CHAPTER 2 LITERATURE RESEARCH

2.0

Introduction

The source of research that we took was from internet, references book, handbook, and an observation. In our project, we did our research in two elements. The two elements in our project are: 2.1 Tool holder Grinding Machine Tool holder

Tool holder is a part of lathe machine. It holds a cutting tool when the cutting tool did their work. The holders of the cutting tool are differences according to the types of cutting tool. There are several types of cutting tool such as cut-off, boring, roughing, internal and external thread and etc.

Figure 2.1a: Boring Cutter Holder Source ((http://www.popsci.com/diy/article/2009-10/lathe-boring-bar) )

Figure 2.1b: Cut-off Cutter Tool Holder

Figure 2.1c: Internal Thread Cutter Holder

Figure 2.1d: Roughing and Finishing Cutter Holder

2.2

Grinding Machine

A grinding machine, often shortened to grinder, is a machine tool used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear deformation. Grinding is used to finish work pieces which must show high surface quality (e.g., low surface roughness) and high accuracy of shape and dimension. They are several types of grinding machine such as: a. Bench grinder A bench grinder is a type of bench top grinding machine used to drive abrasive wheels. A pedestal grinder is a larger version of a bench grinder that is mounted on a pedestal, which is bolted to the floor. These types of grinders are commonly used to hand grind cutting tools and perform other rough grinding. It is usually has two wheels of different grain sizes for roughing and finishing operations and is secured to a workbench or floor stand. Its uses include shaping tool bits or various tools that need to be made or repaired. Bench grinders are manually operated. b. Cylindrical grinder It includes the centre less grinder. A cylindrical grinder may have multiple grinding wheels. The work piece is rotated and fed past the wheel(s) to form a cylinder. It is used to make precision rods. c. Surface grinder 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 non metallic substance from a work piece, making a face of it flat or smooth. It includes the wash grinder. A surface grinder has a "head" which is lowered, and the work piece is moved back and forth past the grinding wheel on a table that has a permanent magnet for use with magnetic stock. Surface grinders can be manually operated or have CNC controls. d. Tool and cutter grinder A tool and cutter grinder is used to sharpen milling cutters and tool bits along with a host of other cutting tools. It is an extremely versatile machine used to perform a variety of grinding operations: surface, cylindrical, or complex shapes. These usually can perform the minor function of the drill bit grinder, or other specialist tool room grinding operations.

2.1.1

Grinding Wheel

A grinding wheel is a precision tool with thousands of cutting points. It consists of abrasive grains held in a matrix of bond and separated by pores. The abrasive grains are the cutting points while the purpose of the bond is to hold the individual grains together. The pores (hollow spaces between adjacent abrasive grains and the bond) serve to provide clearance for coolant penetration and metal chips removed in the grinding process. When the wheel is rotated at grinding speed and applied to the work piece, the abrasive grains cut the material that is being ground, removing the material in small chips. Under the action of the forces imposed during grinding the abrasive cutting points is worn fl at, resulting in the points becoming blunt. This causes an increase in friction, heat build up and the forces imposed on the wheel. The increase in grinding forces causes either the abrasive to fracture, exposing new cutting edges, or fractures the bond bridges holding the abrasive grains. In the latter case fresh abrasive grains are exposed to cut the work piece. In normal vitrified grinding applications the wheel has to be dressed. By varying the properties of the abrasive, the type of bond, the make-up of the wheel, it is possible to produce grinding wheels with a vast range of different grinding characteristics. 2.1.2 Abrasive

An abrasive is a material, often a mineral that is used to shape or finish a work piece through rubbing which leads to part of the work piece being worn away. While finishing a material often means polishing it to gain a smooth, reflective surface it can also involve roughening as in satin, matte or beaded finishes. Abrasives are extremely commonplace and are used very extensively in a wide variety of industrial, domestic, and technological applications. This gives rise to a large variation in the physical and chemical composition of abrasives as well as the shape of the abrasive. Common uses for abrasives include grinding, polishing, buffing, honing, cutting, drilling, sharpening, lapping, and sanding (see abrasive machining) 2.2 Introduction to the Domain

By using mechanical and electrical principle as human assistant, it can build up an idea to design and improvement a portable grinding machine. Nowadays, sharpening work and making a cutting tool only in workshop. The process of manufacturing meets the objectives of this project. 2.3 Important Research

Before the project of Portable Grinding Machine with tool holder was done, few studies have been made to ensure that the product is achieving the objectives and targets. Reviews research that has been made is based on observation and research of existing products as well as appearing in the Internet used as a reference source. In this work, the

student should make a study and research concerning the problems faced by consumers. The study was conducted to facilitate the process of production.

