IIT BHU

Metal machining and

machine tools

effect of process parameters on

ground surface quality and spark
intensity in cylindrical grinding.
03/02/2016

NAME : Shubham Khatri

ROLL NO. : 14135077
CLASS : B. TECH. PART II, Semester IV
MECHANICAL ENGG.

Effect of Depth of Cut on MRR in Surface Grinding

What is Machining?
Machining is a manufacturing term encompassing a broad range of technologies and
techniques. It can be roughly defined as the process of removing material from a
workpiece using power-driven machine tools to shape it into an intended design. Most
metal components and parts require some form of machining during the
manufacturing process. Other materials, such as plastics, rubbers, and paper goods,
are also commonly fabricated through machining processes.

Types of Machining Process

Boring Process: In machining, boring is the process of enlarging a hole that has
already been drilled (or cast), by means of a single-point cutting tool (or of a
boring head containing several such tools), for example as in boring a gun
barrel or an engine cylinder. Boring is used to achieve greater accuracy of the
diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed
as the internal-diameter counterpart to turning, which cuts external diameters.

Cutting process: Cutting is a collection of processes wherein material is

brought to a specified geometry by removing excess material using various kinds
of tooling to leave a finished part that meets specifications. The net result of
cutting is two products, the waste or excess material, and the finished part.

Drilling process: Drilling is a cutting process that uses a drill bit to cut or
enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary
cutting tool, often multipoint. The bit is pressed against the workpiece and
rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the workpiece, cutting off chips (swarf) from
the hole as it is drilled.

Grinding process: Grinding practice is a large and diverse area

of manufacturing and tool making. It can produce very fine finishes and very
accurate dimensions; yet in mass production contexts it can also rough out
large volumes of metal quite rapidly. It is usually better suited to the machining
of very hard materials than is "regular" machining (that is, cutting larger chips

with cutting tools such as tool bits or milling cutters), and until recent decades
it was the only practical way to machine such materials as hardened steels.

Milling process: Milling is the machining process of using rotary cutters to

remove material from a workpiece advancing (or feeding) in a direction at an
angle with the axis of the tool. It covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty gang
milling operations. It is one of the most commonly used processes in industry
and machine shops today for machining parts to precise sizes and shapes.

Turning process: Turning is a machining process in which a cutting tool,

typically a non-rotary tool bit, describes a helical toolpath by moving more or less
linearly while the workpiece rotates. The tool's axes of movement may be
literally a straight line, or they may be along some set of curves or angles, but
they are essentially linear (in the nonmathematical sense).

Grinding Process:
Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish
obtained through grinding can be up to ten times better than with either turning or
milling.
Grinding employs an abrasive product, usually a rotating wheel brought into controlled
contact with a work surface. The grinding wheel is composed of abrasive grains held
together in a binder. These abrasive grains act as cutting tools, removing tiny chips of
material from the work. As these abrasive grains wear and become dull, the added
resistance leads to fracture of the grains or weakening of their bond. The dull pieces
break away, revealing sharp new grains that continue cutting. The requirements for
efficient grinding include:

Abrasive components which are harder than the work

Shock- and heat-resistant abrasive wheels
Abrasives that are friable. That is, they are capable of controlled fracturing.

Types of Grinding:
There are many forms of grinding, but the four major industrial grinding processes are:

Cylindrical grinding
Internal grinding

Centerless grinding
Surface grinding

Grinding wheel
A grinding wheel is an expendable wheel used for
various grinding and abrasive machining
operations. It is generally made from a matrix of
coarse abrasive particles pressed and bonded
together to form a solid, circular shape, various
profiles and cross sections are available
depending on the intended usage for the wheel.
Grinding wheels may also be made from a solid
steel or aluminium disc with particles bonded to
the surface.
Wheel dressing and truing is done with special tools designed for that purpose.
Although wheel dressing is often done manually between work cycles, some grinding
machines perform the dressing task automatically. The application of coolants to the
grinding process is important. Coolants reduce grinding machine power requirements,
maintain work quality, stabilize part dimensions, and insure longer wheel life. Coolants
are either emulsions, synthetic lubricants or special grinding oils. Coolants are applied
by either flooding the work area or by high pressure jet streams.

