Lab Session 10

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Machining Process Lab 10

To perform plain surface grinding on the given work piece to the required
dimensions.
Apparatus:
Grinding machine, Grinding Wheel, Vernier Caliper.

Material:
MS / CI plate _________mm X _________mm X ________mm

Figure:

Theory

Surface Grinding

Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used abrasive
machining process in which a spinning wheel covered in rough particles (grinding wheel) cuts chips
of metallic or nonmetallic substance from a workpiece, making a face of it flat or smooth

Process
Surface grinding is the most common of the grinding operations. It is a finishing process that uses
a rotating abrasive wheel to smooth the flat surface of metallic or non-metallic materials to give
them a more refined look by removing the oxide layer and impurities on work piece surfaces. This
will also attain a desired surface for a functional purpose.

The surface grinder is composed of an abrasive wheel, a work holding device known as a chuck,
and a reciprocating or rotary table. The chuck holds the material in place while it is being worked
on. It can do these one of two ways: ferromagnetic pieces are held in place by a magnetic chuck,
while nonferromagnetic and non-metallic pieces are held in place by vacuum or mechanical means.
A machine vise (made from ferromagnetic steel or cast iron) placed on the magnetic chuck can be
used to hold nonferromagnetic workpieces if only a magnetic chuck is available.

Factors to consider in surface grinding are the material of the grinding wheel and the material of the
Machining Process Lab 10

piece being worked on.

Typical workpiece materials include cast iron and mild steel. These two materials don't tend to clog
the grinding wheel while being processed. Other materials are aluminum, stainless steel, brass and
some plastics. When grinding at high temperatures, the material tends to become weakened and is
more inclined to corrode. This can also result in a loss of magnetism in materials where this is
applicable.

The grinding wheel is not limited to a cylindrical shape and can have a myriad of options that are
useful in transferring different geometries to the object being worked on. Straight wheels can be
dressed by the operator to produce custom geometries. When surface grinding an object, one must
keep in mind that the shape of the wheel will be transferred to the material of the object like a reverse
image.

Spark out is a term used when precision values are sought and literally means "until the sparks are
out (no more)". It involves passing the workpiece under the wheel, without resetting the depth of
cut, more than once and generally multiple times. This ensures that any inconsistencies in the
machine or workpiece are eliminated.

Machine Tool
A surface grinder is a machine tool used to provide precision ground surfaces, either to a critical
size or for the surface finish.

The typical precision of a surface grinder depends on the type and usage, however ±0.002 mm
(±0.0001 in) should be achievable on most surface grinders.

The machine consists of a table that traverses both longitudinally and across the face of the wheel.
The longitudinal feed is usually powered by hydraulics, as may the cross feed, however any mixture
of hand, electrical or hydraulic may be used depending on the ultimate usage of the machine (i.e.,
production, workshop, cost). The grinding wheel rotates in the spindle head and is also adjustable
for height, by any of the methods described previously. Modern surface grinders are semi-
automated, depth of cut and spark-out may be pre-set as to the number of passes and, once set up,
the machining process requires very little operator intervention.
Depending on the workpiece material, the work is generally held by the use of a magnetic chuck.
This may be either an electromagnetic chuck, or a manually operated, permanent magnet type chuck;
both types are shown in the first image.
The machine has provision for the application of coolant as well as the extraction of metal dust
(metal and grinding particles).
Machining Process Lab 10

Types of surface grinders

Grinding wheels for surface grinders

Aluminum oxide, silicon carbide, diamond, and cubic boron nitride (CBN) are four commonly used
abrasive materials for the surface of the grinding wheels. Of these materials, aluminum oxide is the
most common. Because of cost, diamond and CBN grinding wheels are generally made with a core
of less expensive material surrounded by a layer of diamond or CBN. Diamond and CBN wheels
are very hard and are capable of economically grinding materials, such as ceramics and carbides,
that cannot be ground by aluminum oxide or silicon carbide wheels. As with any grinding operation,
the condition of the wheel is extremely important. Grinding dressers are used to maintain the
condition of the wheel, these may be table mounted or mounted in the wheel head where they can
be readily applied.

Lubrication

Lubricants are sometimes used to cool the workpiece and wheel, lubricate the interface, and remove
Machining Process Lab 10

swarf (chips). It must be applied directly to the cutting area to ensure that the fluid is not carried
away by the grinding wheel. Common lubricants include water-soluble chemical fluids, water-
soluble oils, synthetic oils, and petroleum-based oils. The type of lubrication used depends on the
workpiece.

Precautions:

Coolant usage is compulsory as the speeds employed are very high and continuous application
of coolant is necessary for ductile materials like-steel etc.

The grinding tools are first dressed properly.

Care has to be taken so as to maintain the right feed of the material.

Work-wheel interface zone is to be flooded with coolant

Dressing of grinding wheel to be done before commencement of cutting action,

intermittent dressing also to be done if wheel is loaded

Procedure

First the work piece is placed on the magnetic chuck

1. The positioning of the work piece is aligned at right angles to the grinding wheel and exactly
parallel to the sides of the magnetic chuck by using slip gauges if necessary

2. The magnetic chuck is switched on and the powerful electromagnet holds the job firmly in
position

3. Now the spindle is turned on and the grinding wheel is just touched the work piece surface to
mark its zero / reference position

4. Now the required feed, either totally or in steps, is given to the grinding wheel and the wheel
is traversed all over the work piece

5. Same procedure is repeated until the required dimensions are achieved

6. Care should be taken for maintaining the surface finish

7. Finally, the dimensions are checked using either a Vernier caliper or a screw Gauge

Final Part Dimension:

MS / CI plate _________mm X _________mm X ________mm

Questions
1. State the purpose of grinding?
Machining Process Lab 10

2. What is meant by truing and dressing of grinding wheels??

3. What is the approximate thickness of metal removed in grinding operation?

4. What types of work can be ground by a surface grinder?

Comments:

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