Lesson Outcomes:

After todays lecture, students are expected to: Analyze appropriate grinding operations and machines Analyze finishing operations

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Abrasive Machining and Finishing Operations

General Characteristics of Abrasive Machining Processes and Machines

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Grinding Operations and machines

1. Surface Grinding Most common operation done on the flat surfaces Method used can be in surface grinder or vertical spindles with rotary table

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Various Surface-Grinding Operations

Schematic illustrations of various surface-grinding operations. (a) Traverse grinding with a horizontal-spindle surface grinder. (b) Plunge grinding with a horizontal-spindle surface grinder. (c) A vertical-spindle rotary-table grinder (also known as the Blanchard type.)
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Grinding Operations and machines (cont.)

2. Cylindrical Grinding Also called center-type grinding where the external cylindrical surfaces and shoulders of the workpiece are ground. Application : crankshaft bearings, spindles, pins, bearing rings, and rolls of rolling mills
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Cylindrical-Grinding Operations

Examples of various cylindrical-grinding operations. (a) Traverse grinding, (b) plunge grinding, and (c) profile grinding. Source: Courtesy of Okuma Machinery Works Ltd.
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Thread Grinding
3. Thread Grinding To finely grind small thread

Thread grinding by (a) traverse and (b) plunge grinding.

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Grinding Operations and machines (cont.)

4. Internal Grinding Small wheel used to grind inside diameter of the part. Eg : bushings and bearing races

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Internal Grinding Operations

Schematic illustrations of internal grinding operations: (a) traverse grinding, (b) plunge grinding, and (c) profile grinding.
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Grinding Operations and machines (cont.)

6. Centerless Grinding High-production process for continuously grinding cylindrical surfaces in which the workpiece is supported by a blade. Eg : roller bearings, piston pins, engine valves and camshafts.
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Centerless Grinding Operations

Schematic illustration of centerless grinding operations: (a) through-feed grinding, (b) plunge grinding, (c) internal grinding, and (d) a computer numerical-control cylindrical-grinding machine. Source: Courtesy of Cincinnati Milacron, Inc.
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Design considerations for grinding

a) Parts to be ground should be designed so that they can be held securely. b) If high dimensional accuracy is required, such as holes & keyways, should be avoided. c) In cylindrical grinding, parts should be balanced and long to minimize deflections. d) In centerless grinding, short pieces may be difficult to grind accurately because of their lack of support.
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Design considerations for grinding (cont.)

e) Designs should be kept simple to avoid frequent wheel dressing. f) Deep and small holes, and blind holes requiring internal grinding, should be avoided. g) For soft metal, large grit size and harder grade h) For harder metal, small grit size and softer grade
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Finishing Operations
Fine abrasive grains are used on

workpieces as the final finishing operation Coated abrasives Sandpaper & emery cloth. Made of aluminum oxide, with silicon carbide & zirconia alumina. Available as sheets, belts and disks.
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Coated Abrasive

Schematic illustration of the structure of a coated abrasive. Sandpaper (developed in the 16th century) and emery cloth are common examples of coated abrasives.
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Belt Grinding of Turbine Nozzle Vanes

Belt grinding of turbine nozzle vanes.

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Finishing Operations (cont.)

Honing To give holes a fine surface Surface finish controlled by the type & size of abrasive used, the pressure applied, and speed.

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Honing Tool

Schematic illustration of a honing tool used to improve the surface finish of bored or ground holes.
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Finishing Operations (cont.)

Superfinishing Process controlled at very light pressure & the motion has a short stroke.

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Superfinishing Process

Schematic illustration of the superfinishing process for a cylindrical part. (a) Cylindrical microhoning. (b) Centerless microhoning.
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Finishing Operations (cont.)

Lapping Used on flat or cylindrical surfaces. The lap made of cast iron, copper, leather, or cloth

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Production Lapping

(a) Schematic illustration of the lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on cylindrical surfaces.
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Deburring Operations
Burrs are thin rigid, usually triangular in

shape, that develop along the edges of a workpiece. Can cause jamming in parts, misalignment, and short circuits in electrical components. Common deburring processes;
a)Manual deburring, b)Mechanical deburring c)Wire brushing
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Deburring Operations (cont.)

d) e) f) g) h) i) j) k) Abrasive belts Ultrasonic machining Electropolishing Electrochemical polishing Magnetic abrasive finishing Vibratory finishing Shot blastingor abrasive blasting Abrasive-flow machining
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Abrasive-Flow Machining

(b)

(a) Schematic illustration of abrasive-flow machining to deburr a turbine impeller. The arrows indicate movement of the abrasive media. Note the special fixture, which is usually different for each part design. (b) Value fittings treated by abrasive-flow machining to eliminate burrs and improve surface quality. Source: (b) Courtesy of Extrude Hone Corp.
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Deburring Operation on a Die-Cast Part Using Grinding Wheel

A deburring operation on a robot-held die-cast part for an outboard motor housing using a grinding wheel. Abrasive belts or flexible abrasive radial-wheel brushes also can be used for such operations. Source: Courtesy of Acme Manufacturing Company.

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Thats all for today.. Any questions??

IQ + EQ + SQ = TQ
Thank You for coming and see you again..