1. 1
Government Polytechnic
MURTIjAPUR
Department of Mechanical Engineering
2020-2021
PROJECT REPORT
“Abrasive Belt grinder”
Submitted in the partial fulfillment of the Diploma in Mechanical
Engineering
Submitted by
Deven M. Mahajan
(1700220008)
Guide by
PROF. A.P. CHAVAN
(Lecturer, Mechanical Engineering Department,
Govt. Polytechnic, Murtijapur)

2. 2
Certificate
2020-2021
This is to certify that the project report entitled
“ABRASIVE BELT GRINDER”
Has been duly completed by the following students under
my guidance, in satisfactory manner as partial fulfillment
of the diploma course in Mechanical Engineering Board of
Technical Education, Mumbai.
Submitted by
Deven M. Mahajan
(1700220008)
Guided By
Prof.A.P.CHAVAN
(Lecturer, Mechanical Engineering Department)
P r o f . D . S . D H O B L E
H.O.D. Mechanical Engineerin g
Government Polytechnic, Murtijapur
P r o f . A . A . G U L H A N E
P r i n c i p a l
Government Polytechnic, Murtijapur

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DECLARATION
We declare that, the project entitled,
“ABRASIVE BELT GRINDER”
Is a bonafide work carried it by us, under guidance of Prof. A.P. Chavan , Lecturer,
Mechanical Engg. Department. We further declare that, this project has not previously
formed on the basis of any diploma, associate ship or other similar diplomas.
Submitted by
Deven M. Mahajan
(1700220008)
(Students of Final Year Diploma in Mechanical Engg.
Govt. Polytechnic, Murtijapur.)
Place: Murtijapur
Date: ………….

4. 4
ACKNOWLEDGEMENT
On the event of successful completion of our research, study, observations, we would
like to thanks our Institution, Govt. Polytechnic, Murtijapur for providing us with an
opportunity of a research study on…………
“ABRASIVE BELT GRINDER”
We would like to express our profound gratitude towards our guide Prof. A.P.Chavan
lecturer, Mechanical Engg. Department, Govt.Polytechnic, Murtijapur, for guiding us and
showing the way for completing the project successfully.
We wish to acknowledge that the information provided in this project report is drawn
from various publications, conference, research papers, magazines and websites. Of
course, an attempt has been made to enlist them at the end. Omission, However, if any
are unintentional.
We express our sincere gratitude to Prof. D.S. DHOBLE, Head, Mechanical Engg.
Department Govt. Polytechnic, Murtijapur, for providing necessary support and
guidance for the completion of the project.
We are also thankful to Prof.A.A.GULHANE, Principal, Govt. Polytechnic, Murtijapur for
giving time to time encouragement during the project work.
We express our sincere thanks to one and all that have directly or indirectly have helped
us in completing the project successfully.
Submitted by
Deven M. Mahajan
(1700220008)
(Students of Final Year Diploma in Mechanical Engg. Govt. Polytechnic, Murtijapur.)
Place: Murtijapur
Date: ________

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ABSTRACT
Machining processing industries have continuously developed and
improved technologies and processes to transform finished product to
obtain better super finished product quality and thus increase
products. Abrasive machining is one of the most important of these
Processes and therefore merits special attention and study.Belt grinding is
an abrasive machining process used on metals and other materials.
It is typically used as a finishing process in industry. The main
objective of this project is to design and fabricate an abrasive belt
grinding which can be used as versatile grinding machine, the work area
can be rotated from 0 degree to 180 degree. The 0 degree work area can
be used for bottom grinding of component, the 90 degree work area can
be used for vertical grinding of component and The 180 degree work area
can be used for top grinding of component.

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CONTENTS
CHAPTER
NO.
DESCRIPTION PAGE NO.
Front Page
Certificate
Declaration
Acknowledgement
Abstract
1.
2.
3.
4.
5.
1. Introduction
Background
8.
9.
2. Literature Review
Oblique Grinding Machine Over view
11.
12.
3. Construction And Design 14. to 16.
4. Working Principle
Operation Methodology
Cost Estimation
18.
19.
20.
5. Applications
Advantages and Disadvantages
22.
23.
6. Conclusion
Bibliography
25.
26.

