Engineering Materials

Abrasives

Dr.V.S.Gayathri & Dr.K.Yamuna

Contents
Definition

Synthesis of SiC and B4C

Classification with
examples

Abrasive products

Coated Abrasives

Mohs Scale

Grinding wheels
Natural Abrasives
Synthetic Abrasives

Dr.V.S.Gayathri & Dr.K.Yamuna

Definition
Abrasive is a substance used to wear down ( cut / polish
/ grind /sharp) the surface of the materials with which it
is in contact
Abrasive power / Abrasion It is the strength of an
abrasive to grind away another materials. It depends on
hardness, toughness and refractoriness.

Dr.V.S.Gayathri & Dr.K.Yamuna

Terms and Terminologies

They should possess good hardness, toughness and

refractoriness
Hardness: Ability to resist scratching
Toughness: Ability to make indentation
Refractoriness: Ability to withstand high temperature
(Frictional Heat)

Mohs Scale - Mineral Hardness

The Mohs scale of mineral hardness was devised by
Frederich Mohs, a German mineralogist in 1812.
To devise the scale, he selected ten minerals as a basis
because they were common or readily available, thus the
scale is not linear, but is a bit arbitrary.
It is a measure of the relative hardness and resistance to
scratching between minerals (tested by Pin on Disc
method)
Though there are other scales like Rockwell, Vickers and
Brinell, Mohs scale is still the most common scale of
mineral hardness.

Dr.V.S.Gayathri & Dr.K.Yamuna

Mineral

Mohs scale

composition

Talc

Mg3Si4O10(OH)2

Gypsum

CaSO4.2H2O

Calcite

CaCO3

Fluorite

CaF2

Apatite

CaF2.3Ca3(PO4)2

Feldspar

K2O.Al2O3.6H2O

Quartz

SiO2

Topaz

AlF3.SiO2

Corundum

Al2O3

Diamond

10

Dr.V.S.Gayathri & Dr.K.Yamuna

Microcline is commonly called Feldspar

To Get Candy From Aunt Fanny Quit Teasing Cousin
Danny
Dr.V.S.Gayathri & Dr.K.Yamuna

Classification
Based on Occurrence -2 types
Based on Hardness 3 types

Dr.V.S.Gayathri & Dr.K.Yamuna

Dr.V.S.Gayathri & Dr.K.Yamuna

Note

Files which are used in workshop are not abrasives.

They remove material not by scratching or rubbing, but by
the cutting action of sharp teeth which have been cut into
the surface of the file, very much like those of a saw.

Dr.V.S.Gayathri & Dr.K.Yamuna

Natural Abrasives
Corundum
Diamond
Emery
Garnet
Quartz

Corundum / Alundum - Al2O3

Properties
Crystalline
Very Hard
Mohs scale-9
brown to grey

Uses
in grinding wheels
to grind glass/lens/metals,
ruby lasers

Dr.V.S.Gayathri & Dr.K.Yamuna

Diamond

Dr.V.S.Gayathri & Dr.K.Yamuna

Diamond (C)
Properties
crystalline and Chemically inactive
Mohs scale-10
Exist in three major forms
Diamond (gem)
Borts (Faulty)
Carbonade ( black diamond of Brazil)
Uses
Gem quality : Jewellery
Borts and Carbonade: in bits of drilling points
saw teeth for cutting rocks
in grinding wheels
in engraving tools

Dr.V.S.Gayathri & Dr.K.Yamuna

Emery
Composition
Alumina (crystalline)
Magnetite
Other minerals

50 - 75%
20 - 40%
12 %

Properties
Dark grey to black
Hardness depends upon alumina content
Mohs scale 8

Uses In emery paper and cloth used for

polishing. In bits of cutting and drilling tools

Dr.V.S.Gayathri & Dr.K.Yamuna

Garnets
Like diamond available in two forms : gem and
abrasive
Tri silicates of alumina/ magnesia/
ferrousoxide. (Gem quality)
Abrasive garnet- Calcium aluminium iron
silicate
Properties
Moderate Hardness
Mohs scale 6 -7.5
Uses
to paper/cloth to polish wood /metals,
as bearing pivots in watches
in glass grinding
Dr.V.S.Gayathri & Dr.K.Yamuna

Quartz (SiO2)
Properties
SiO2 (pure crystalline)
Moh 7
Hydrated form of SiO2 is called Flint

Uses
Impure grey quartz used in sand paper
As granules in grinding
machines used to grind flour, pigments & ores.

