Abrasive Abrasive Machining and Machining and

Finishing Finishing OperationsOperations

Examples of Bonded AbrasivesExamples of Bonded Abrasives

Fig: A variety of bonded abrasive used in abrasive machining processesFig: A variety of bonded abrasive used in abrasive machining processes

Workpiece GeometriesWorkpiece Geometries

Fig: The types of work pieces and operations typical of grinding: (a) cylindrical surfaces, (b) conical Fig: The types of work pieces and operations typical of grinding: (a) cylindrical surfaces, (b) conical surfaces, (c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or slotting with thin surfaces, (c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or slotting with thin

wheels, and (g) internal grindingwheels, and (g) internal grinding

Grinding WheelGrinding Wheel

Fig: Physical model of a grinding wheel, showing is structure and wear and fracture patterns.Fig: Physical model of a grinding wheel, showing is structure and wear and fracture patterns.

Common Grinding WheelsCommon Grinding Wheels

Fig: Common Type of Grinding Wheels made with conventional abrasives. Note that each wheel has Fig: Common Type of Grinding Wheels made with conventional abrasives. Note that each wheel has a a specific grinding face; grinding on other surfaces is improper and unsafespecific grinding face; grinding on other surfaces is improper and unsafe

Superabrasive Wheel Superabrasive Wheel ConfigurationConfiguration

Fig: Examples of Superabrasive Wheel Configuration. The annular regions (rim) are superabrasive Fig: Examples of Superabrasive Wheel Configuration. The annular regions (rim) are superabrasive grinding surfaces, and the wheel itself (core) is generally made of metal or composites. The bonding grinding surfaces, and the wheel itself (core) is generally made of metal or composites. The bonding

materials for the super abrasives are: (a), (d), and (e) resinoid, metal, or vitrified, (b) metal, (c) vitrified, materials for the super abrasives are: (a), (d), and (e) resinoid, metal, or vitrified, (b) metal, (c) vitrified, and (f) resinoidand (f) resinoid

Grinding ChipsGrinding Chips

Fig: (a) Grinding chip being produced by a single abrasive grain. (A) chip, (B) workpiece, (C) abrasive Fig: (a) Grinding chip being produced by a single abrasive grain. (A) chip, (B) workpiece, (C) abrasive grain. Note the large negative rake angle of the grain. The inscribed circle is 0.065mm in diameter. (b) grain. Note the large negative rake angle of the grain. The inscribed circle is 0.065mm in diameter. (b) Chip formation by an abrasive grain with a wear flat. Note the negative rake angle of the grain and the Chip formation by an abrasive grain with a wear flat. Note the negative rake angle of the grain and the small shear anglesmall shear angle

Grinding Wheel SurfaceGrinding Wheel Surface

Fig: The surface of a grinding wheel Fig: The surface of a grinding wheel showing abrasive grains, wheel showing abrasive grains, wheel porosity, wear flats on grains, and porosity, wear flats on grains, and metal chips from the workpiece metal chips from the workpiece adhering to the grains. Note the adhering to the grains. Note the random distribution and shape of random distribution and shape of abrasive grains.abrasive grains.

Surface grinding and PlowingSurface grinding and Plowing

Fig: Surface grinding process, showing Fig: Surface grinding process, showing various process variables.various process variables.

Fig: Chip formation and Plowing of the workpiece Fig: Chip formation and Plowing of the workpiece surface by and abrasive grain. This action is similar surface by and abrasive grain. This action is similar to abrasive wearto abrasive wear

Shaping using Computer Shaping using Computer ControlControl

Fig: Shaping the grinding face of a wheel Fig: Shaping the grinding face of a wheel by dressing it with computer control. by dressing it with computer control.

Note that the diamond dressing tool is Note that the diamond dressing tool is normal to the surface at point of contact normal to the surface at point of contact

with the wheel.with the wheel.

Surface Grinding OperationsSurface Grinding Operations

Fig: Surface Grinding Operations. (a) Traverse grinding with a horizontal-spindle surface grinder. (b) Fig: Surface Grinding Operations. (a) Traverse grinding with a horizontal-spindle surface grinder. (b) Plunge grinding with a horizontal-spindle surface grinder, producing a groove in the workpiece. (c) A Plunge grinding with a horizontal-spindle surface grinder, producing a groove in the workpiece. (c) A vertical-spindle rotary-table grinder (also known as the Blanchard type)vertical-spindle rotary-table grinder (also known as the Blanchard type)

Surface GrindingSurface Grinding

Fig: (a) Rough grinding of steel balls on a Fig: (a) Rough grinding of steel balls on a vertical-spindle grinder; the balls are guided vertical-spindle grinder; the balls are guided by a special rotary fixture. (b) The balls are by a special rotary fixture. (b) The balls are ground to within 0.013mm of their final size.ground to within 0.013mm of their final size.