Grinding Theory
The nature and intensity of the applied stresses on the particles affect the particle
size reduction process. In comminution the following three main breakage mechanisms
have been identified.


Abrasion occurs when stress is applied on
particles along the tangential axis(shear). Particle
breakage in this cases gives a bimodal particle size
distribution comprising fine particles that are
released from the surface of the initial particle and
particles with a size close to that the initial particles.

Cleavage of particles occurs when intense

stresses are slowly applied on a particle(compression).
This produces fragments of sizes 5080 vol. % smaller
than the initial particles.

Fracture occurs through rapidly applying

intense stresses(impact). The particle size
distribution in this case will range between 20 and 70
vol. % of the size of the initial particle.

Cylindrical Grinding:
Cylindrical grinding (also called center-type grinding) is used to grind the cylindrical
surfaces and shoulders of the workpiece. The workpiece is mounted on centers and
rotated by a device known as a drive dog or center driver. The abrasive wheel and the
workpiece are rotated by separate motors and at different speeds. The table can be
adjusted to produce tapers. The wheel head can be swiveled. The five types of
cylindrical grinding are: outside diameter (OD) grinding, inside diameter ( ID ) grinding,
plunge grinding, creep feed grinding, and centerless grinding.
A cylindrical grinder has a grinding (abrasive) wheel, two centers that hold the
workpiece, and a chuck, grinding dog, or other mechanism to drive the work. Most
cylindrical grinding machines include a swivel to allow for the forming of tapered
pieces. The wheel and workpiece move parallel to one another in both the radial and
longitudinal directions. The abrasive wheel can have many shapes. Standard diskshaped wheels can be used to create a tapered or straight workpiece geometry while
formed wheels are used to create a shaped workpiece. The process using a formed
wheel creates less vibration than using a regular disk-shaped wheel.
Cylindrical grinding is defined as having four essential actions:

The work (object) must be constantly rotating

The grinding wheel must be constantly rotating
The grinding wheel is fed towards and away from the work
Either the work or the grinding wheel is traversed with respect to the other.

Types of Cylindrical Grinding:

1.
2.
3.
4.

External cylindrical grinding

Centerless grinding
Internal cylindrical grinding
Creep feed grinding

Universal Cylindrical Surface Grinder

Universal cylindrical grinder is similar to a plain cylindrical one except that it is more
versatile. In addition to small worktable swivel, this machine provides large swivel of
head stock, wheel head slide and wheel head mount on the wheel head slide.

A: swivelling wheel head

B: swivelling wheel head slide
C: swivelling head stock
D: rotation of grinding wheel

This allows grinding of

any taper on the
workpiece. Universal
grinder is also equipped
with an additional head
for internal grinding.
Schematic illustration
of important features
of this machine is
shown in figure.

EXPERIMENT
OBJECTIVE :
To study the effect of process parameters on ground surface quality and spark
intensity in cylindrical grinding.

THEORY:
Grinding Process
Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish
obtained through grinding can be up to ten times better than with either turning or
milling.

Basics of Grinding
Another aspect of grinding wheels is their pore structure or density, which refers to
the porosity between individual grains. This pore structure creates spaces between
the grains that provide coolant retention and areas for the chips to form. Dense
wheels are best for harder materials, while more open densities are better for the
softer metals.
The application of coolants to the grinding process is important. Coolants reduce
grinding machine power requirements, maintain work quality, stabilize part dimensions,
and insure longer wheel life. Coolants are emulsions, synthetic lubricants or special
grinding oils. Coolants are applied by either flooding the work area or by high pressure
jet streams.