2.4

Traditional System / Manual

Figure 2.4.a: Conventional sharpening method (sources: pergeo.photopages.com) A knife also known as scissors grinder. Humans also use these things for their use. In medieval times, the ancients were not willing to buy a new knife because knives are very expensive. Maybe some people will think sharpening a knife is not important for survival activities but it is very important for maintaining the equipment that is often used when in the forest. How to use the sharpening stone is very easy. First, sharpening stone need be immersed in water. Let it until no bubbles coming out of the sharpening stone. This step is important to get the update and smooth hone. Second step, grind stone is set on a flat surface and not moving. It is because to get the blade inclination angle in the right position so that the shavings will be sharp the blade. If the hone angle is not correct, two possibilities will occur. First a sharpened blade is too inclined it will be sharp, but it was easy to blunt because the eyes are too thin. If a knife using a relatively large angle, the blade will be thicker and sharpness will be reduced. The most appropriate angle is of the thickness of the knife.

2.4.1 i ii iii

Advantage of conventional method Easy to bring by user Price of sharpening stone is cheap Can shape and sharpen the cutting tool and knife in accordance with the requirements of the user. Disadvantage of conventional method Consumer required use more energy during sharpened Sharpening process are complicated Using conventional methods, safety factors are not addressed.

2.4.2 i ii iii

iv

Dust scattered debris tool.

2.5

Development and Implementation

To sharpen the cutting tool, the technique used to sharpen is by hand. Users need to hold the cutting tool to be sharpened on a grinding wheel. Users must determine and ensure their own and to anticipate the angle to be sharpened. In the mechanical workshop polytechnics, the type of grinding machine used is bench grinding machine. The machine tied to a desk. Thus, the machine cannot be brought anywhere. Existing machines with two wheels on the sides grinding driven by an electric motor. Coolant fluid-filled containers are provided at the front desk to dip the tool. Through the machine tools we build, we use the existing grinding machine so that it helps consumers, especially lecturers and students during sharpening cutting tools. Cutting tool holder is designed to hold the cutting tool. With this holder, the user is not required to hold a cutting tool during sharpening. In addition, the safety factor can be improved. Consumers will also be susceptible to the angle formed at the cutting tool with the angular scale of measurement facilities. Users only need to feed the cutting tool on the grinding wheel. As the result, at the right angle of cutting tool are ready re-sharpened. To facilitate the grinding machine is carried anywhere, we use grinding machines and small grinding wheel where all the above installed on a medium-sized container that can be taken anywhere. Liquid coolant is also available.

2.6

Case Studies

Through the reading of the literature collected (e.g.: from internet, book), there are many grinding machines at polytechnic, industrial plants and small and medium industry ( IKS) can only sharpen and hold the cutting tool by hand. In addition, do not have containers for tray dust and debris also does not have a high safety factor. The machine also cannot be brought anywhere. Accordingly, the project done this time is intended to overcome this. From the readings that have been done there are several types of grinding machines in the market. Examples of grinding machines available in the market are: i Belt grinder

Figure 2.7a: Belt grinder Sources: http://farm2.static.flickr.com/1210/1464176879_f616cf0a0a_o.jpg It is usually used as a machining method to process metals and other materials, with the aid of coated abrasives. Sanding is the machining of wood; grinding is the common name for machining metals. Belt grinding is a versatile because it is suitable for all kind of applications like finishing, debarring, and stock removal. ii Bench grinder

Figure 2.7b: Bench grinder Source:http://upload.wikimedia.org/wikipedia/commons/a/a2/Rotating_grinder.gif This usually has two wheels of different grain sizes for roughing and finishing operations and is secured to a workbench or floor stand. Its uses include shaping tool bits or various tools that need to be made or repaired. Bench grinders are manually operated. iii Cylindrical grinder

Figure 2.7c: Cylindrical grinder Source:http://upload.wikimedia.org/wikipedia/commons/6/63/Centerless_cylindrical_grinder.

jpg

This includes the centerless grinder. A cylindrical grinder may have multiple grinding wheels. The work piece is rotated and fed past the wheels to form a cylinder. It is used to make precision rods. iv Surface grinder

Figure 2.7d: Surface grinder Source: http://en.wikipedia.org/wiki/File:SurfaceGrinder-Proth-insetMagChuck.jpg This surface grinder includes the wash grinder. A surface grinder has a "head" which is lowered, and the work piece is moved back and forth past the grinding wheel on a table that has a permanent magnet for use with magnetic stock. Surface grinders can be manually operated or have CNC controls.

Tool and cutter grinder

Figure 2.7e: Tool and cutter grinder (sources:

http://en.wikipedia.org/wiki/File:ToolandCutterGrinder-table-head.jpg)

These usually can perform the minor function of the drill bit grinder, or other specialist tool room grinding operations. vi Jig grinder

Figure 2.7f: Jig grinder (sources:

http://www.aspenmachining.com/images/equipment/moore%20jig%20grinder.jpg)

Which as the name implies, has a variety of uses when finishing jigs, dies, and fixtures. Its primary function is in the realm of grinding holes and pins. It can also be used for complex surface grinding to finish work started on a mill.