Fig: A Horizontal-spindle surface grinderFig: A Horizontal-spindle surface grinder

Cylindrical Grinding Cylindrical Grinding OperationsOperations

Fig: Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge grinding, Fig: Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge grinding, andand (c) profile grinding. (c) profile grinding.

Plunge and Noncylindrical Plunge and Noncylindrical GrindingGrinding

Fig: Plunge Grinding of a workpiece on a Fig: Plunge Grinding of a workpiece on a cylindrical grinder with the wheel cylindrical grinder with the wheel dressed to a stepped shape.dressed to a stepped shape.

Fig: Grinding a noncylindrical part on a Fig: Grinding a noncylindrical part on a cylindrical grinder with computer controls cylindrical grinder with computer controls to produce the shape. The part rotation to produce the shape. The part rotation and the distance x between centers is and the distance x between centers is varied and synchronized to grind the varied and synchronized to grind the particular workpiece shape.particular workpiece shape.

Thread and Internal Grinding Thread and Internal Grinding

Fig: Thread grinding by (a) traverse, and (b) plunge grindingFig: Thread grinding by (a) traverse, and (b) plunge grinding

Fig: Internal grinding operationsFig: Internal grinding operations

Cycle Pattern in Cylindrical Cycle Pattern in Cylindrical GrindingGrinding

Centerless GrindingCenterless Grinding

Fig: Centerless grinding operations: (a) through feed Fig: Centerless grinding operations: (a) through feed grinding. (b) Plunge grinding. (c) A computer numerical grinding. (b) Plunge grinding. (c) A computer numerical control grinding machine control grinding machine

Creep-Feed GrindingCreep-Feed Grinding

Fig: (a) Creep-Feed Grinding process. Note the large wheel depth of cut, d. (b) A shape groove Fig: (a) Creep-Feed Grinding process. Note the large wheel depth of cut, d. (b) A shape groove produced on a flat surface by creep-feed grinding in one pass. Groove depth is typically on the orde produced on a flat surface by creep-feed grinding in one pass. Groove depth is typically on the orde of a few mm. (c) An example of creep-feed grinding with a shaped wheel. This operation can also be of a few mm. (c) An example of creep-feed grinding with a shaped wheel. This operation can also be

performed by some of the processes described .performed by some of the processes described .

Ultrasonic Maching and Ultrasonic Maching and Coated AbrasivesCoated Abrasives

Fig: (a) Ultrasonic Maching process. (b) and (c) Types of parts Fig: (a) Ultrasonic Maching process. (b) and (c) Types of parts made by this process. Note the small size of holes producedmade by this process. Note the small size of holes produced

Fig: Structure of a coated Fig: Structure of a coated abrasive.Sandpaper, developed in abrasive.Sandpaper, developed in the 16the 16thth century, and emery cloth century, and emery cloth are common examples of coated are common examples of coated abrasivesabrasives

Belt GrindingBelt Grinding

Honing and SuperfinishingHoning and Superfinishing

Fig: Honing tool used to improve the Fig: Honing tool used to improve the surface finish or ground holessurface finish or ground holes

Fig: The Superfinishing process for a Fig: The Superfinishing process for a cylindrical part. (a) Cylindrical cylindrical part. (a) Cylindrical microhoning, (b) Centerless microhoningmicrohoning, (b) Centerless microhoning

LappingLapping

Fig: (a) Lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on Fig: (a) Lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on cylindrical surfaces.cylindrical surfaces.

Polishing Using Magnetic Polishing Using Magnetic FieldsFields

Fig: Polishing of balls and rollers using magnetic fields. (a) Magnetic float polishing of ceramic balls. Fig: Polishing of balls and rollers using magnetic fields. (a) Magnetic float polishing of ceramic balls. (b) Magnetic-field-assisted polishing of rollers.(b) Magnetic-field-assisted polishing of rollers.

Abrasive Flow MachiningAbrasive Flow Machining

Fig: Abrasive Flow Machining to deburr a turbine impeller.The arrows indicate movement of abrasive Fig: Abrasive Flow Machining to deburr a turbine impeller.The arrows indicate movement of abrasive media. Note the special fixture, which is usually different for each part design.media. Note the special fixture, which is usually different for each part design.

Robot DeburringRobot Deburring

Fig: A Deburring operation on a robot-held die-cast part for an outboard motor housing, using a Fig: A Deburring operation on a robot-held die-cast part for an outboard motor housing, using a grinding wheel. Abrasive belts or flexible abrasive radial-wheel brushes can also be used for such grinding wheel. Abrasive belts or flexible abrasive radial-wheel brushes can also be used for such operations.operations.