Types of Grinding:
There are many forms of grinding, but the four major industrial grinding process are:

Cylindrical Grinding
In cylindrical grinding, the workpiece rotates about a fixed axis and the surfaces
machined are concentric to that axis of rotation. Cylindrical grinding produces an
external that may be either straight, tapered, or contoured. The basic components of
a cylindrical grinder include a wheelhead, to and from the workpiece; a headstock,

which locates, holds, and drives workpiece, and a tailstock, which holds the other end
of the work.

Internal Grinding
Internal diameter or "I.D." grinders finish the inside of a previously drilled, reamed, or
bored hole, using small grinding wheels at high RPM. The principle elements of an
internal grinding machine are the workhead, which holds the work and has its own
drive; and the wheelhead, which is the internal grinding spindle. In addition to the
rotary motions of work and wheel, an internal grinder has a traverse movement to
bring the wheel to and from the work zone, and a reciprocating spindle movement for
both the wheel's approach to the work surface and for the feed movement of the
wheel during grinding. Several different internal contours can be produced within a
workpiece using I.D. grinding.

Cylindrical Grinding Machine

Centerless Grinding
In Centerless grinding, the workpiece rotates between a grinding wheel and a
regulating drive wheel. The work is supported from below by a fixed work-rest blade.
The two basic modes of Centerless grinding are "thru-feed" and "in-feed" or "plunge"
mode. In the thru-feed mode, the work proceeds in the axial direction through the
slowly narrowing gap between the grinding wheel and the regulating wheel. Work is
advanced by the axial force exerted on it by the rotating surface of the regulating

wheel. The "in-feed" mode is used for work with projecting heads that would prohibit
"thru-feeding," the work is placed on the work-rest blade while one wheel is retracted
and fed to an end stop. The wheel is then brought back, reducing the gap between the
wheels, grinding the work.

Surface Grinding
Surface grinding produces flat, angular, or contoured surfaces by feeding work in a
horizontal plane beneath a rotating grinding wheel. Work is most often magnetically
attached to the table, and may be ground by either a traversing or rotating movement
of the table. Most surface grinding machines use a horizontal spindle which adjusts up
and down allowing either the edge or the face of the wheel to contact the work.

APPARATUS AND MATERIAL REQUIRED:

Cylindrical Rod, Catch, Coolant, Cylindrical grinder

PROCEDURE :
1. Switch on the power supply.
2. Check the stoke length and it
according to the length of the work
to be grind.
3. Adjust the tailstock to make the
proper gap between the head stock
and tail stock according to the
length of the work piece.
4. Position the grinding wheel and
fix the sample between the head
stock and tail stock with the catch
attachment.
5. Start the rotation of the grinding wheel and adjust the stoke length movement.
6. Make sure the contact between grinding wheel and workpiece is maintained.
7. After insuring the contact between the grinding wheel and the work piece, start to
provide the feed with required step increment.

OBSERVATION TABLE :

Grinding with coolant

Grinding without coolant

RESULT AND CONCLUSIONS:

On grinding without coolant even changing parameters will not affect as the
grinded particles havent flushed out.
Every time on increasing feed rate spark intensity. Its because of increase in
contact pressure due to increase in depth of cut.
The sound due to contact also increases on increasing feed rate.
After a particular surface finish, even changing parameters will not affect the
surface finish too much.
The infeed should be kept low and the grinding operation should be done in
steps which will increase the quality of surface finish. High infeed may lead to
surface damage if large size particle gets stuck and can make grooves on the
surface.

After the experiment we concluded that it should be performed with coolant

otherwise the process is of no use.
The feed rate and the speed should not be too much high as it will allow the particles
to skip the contact area.

Safety and Precautions:

Never operate grinding wheels at speeds in excess of the recommended speed.

Never adjust the workpiece or work mounting devices when the machine is operating.

Remove workpiece from grinding wheel before turning machine off.