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Chapter 1

8. 8
Introduction
Machine manufacturing in the aerospace industry has been developed
towards multiple categories and small batches. Large scale and thin-
walled components are widely used to meet the requirements of aero-
vehicles.Special purpose CNC machines are not able to face the demand of
the flexible manufacturing come with the casting distortion and datum
loss. As industrial manipulator is a flexible unit, it can be adapted to
various types of production. Off-line robot pro- gramming technology
has also been applied in this situation so that downtime on the production
line can be reduced[2], thus benefiting the small batch processing and
even sin- gle workpiece with different datums. Nowadays, industrial
manipulators are applied widely in material transfer, pre- cision
assembly, welding, and machining.However, due to limited robot rigidity
and poor trajectory accurac, grinding is rarely generated with 6-DOF
manipulator. As accuracy robustness and good finishing surface quality
can be obtained, polishing and deburring are the primary machining type,
while feed rate, depth of cut, and cutter diameter must be kept to small
values.
Belt grinding has been deeply applied in robotic grind- ing, such as
sanitary product[6], turbine blade], and other casting part]. Abrasive
belt grinding as a finishing process can achieve high material removal
rate with good surface quality. Besides, it processes under a relatively
low temperature which benefits many intractable material, such as
aluminium alloy and titanium alloy.], Because of the flexibility of the
abrasive belt, various structure of the belt grinders are carried out to
implement abnormity workpiece grinding. When applied to industrial
manipulator, belt grinder goes in two forms, i.e., robot carries
workpieces to grind on fixed belt grinder, or robot carries belt
grinder. In this paper, we will focus on those large scale workpiece
with abnormity curved surface so that the latter form is chosen for the
payload limit of the manipulator.

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BACKGROUND
Abrasive belt grinding is a form of coated abrasive grinding. As early as in
1760, the first piece of sandpaper is available in the world, but it was
limited to manual operation at the time. Until 1900 to 1910, people went
in an era of sandpaper and emery cloth, and for the first time, they are
applied in wood industry as a form of endless belt.
After 1930, abrasive belt grinding gradually develops heading to metal
processing. In the second world war, the United States took the lead using
abrasive belt grinding in the manufacture of weapons, and they achieved
significant effect. In early 1950, the emergence of the electrostatic
flocking sand method pushed belt grinding to a new stage, which was
gradually used widely. Later, Europe and Japan also had conducted the
research and application of abrasive belt grinding technology, abrasive
belt grinding technology then gradually developed into a comprehensive,
relatively complete and independent processing technology.
Abrasive belt grinding has gained rapid progress and development,
which is widely used in various industries, such as metal, machinery, 3C
communications, electronic appliances, furniture manufacturing,
aerospace, machinery manufacturing and precision manufacturing.

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Chapter 2

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LITERATURE REVIEW :-
Belt grinding is an abrasive machining process used on metals and other
materials. It is typically used as a finishing process in industry.
A belt, coated in abrasive material, is run over the surface to be
processed in order to remove material or produce the desired finishThe
belt grinding process is variable by adjusting certain parameters such as
belt speed, grinding pressure, feed speed, durometer of the contact drum,
size of the contact drum and the abrasive belt that is used. The machines
can be made for wet or dry operation. Furthermore, a wide belt
grinding machine can be constructed with single or multiple heads. The
first head is used for coarse grinding and the next heads gradually make a
finer finish. Wide belt grinding is also used as a high stock removal method
for special metals (e.g. stainless steel, titanium, and nickel alloys).
Belt grinding belongs to elastic grinding and has the multi-functions
of grinding, milling and polishing, etc. It is characterized by good
workpiece-shape adaptability, low vibration of grinding system, low
roughness of machining surface, maintenance of residual compressive
stresses, low grinding temperature and resistance to workpiece burning; it
also has the feature of cool grinding. The V-shaped section can be finished
only by the belt grinding method.

