tool and
surface
* Smaller grit sizes
Figure 25.18 Superfinishing on
an external cylindrical surface.
Manufacturing Processes
Prof Simin Nasseri

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The basics of sentences session 10pptx.pptx
 

Chapter 25 (grinding)

  • 2. Material Removal Processes A family of shaping operations, the common feature of which is removal of material from a starting workpart so the remaining part has the desired geometry. Machining – material removal by a sharp cutting tool, e.g., turning, milling, drilling. Material Removal Nontraditional processes various energy forms other than sharp cutting tool to remove material, e.g. electrochemical and thermal energy processes. Manufacturing Processes Prof Simin Nasseri Abrasive processes – material removal by hard, abrasive particles, e.g., grinding.
  • 3. Machining Processes Traditional Chip Removal • • • • • • Turning Milling Drilling Boring Reaming Shaping Manufacturing Processes Prof Simin Nasseri  Sawing Broaching  Planing  Grinding Honing Lapping    Nontraditional Machining          Ultrasonic Electrical Discharge Electro-arc Optical Lasers Electrochemical Chem-milling Abrasive Jet Cutting Electron Beam Machining Plasma Arc Machining
  • 4. Abrasive Machining  Material removal by action of hard, abrasive particles usually in the form of a bonded wheel  Generally used as finishing operations after part geometry has been established by conventional machining  Grinding is most important abrasive process  Other abrasive processes: honing, lapping, superfinishing, polishing, and buffing Manufacturing Processes Prof Simin Nasseri
  • 5. Why Abrasive Processes are Important  Can be used on all types of materials  Some can produce extremely fine surface finishes, to 0.025 m (1 -in)  Some can hold dimensions to extremely close tolerances Manufacturing Processes Prof Simin Nasseri
  • 6. Grinding Material removal process in which abrasive particles are contained in a wheel that operates at very high surface speeds. Manufacturing Processes Prof Simin Nasseri
  • 7. Wheel Structure The grinding wheel: is usually disk-shaped and precisely balanced for high rotational speeds. Consists of abrasive particles and bonding material. • Abrasive particles accomplish cutting. • Bonding material holds particles in place and establishes shape and structure of wheel. Figure 25.1 Typical structure of a grinding wheel. Manufacturing Processes Prof Simin Nasseri
  • 8. Abrasive Material Properties     High hardness Wear resistance Toughness Friability - capacity to fracture when cutting edge dulls, so a new sharp edge is exposed Manufacturing Processes Prof Simin Nasseri
  • 9. Traditional Abrasive Materials Aluminum oxide (Al2O3) - most common abrasive Silicon carbide (SiC) - harder than Al2O3 but not as tough Used to grind steel and other ferrous high-strength alloys Used on aluminum, brass, stainless steel, some cast irons and certain ceramics Manufacturing Processes Prof Simin Nasseri
  • 10. Hardness of Abrasive Materials Abrasive material Aluminum oxide Silicon carbide Cubic boron nitride Diamond (synthetic) Manufacturing Processes Prof Simin Nasseri Knoop hardness 2100 2500 5000 7000
  • 11. Surface Finish Most grinding is performed to achieve good surface finish Best surface finish is achieved by:  Small grain sizes  Higher wheel speeds  Denser wheel structure = more grits per wheel area Two main categories of grinding:  Surface grinding  Cylindrical grinding Manufacturing Processes Prof Simin Nasseri
  • 12. Four Types of Surface Grinding Figure 25.7 (a) Horizontal spindle with reciprocating worktable, (b) horizontal spindle with rotating worktable, (c) vertical spindle with reciprocating worktable, (d) vertical spindle with rotating worktable. Manufacturing Processes Prof Simin Nasseri
  • 13. Surface Grinder Figure 25.8 Surface grinder with horizontal spindle and reciprocating worktable (most common grinder type). Manufacturing Processes Prof Simin Nasseri
  • 14. Cylindrical Grinding Figure 25.9 Two types of cylindrical grinding: (a) external, and (b) internal. Manufacturing Processes Prof Simin Nasseri
  • 15. Other Abrasive Processes  Honing  Lapping  Superfinishing Manufacturing Processes Prof Simin Nasseri
  • 16. Honing Abrasive process performed by a set of bonded abrasive sticks using a combination of rotational and oscillatory motions. Creates a characteristic cross-hatched surface that retains lubrication. Grit sizes range between 30 and 600. Figure 25.16 The honing process: (a) the honing tool used for internal bore surface. Manufacturing Processes Prof Simin Nasseri Surface finishes of 0.12 m (5 -in) or better.
  • 17. Honing Common application is to finish the bores of internal combustion engines. Manufacturing Processes Prof Simin Nasseri
  • 18. Lapping Uses fluid suspension of very small abrasive particles between workpiece and lap (tool). Lapping compound - fluid with abrasives, general appearance of a chalky paste. Applications: optical lenses, metallic bearing surfaces, gages. Figure 25.17 The lapping process in lens-making. Manufacturing Processes Prof Simin Nasseri
  • 19. Superfinishing Similar to honing - uses bonded abrasive stick pressed against surface and reciprocating motion Differences with honing: * Shorter strokes * Higher frequencies * Lower pressures between tool and surface * Smaller grit sizes Figure 25.18 Superfinishing on an external cylindrical surface. Manufacturing Processes Prof Simin Nasseri