Dr.V.S.Gayathri & Dr.K.Yamuna

Synthetic Abrasives

SiC :Silicon Carbide / Carborundum / Crystolon

B4C:Boron Carbide / Norbide

Preparation of SiC
i. Petroleum Coke (source of carbon)
ii. Sand (source of Si)
iii. Saw Dust
All raw materials sized, dried and mixed along with old charge and fed
into the Acheson furnace with little amount of NaCl (flux)
1650 - 2200oC

3C+SiO2SiC+2CO
(36 hrs)
Sawdust added to produce porosity and to permit gas to escape during
Operation in addition to providing hardness
Salt added to assist in removing impurities

Properties and uses

Suited for grinding materials that have low tensile strength and high
density
Harder and tougher than aluminum oxide
Color varies from green to black
Green used mainly for grinding cemented carbides and other hard
materials
Black used for grinding cast iron and soft nonferrous metals (also
ceramics)
M.Pt. is 2700oC
Mohs scale hardness is 9.3
Chemically Inert
High Thermal Stability
Brittle
Cutting tools , Grinding of cast iron , brass , bronze , porcelain and marble
Polishing leather , lenses ( Abrasive paper and Cloth)
Refractory in furnace

Dr.V.S.Gayathri & Dr.K.Yamuna

Norbide
Preparation
i.Petroleum Coke (source of carbon)
ii. Boron Oxide
iii. Saw Dust ( To provide hardness)
All raw materials sized, dried and mixed along with old charge and
fed into the Acheson furnace with little amount of NaCl (flux).
2700oC
7C+2B2O3B4C+6CO

Properties and Uses

Mohs scale hardness - 9 . 7
Chemically inert
Hardest material manufactured with exception of diamond
Not suitable for use in grinding wheels
Used only as loose abrasive and as cheap substitute for diamond
dust
Manufacture of precision gages and sand blast nozzles
Used in ultrasonic machining applications
Grinding dies & Cutting and sharpening hard & high speed tools

Dr.V.S.Gayathri & Dr.K.Yamuna

Advantages of Synthetic Abrasives

Uniform Chemical Composition

Uniform Hardness
Size Purity and Hardness can be controlled

Abrasive Products
After abrasive is synthesised, they are converted into
products
Grinding wheel ,Paper, Cloth ,sticks etc.,

Supporting base material components and abrasive

grain are bond using a suitable adhesive

Dr.V.S.Gayathri & Dr.K.Yamuna

Bond Types
Function of bond is to hold abrasive grains together in
form of wheel / paper / cloth
Six common bond types used in grinding wheel
manufacture:
Vitrified
Resinoid
Rubber
Shellac
Silicate
Metal

Dr.V.S.Gayathri & Dr.K.Yamuna

Coated Abrasives
(paper / cloth

Dr.V.S.Gayathri & Dr.K.Yamuna

Common types of coated abrasive (sand paper)

Abrasive Material

Use of paper

Garnet

Wood Working

Aluminium Oxide

Metal Working

Silicon Carbide

Wet / dry
application

Dr.V.S.Gayathri & Dr.K.Yamuna

 A coated abrasive comprises an abrasive fixed to a

backing material such as paper, cloth, rubber, resin,
polyester or even metal sheet, which are flexible
Sandpaper is a very commonly used coated abrasive.

Dr.V.S.Gayathri & Dr.K.Yamuna

Manufacture of coated abrasives

Supporting base material consist of flexible backing (cloth or paper) to
which abrasive grains have been bonded
Two purposes for which coated abrasives are made
Metal grinding and polishing
Coarse-grit used for rapid removal of metal; fine grits used for polishing
Two types of abrasive materials used
Natural: garnet, flint, and emery
Manufactured: aluminum oxide, silicon carbide

Dr.V.S.Gayathri & Dr.K.Yamuna

Scheme

Dr.V.S.Gayathri & Dr.K.Yamuna

Grinding Wheels
Grinding wheel consists of hard abrasive grains called
grits, held in the weak bonding matrix
A grinding wheel is commonly identified by the type of
the abrasive used

Dr.V.S.Gayathri & Dr.K.Yamuna

Manufacture of Grinding wheels

Manufacture of these wheels is a precise and tightly
controlled process
The wheels are generally made from a matrix of coarse
particles pressed and bonded together to form a solid,
circular shape
Alternatively they may also be made from a solid steel
or aluminium disc with abrasive particles bonded to the
surface

Dr.V.S.Gayathri & Dr.K.Yamuna

Dr.V.S.Gayathri & Dr.K.Yamuna

Corundum wheel

Dr.V.S.Gayathri & Dr.K.Yamuna

Carborundum wheel

To use the grinding wheel, it must first be clamped to or mounted

on the grinding machine

A grinding wheel with a

reservoir to hold water as a
lubricant and coolant.
Dr.V.S.Gayathri & Dr.K.Yamuna

 Grinding wheels with diamond or Cubic Boron Nitride

(CBN) grains are called super abrasives
Grinding wheels with Aluminum Oxide (corundum),
Silicon Carbide or Ceramic grains are called
conventional abrasives

Dr.V.S.Gayathri & Dr.K.Yamuna

Basic Functions of Grinding Wheels

Generation of cylindrical, flat and curved surfaces

Removal of stock

Production of highly finished surfaces

Cutting-off operations

Production of sharp edges and points

Dr.V.S.Gayathri & Dr.K.Yamuna