Seminar Presentation

on Mechanics of Grinding (Theory of Metal Cutting)

By Kudzanayi Chiteka

Introduction
Abrasive Machining Material removal by the action of hard, abrasive particles usually in a form of a bonded wheel. Similar to slab milling - Cutting occurs at either the periphery or the face of the grinding wheel. Different than milling - Cutting occurs by the abrasive grains that are much smaller, numerous and random,
Cutting speeds are higher, Higher negative rake angle, Self-sharpening as each abrasive falls off

Can be used on all types of materials. Generally a finishing operation achieving the surface finish of up to 0.025m and extremely close tolerance.

Grinding wheel
Consists of abrasive material and bonding material,
Abrasive particles accomplish cutting Bonding material holds particles in place and establishes shape and structure of wheel.

Parameters Abrasive materials Grain size Wheel grade Wheel structure Bonding material

Abrasive Materials
Properties High hardness, Wear resistance, Toughness Friability - Capacity to fracture when cutting edge dulls, so a new sharp edge is exposed.

Materials Al2O3 most common, for ferrous and high-strength alloys SiC harder but not as tough, for aluminum, brass, stainless steel, cast irons and certain ceramics CBN very hard, very expensive, ex.: Borazon by GE, for harden tool steels and aerospace alloys Diamond Harder and more expensive, natural and synthetic, for hard, abrasive materials such as ceramics

Grinding wheel

Three Types of Grain Action

Cutting -grit projects far enough into surface to form a chip material is removed Plowing - grit projects into work, but not far enough to cut instead, surface is deformed and energy is consumed but no material is removed Rubbing - grit contacts surface but only rubbing friction occurs, thus consuming energy, but no material is removed

Mechanics of Grinding

Uncut Chip thickness per grit, t1 is given by t1 = f mm

ZN

Where

f= Feed (m/sec)
Z = Number of active grains N= rpm of the wheel

Number of active grains

Z = DCb
Where: D=Diameter of the wheel C=Surface density of active grains (mm-2) b=Average grain width of cut (mm)

rg = cutting ratio in grinding

Power, W

Force per single grit, Fc

Where: D=Diameter of the wheel C=Surface density of active grains (mm-2) b=Average grain width of cut (mm) Uc = Specific energy A = Cross-sectional area

Chip Formation during surface grinding

Components of Grinding Force

Average force per grit

Residual stress in workpiece after surface grinding

Growth of power requirement of different wheel grades

Grinding wheel wear

References
1. Rao P. N., Manufacturing Technology : Metal Cutting and Machine Tools, Tata McGraw-Hill Publishing Co. Ltd., New Delhi. (2000) 2. Pandey P. C. and Singh C. K, Production Engineering Science, Standard Publishers Distributors, Delhi. . (1998) 3. Lal G. K, Introduction to Machining Science, New Age International Publishers, New Delhi. (1996) 4. Kalpakjian S. Manufacturing Engineering and Technology, Addison-Wesley Publishing Co., New York. (1989) 5. Gerling H. All About Machine Tools, Willey Eastern Ltd.,New Delhi. (1965),

The end

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