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OBLIQUE GRINDING MACHINE OVERVIEW
Objective
The Objective of this project is to design and fabricate an abrasive belt
grinding which can be used as versatile grinding machine by changing its
work area from 0 to 180 degree with four rollers and length of the belt
could be adjustable for making belt at proper tension.
Problem Definition
The abrasive belt grinding which is used currently have the working area as
fixed one. The work can be rotated here the work area cannot be changed.
so it can be used only for components which can be carried by hand and the
fixed components where we have grind down or upside cannot be done
with the current machines. In normal hand grinding the burr removal and
finishing process cannot done at same level in a large surface.
Solution Methodology
In this project we are going to design and fabricate a abrasive belt grinding
which can be used as versatile grinding machine, the work area can be
rotated from 0 degree to 180 degree. The 0 degree work area can be used
for bottom grinding of component, the 90 degree work area can be used for
vertical grinding of component and The 180 degree work area can be used
for top grinding of component.

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Chapter 3

14. 14
CONSTRUCTION AND DESIGN :-
Raw Material Used-
1. Mild Steel bars for base frame.
2. Nut Bolt
3. Hollow cylindrical pipes, support links
4. Angle section for pulling fitting
5. Assembly rod with bending expenditure
6. Joints and couplings.
PHYSICAL DESIGN
The belt grinding tool is designed as three parts: the drive and transfer part,
the tension part, and the displacement compensation part. The grinding
process which uses the belt grinding tool is shown in Figure 3, and the
whole design is shown as Figure 4. The tension part is on the top of the
whole tool. The drive and transfer part is on the back part while the
displacement compensation part is on the front part, the compensation part
is protruded from the other parts to avoid interference to the workpiece
during the grinding process.
Design of the drive and transfer part
The design of the drive and transfer part is shown as Figure 5. This
part is drove by an AC Servomotor which is connected with a sync

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belt gear in a same spindle while the gear is connected with the
driving wheel by the sync belt, finally the driving wheel drives the
grinding belt. In the actual process, the change of the workpiece
geometry will cause the variation of the force and speed of the
working. The purpose of using the AC servomotor is to control the
speed of the motor and two sync belt gears as the method we used, then the
speed of the grinding belt can be controlled. So when tuning the motor we
choose the speed mode in the settings.
Fig. 5. The design of the drive and transfer part
Design of the tension part
The design of the tension part is shown as Figure 6. This part can be
divided into the pneumatic tension system and tension wheel. The
pneumatic tension system contains a thin cylinder with guide rod and the
thin cylinder is designed for the consideration of the structure’s
compactness. The motion of the pneumatic tension system is controlled
by a servo valve. When the system is running, the part of the cylinder body
is fixed on the shell of the grinding tool while the rod extends or shortens
and it causes the tension and the loosen of the grinding belt.
Fig. 6. The design of the tensioning part

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Design of the displacement compensation part
The design of the displacement compensation part is shown as Figure
7. The displacement compensation part is the key part of the whole
grinding tool and it is the executive device of the tool which controls the
displacement of the tool related to the robot manipulator. In the processing,
the manipulator moves along a simple trajectory and the tool
implements the compensation, then the whole machining trajectory
which is a complex curve can be move along by the manipulator. The
six-component force sensor is mounted on the spindle of the contact wheel
and it measures the force during the grinding process, the model of the
force sensor will be discussed in the next section. The motion of the
displacement compensation is executed by a servo electric cylinder
whose control modeling is in the next section.
Fig. 7. The design of the displacement compensation part

