Grinding 1

15.
GRINDING AND ABRASIVE PROCESSES
 Grinding refers to the removal of metal by a rotating abrasive wheel.

 A grinding wheel is composed of many small grains bonded together, each one
acting as a miniature cutting point.
 Precision grinding is the last, or close to last, process performed on a part.
 Grinding is usually a finishing operation - it can finish work to accurate
dimensions ( 0,4 – 2200μm are possible).
 Grinding machines finish parts having cylindrical, flat or internal surfaces.
15.1 THE GRINDING WHEEL

 Selection of a grinding wheel for a definite purpose is important.
 The most important factors are:
 Size and shape of wheel, type of abrasive (abrasiveness), grain size of
abrasive (size of grit), grade and strength of bond, structure of grain
spacing and type of bond material.
A grinding wheel is identified by a standard set of markings which must be

specified when ordering a wheel for a particular purpose e.g.
A 36 L 5 VBE
Abrasives Grain Size Grade Structure Bond
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15.2 MOUNTING OF GRINDING WHEEL
 Select the correct type of wheel.

 Ensure wheel does not exceed recommended speed
 Inspect for cracks - apply "ringing test."
 Fit wheel onto spindle - do not force wheel onto spindle (can cause
bursting).
 Use smooth paper spacers on side of wheel.
 Use correctly recessed flanges ( diameter of wheel).
 Tighten spindle nut gently without tapping spanner.
 Replace guard.
 Stand aside and let wheel run for 1 minute before trimming it with a wheel
dresser.
 Stop grinder and reset tool rest to within 3 mm of wheel and parallel to it.
15.3 RINGING TEST

Support the wheel with a finger through the bore.
Tap the side of wheel lightly with a wooden object e.g. handle of a hammer.
A clear, ringing sound indicates the wheel is free from cracks.
A dull sound means the wheel is cracked.
Do not use wheel if it is cracked.
15.4 THE BENCH/PEDESTAL GRINDER
 May be mounted on a bench or pedestal.
 May be fitted with two grinding wheels - 1 coarse wheel for roughing work
and a fine wheel for finishing.
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 Used for sharpening of tools such as chisels, drills, scrapers etc. by

holding tool in hand.
 The tool is moved across the face of the wheel to avoid grinding on one
spot.
15.5 DRESSING THE WHEEL

 It is the operation of cleaning (smoothing) the surface of the cutting face.
 Performed with a star-and-disc type dresser.
 The tool rest is moved back to allow dresser lugs to locate against rest
with discs just clearing wheel.
 With wheel in motion, the handle is lifted until discs are in contact with
wheel - enough pressure is applied to drive the discs and dress the wheel.
15.6 SHAFT THREADS

 A left-hand thread if fitted on the left
side spindle.
 When grinding takes place, a force is
applied against the rotation of the
wheel.
 This implies that the force is in the
same direction as tightening the nut.
 The nut will take up any slippage of
the wheel, due to the force, that may occur.
 If the thread was in the opposite direction, it will cause the nut to loosen
and cause possible damage.
15.7 SAFETY PRECAUTIONS
 Always wear safety goggles when grinding.
 Ensure guards are correctly fitted.
 Ensure tool rest is not more than 3 mm away from grinding wheel.
 Never grind on side of wheel - use only the face.
 Do not grind soft materials like lead, copper, aluminium, wood, etc. (it
clogs the pores).
 Never put grinding matter on the wheel.
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 Never force grinds so it stops or slows down drive motor excessively.

 Do not adjust tool-rest while wheel is running.
 Never let the wheel stand in cutting fluid, as this will cause it to move
out of balance - it may have disastrous results when setting the wheel in
motion again.
 Ensure no oil or grease is around machine (floor).
 Never stand in front of m/c when starting.
 Workpieces must be held firmly.
15.8 SURFACE GRINDING:

 Grinding plane surfaces is known as “surface grinding”.
 Surface grinders are planer-type machines with a reciprocating table and
some may have a rotating worktable.
 Some machines have the possible variation of a horizontal or vertical
positioned wheel spindle.
 These machines grind
gear faces, thrust
washers, cylinder heads
surfaces and other flat-
surfaced parts.
 Surface grinders are also
used to recondition dies,
grind machine tool ways
and other long surfaces.
 Grinding is done on the
outside face or the
circumference of the
parts.
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15.9 CYLINDRICAL GRINDING:
Cylindrical grinders are used mainly for grinding cylindrical surfaces although
tapered and simple-formed surfaces are also ground.
A cylindrical grinder traverses

the work to and fro in repeated
passes along the length of the
diameter.
The depth of cut is controlled
by feeding the wheel into the
work.
Roughing cuts are about
0.05mm per pass and for
finishing material removal
should be reduced to about
0,005mm per pass or less.
The method of work support is:

(a) between centres
(b) centreless grinding
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15.

GRINDING AND ABRASIVE PROCESSES

 Grinding refers to the removal of metal by a rotating abrasive wheel.

15.1 THE GRINDING WHEEL

A grinding wheel is identified by a standard set of markings which must be

15.2 MOUNTING OF GRINDING WHEEL

 Select the correct type of wheel.

15.3 RINGING TEST

 Used for sharpening of tools such as chisels, drills, scrapers etc. by

15.5 DRESSING THE WHEEL

15.6 SHAFT THREADS

 Never force grinds so it stops or slows down drive motor excessively.

15.8 SURFACE GRINDING:

15.9 CYLINDRICAL GRINDING:

A cylindrical grinder traverses

The method of work support is:

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