Grinding and Finishing: Illegitimi Non Carborundum

Grinding and Finishing
Illegitimi non carborundum

ver. 1
ME 338: Manufacturing Processes II

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Overview
Processes
Analysis


Horizontal Grinding


Horizontal grinding
Vertical grinding

Centered grinding
Centerless grinding

Creep Feed Grinding
Full depth and stock is removed with

one or two passes at low work speed
Very high forces are generated
High rigidity and power
Advantages
Increased accuracy
Efficiency
Improved surface finish
Burr reduction
Reduced stress and fatigue


10

11

12
Grinding Wheels

13
Grinding Wheels

14
Grinding Wheel Information

15
Correctly Mounted Wheel

16
Grinding Wheel Surface

17
Grind Wheel Dressing

18
Grinding Wheel Dressing

19
Grinding Chips

20
Chip formation geometry

w
D
q
t
l
v

21

Chip geometry
As with rolling contact length, the chip length,
l
D = wheel diameter, d = depth of cut
l Dd
Material removal rate, MRR
v = workpiece velocity, d = depth of cut, b = width
of cut
MRR v d b

23
Material removal rate

The chips have a triangular cross-section,
and ratio (r) of chip thickness (t) to chip width
w
(w)
w
r 10 to 20
t
So, the average volume per chip
1 1
1
Volchip w t l wtl
2 2
4
24
Chips
The number of chips removed per unit time
(n), where c = number of cutting edges
(grains) per unit area (typ. 0.1 to 10 per mm2,
and V = peripheral wheel velocity
n V bc
25
Combining
MRR v d b n Volchip
1
v d b Vbc wtl
4
w r t
l Dd
1
vd b V cb r t t Dd
4
26
Chip thickness
4v d
t
V cr Dd
2
or
4v
t
V cr
d
D

27
Specific grinding energy, u
Consist of chip formation, plowing, and sliding
u uchip u plowing usliding

28
Total grinding force

Get force from power
Power u MRR
Fgrinding V u v d b
v d b
Fgrinding u
V
29

From empirical results, as t decreases, the
friction component of u increases
1
u
t
or
1
u K1
t
substituting
1 v d b
Fgrinding K1
t V
30

Substituting for t
v d b
Fgrinding K1
V
4v
d
V cr D
1
rearranging
d cr v
Fgrinding K1 b
Dd
4V
31
ME 6222: Manufacturing Processes and
Systems Prof. J.S. Colton GIT 2006
Force on a grain
The force per grain can be calculated
Fgrain u Area
1
Fgrain u wt
2
w rt
and
1
u K1
t
1 1
Fgrain K1 r t t
t 2
32
Force on a grain
substituting for t, and rearranging
K1
4v
Fgrain r
2
V cr
d
D
vr d
Fgrain K1
V c D

33
ME 6222: Manufacturing Processes and
Systems Prof. J.S. Colton GIT 2006
Grinding temperature
Temperature rise goes with energy delivered
per unit area
Energy input
T K2
area
u bl d
1
T K2
K2 K1 d
bl
t
T K1 K2 d
1
4v d
Vcr D

34
Grinding temperature
Rearranging
=
3
1 2 4
Temperatures can be up to 1600oC, but for a

short time.

35
Grinding Ex. 1-1

You are grinding a steel, which has a specific
grinding energy (u) of 35 W-s/mm3.
The grinding wheel rotates at 3600 rpm, has a
diameter (D) of 150 mm, thickness (b) of 25 mm, and
(c) 5 grains per mm2. The motor has a power of 2
kW.
The work piece moves (v) at 1.5 m/min. The chip
thickness ratio (r) is 10.
Determine the grinding force and force per grain.
Determine the temperature (K2 is 0.2oK-mm/N).
Room temperature is 20oC.
36
Grinding Ex. 1-2

First we need to calculate the depth of cut.
We can do this from the power.
Power u MRR u v d b
2
W s
m
min
6 mm
2000 W 35
1.5
d 25 mm 10
3
2
min
60 sec
mm
m
d 91.4 106 m
37
Grinding Ex. 1-3

Now for the total grinding force
v d b
Fgrinding u
V
mm
3
1500
91
.
4
10
mm 25 mm
W s
min
Fgrinding 35
m
mm3 3600 rev 150 mm
min
rev 1000 mm
Fgrinding 70.7 N
38
Grinding Ex. 1-4

Next, the force per grain
1
Fgrain u wt
2
and
w rt
1
Fgrain u r t t
2
we need t
t
4v
V cr
mm
d
91.4 103 mm
min
mm grains
D
150 mm
3600 150
5
10
min
mm2
4 1500
t 1.32 103 mm

39
Grinding Ex. 1-5

Substituting
1
1
3 2
Fgrain u r t t 35 10 1.32 10
2
2
4
Fgrain 3.05 10 J / mm

40
Grinding Ex. 1-6

For the temperature, we need K1 and K2. K2 is
given, so we need to calculate K1.
1
1 1
1
Fgrain u r t t K1 r t t K1 r t
2
t 2
2
1
3.0510 N K1 10 1.32106 m
2
3 N
K1 46.2 10
m
1

41
Grinding Ex. 1-7

substituting
1
T K2 K1 d
t
T 0.2
K m
N
1
6
46.2
91
.
4
10
m 640K
6
N
m 1.32 10 m
T Tinitial T 20 640 660C

42
Honing and Superfinishing

Honing tool used to improve
the surface finish of bored or
ground holes.