17. 17
Chapter 4

18. 18
WORKING PRINCIPLE
The abrasive belt is used to grind the material. This abrasive belt is rotated
by the single phase induction motor. In our project consist of end bearings
with bearing cap, roller wheel, shaft, single phase induction motor and
abrasive belt. This whole arrangement is fixed on the frame structure where
the component rests.
The roller wheel is mounted on the two end bearings with bearing cap by
suitable arrangement. There are two roller wheel is used in our project to
rotate the abrasive belt. One side of the roller wheel shaft, one v-pulley is
coupled by the suitable arrangement. The single phase induction motor with
V-pulley arrangement is used to rotate the abrasive belt through the belt
drive mechanism.
Belt grinding is an abrasive machining process used on metals and other
materials. It is typically used as a finishing process in industry. A belt,
coated in abrasive material, is run over the surface to be processed in order
to remove material or produce the desired finish.

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OPERATION METHODOLOGY
Thus, this Belt type grinding machine is generally used for polishing
the small metallic components and worn the surface of woody
components. In this machine abrasive belt fitted on the rollers. The
coupling is used for transmission of power from electric motor to the roller
shaft. As the first shaft from the motor is rotated then all the rollers rotated
with same speed because of abrasive belt wound over the surface.
When we keep the any small part on abrasive belt and apply the pressure
over the surface of the belt, then the small component polished. Because of
this machine, good quality of glassing also obtained for good looking
component. The abrasive belt is available in various sizes in the market.
Belt grinding machine may be dry belt wet belt or combination belt. Belt
grinding machine is used for heavy stock removal or for light polishing
work depending upon the type of belt grade used. This Oblique grinding
machine is used for the grinding of any oblique surfaces. The grinding can
be done for the stationary object. The angle grinding is done based on the
position of the two adjustable rollers in the machine. The flexibility of the
belts are adjusted using the screw. Thus, the finishing will be smooth and
any angled parts are finished.

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COST ESTIMATION
S.NO
.
NAME OF THE
PARTS
QUANTITY
TOTAL
COST
1 MOTOR 1 450
2 PULLEY BEARING 2 1300
3 V-BELT 1 150
4 PAINTING 1 Lit 110
5 ABRASIVE BELT 1 300
6 MECHANICAL
OPERATIONS
…. 500
7 NUT BOLTS 20 50
8 REPORT 1 400
TOTAL COST RS.3260

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Chapter 5

22. 22
APPLICATIONS
Belt grinding is a versatile process suitable for all kinds of different
applications. There are three different applications of the belt grinding
technology:
1. Finishing: surface roughness, removal of micro burrs, cosmetic finishes,
polishing
2. Deburring: radiusing, burr removal, edge breaking
3. Stock removal: high stock removal, cleaning (e.g. of corrosion),
eliminating mill or tool marks, dimensioning

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ADVANTAGES AND
DISADVANTAGES
ADVANTAGES:
➢ The machine is compact and rigid in size.
➢ Maintenance is less.
➢ It can be used on any place of small grinding application
➢ By varying the pulley diameter the speed of the abrasive belt to be
changed.
DISADVANTAGES :
➢ The abrasive belt should be changeable one for different material.
This process takes more time.

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Chapter 6

25. 25
CONCLUSION
Grinding has traditionally been associated with small rates of material
removal and finishing operations. However, grinding can also be used for
large-scale metal removal operations similar to milling, shaping, and
planing. In creep-feed grinding, the depth of cut d is as much as 6mm, and
the workpiece speed is low. The wheels are mostly softer grade resin
bonded with open structure to keep temperatures low. Creep-feed grinding
can be economical for specific applications, such as grinding cavities,
grooves, etc.

26. 26
BIBLIOGRAPHY
REFERENCES
✓ Stephenson, David A.; Agapiou, John S. (2006). Metal Cutting Theory
And Practice. CRC Press. p. 52. ISBN 0824758889.
✓ Cubberly, W.H. (1989). Tool and Manufacturing Engineers Handbook.
Society of Manufacturing Engineers. Ch. 26. ISBN 0872633519. Retrieved
2013-01-31.
✓ O.p kanna.Tool and Manufacturing Engineers hand book Society of
Manufacturing Engineers