Schematic
illustrations of the
superfinishing
process for a
cylindrical part.
(a) Cylindrical
mircohoning, (b)
Centerless
microhoning.
Lapping
(a) Schematic illustration of the lapping process. (b)
Production lapping on flat surfaces. (c) Production lapping
on cylindrical surfaces.

Polishing Using Magnetic

Fields
Schematic illustration of polishing of balls and rollers

using magnetic fields. (a) Magnetic float polishing of
ceramic balls. (b) Magnetic-field-assisted polishing of
rollers. Source: R. Komanduri, M. Doc, and M. Fox.
Abrasive-Flow Machining
Schematic illustration of
abrasive flow machining to
deburr a turbine impeller.
The arrows indicate
movement of the abrasive
media. Note the special
fixture, which is usually
different for each part
design. Source: Extrude
Hone Corp.

Robotic Deburring
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 operations. Source: Courtesy of
Acme Manufacturing Company and
Manufacturing Engineering Magazine,
Society of Manufacturing Engineers.

Conformal Hydrodynamic Nanopolishing:

Case-study
Applications
Challenges
Most processes can polish only flat

surfaces; concave/profiled surfaces
Defence & Nuclear
are difficult to superfinish
Concave surface on hard brittle
Electronics
materials, such as single crystal
Industrial
sapphire can not be finished via form
Existing Methods
grinding due to process-induced
cracks
Diamond Turning
Diamond turning center can be used
Precision Grinding
for non ferrous materials but it is a
Lapping
super-precision machine-tool (The
equipment cost is ~ 20 crores besides
Ion Beam Polishing
Spot Hydrodynamic Polishing the expensive operational cost)
Optics

Conformal Hydrodynamic
Nanopolishing Process and Machine
Process Description
Improvement over existing

spot hydrodynamic polishing
methods
Superfinish hard and brittle
concave surfaces, specially,
sapphire and hardened steels
Mitigates
existing surface
microcracks
Polishing action due to
elastohydrodynamic film in
the slurry
submerged
rotating conformal contact
(silicone ball in the cavitynd
being
polished)
12st Generation Conformal Hydrodynamic Nanopolishing Machin
Delivered to Precison Engineering Division BARC
Generation
(designed and fabricated in the Machine Tools Lab
at IIT Bombay)

Novelty and Technology Breakthrough

Existing hydrodynamic polishing employs spot polishing unable to
polish small cavities (< 6mm in dia)
More than 3 degrees of freedom required to polish the entire cavity
effectively
Small actuation system and polishing tool is required
Conformal contact has a rotating soft tool which conforms to the shape
of the cavity
Axis of this tool is inclined at 45 and the workpiece is rotated inside a
slurry filled tank which ensures non-zero relative motion between tool
and workpiece at every location in the cavity
The entire cavity can be polished at once which will be much cheaper
and faster than programming the tool path
Alternative to expensive Diamond Turning
Can finish wide range of materials ceramics (sapphire, glass) and
hardened steels
Technology Outcomes
Superfinished surfaces in
steels (< 3nm 3D surface
roughness)
Crack-free surface of < 100
nm 3D surface roughness in
single
crystal
sapphire
cavity
Process
knowhow
and
machine
transferred
to
Precision
Engineering
Division, BARC for strategic
applications in a nuclear
device
The superfinished obtained
at a fraction of cost of
Diamond turning
It can also be used by gem
polishers
which
could
reduce the health hazard by
reducing the dust inhalation
and automation is possible
Nanometric finish on hardened steel
Crack-free superfinished surface on single

crystal sapphire cavity


Economics of Grinding and Finishing

Operations
Increase in the cost of
machining and finishing a
part as a function of the
surface finish required.
This is the main reason
that the surface finish
specified on parts should
not be any finer than
necessary for the part to
function properly.
Summary
Overview of processes
Analysis of process
Example problem

54

Grinding and Finishing: Illegitimi Non Carborundum

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Grinding and Finishing

Illegitimi non carborundum

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

Creep Feed Grinding

Full depth and stock is removed with

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

Grinding Wheel Information

ME 338: Manufacturing Processes II

Correctly Mounted Wheel

ME 338: Manufacturing Processes II

Grinding Wheel Surface

ME 338: Manufacturing Processes II

Grind Wheel Dressing

ME 338: Manufacturing Processes II

Grinding Wheel Dressing

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

Chip formation geometry

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

Material removal rate

So, the average volume per chip

ME 338: Manufacturing Processes II

Specific grinding energy, u

Consist of chip formation, plowing, and sliding

u uchip u plowing usliding

ME 338: Manufacturing Processes II

Total grinding force

Total grinding force

Total grinding force

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

Temperatures can be up to 1600oC, but for a

ME 338: Manufacturing Processes II

Grinding Ex. 1-1

Grinding Ex. 1-2

Grinding Ex. 1-3

Grinding Ex. 1-4

ME 338: Manufacturing Processes II

Grinding Ex. 1-5

ME 338: Manufacturing Processes II

Grinding Ex. 1-6

ME 338: Manufacturing Processes II

Grinding Ex. 1-7

T Tinitial T 20 640 660C

Honing and Superfinishing

ME 338: Manufacturing Processes II

ME 338: Manufacturing Processes II

Polishing Using Magnetic

Schematic illustration of polishing of balls and rollers

ME 338: Manufacturing Processes II