Abrasive Machining Processes

Usuallybroughtintoplayaftercasting,
forging,sheetmetalforming,machining,etc.
Requiredfor:
tighttolerances
smoothsurfacefinishes
hardmaterials
brittlematerials
Notpossiblebyconventionalmachining
processes
Abrasive Machining Processes
Analogy
Thinkofwhettingaknifewithastoneor
"sanding"wood
Abrasivemachiningorgrindingisthe
automatedversionofwhettingwithan
abrasivestoneorsandingwood
Set-up
Abrasivemachiningtypicallyusesspecially
madeabrasivedisksinwhichtheabrasive
powderprotrudesasmallamountfroma
matrix
Thesedisksrotateathighspeedandare
broughttobearonthematerialtobeground
Abrasive vs. conventional Machining
Manymorecuttingedges
Distributionofrakeangles:
+45
o
to60
o
Thegrainsundergomuch
largerdeformationsthan
cuttingtools
Chipsaretiny
2to5%ofgrainsurfacearea
isoperativeatanytime
DOCforanindividualgrain
w.r.tgraindiameterisvery
small
Abrasive-Work-piece Interaction
Abrasives (grits) with
large negative rake
angles or rounded
cutting edges do not
form chips but will plow
or rub
Proportion of cutting,
plowing and rubbing will
change continuously as
the abrasives wear
Abrasive Properties: Requirement
Hardness
Friability
Grainshape
Abrasive Hardness
KnoopHardness
AluminumOxide 20003000
SiliconCarbide 21003000
CubicBoronNitride 40005000
Diamond 70008000
AbrasiveFriability
Theabilityoftheindividualgrainstofractureor
splitintosmallerpieces
Givesaselfsharpeningcapability
Byhavingthegrainsplitorfracture,newsharp
edgesarecreatedtoreplaceroundedorblunt
edges
Advantages
Abrasivewheeldoesnotneedsharpeningor
dressing
Disadvantages
Abrasivewearsmorerapidlythannonfriable
materials
Abrasive Shape
Grainshapedeterminestoolgeometry
Sharpparticlesremovemorematerial
Roundedparticlesgivesmootherfinishes
Abrasive Materials
Hardtosuperhardceramics
Commonabrasivesare:
Garnet
AluminumOxide
SiliconCarbide(SiC)orSiloconNitride(Si
3
N
4
)
CubicBoronNitride(superabrasive)
Diamond(superabrasive)
Classification: Abrasive Tools
Bonded
Loose
BondedAbrasives
Acompositeoftheabrasivepowderanda
matrix
Bondingmaterialcanbeglass,resin,rubber
Canbesoliddiscs(grindingwheel)or
bondedtopaper/clothwhichisthenstuck
toabackingdisc.
Grinding wheel
Cavityorvoidsshouldbelargeenoughtoholdthechips
duringthecut
Grinding Processes
Grinding Process
Centrelessgrinding
Workpiece is not supported by centers or chucks, but by a
blade.
Grinding is done by larger wheel
Smaller wheel mounted at an angle wrt grinding wheel
controls the rotational and longitudinal motion of the
workpiece
Reduced cycle time and hence higher productivity
MachinesforBondedAbrasive
SurfaceGrinder
Finishing Operations
CoatedAbrasive
Sandpaperandemerycloth
Abrasives(mostlyAl
2
O
3
,ZrO
2
,SiC)depositedonflexible
backingmaterial(paper,cotton,rayonpolyester).Matrix
madeofresins
Coatedabrasivesarealsousedasbeltsforhighrate
materialremoval.Beltspeeds~700 1800m/min
Lapping
Lap usually made of cast iron, copper, leather, or cloth
Abrasive particles are embedded in the lap
Dimensional tolerance ~ 0.0004 mm
Surface finish ~ 0.025 0.1 m
Lappingofflatandcylindricalsurfaces
Lapping
Silicon
chips
Heatsink
Honing
Honingprimarilygivesholesafinesurfacefinish
Honingtoolconsistsofasetofaluminiumoxideorsilicon
carbidebondedabrasivescalledstones
Stonesmountedonamandrelthatrotatesinahole
Honing
Surfacegrinding
Honing
Lapping
Polishing
Buffing
COMMERCIALABRASIVEMACHININGPROCESSES
Increasing
Surface
Roughness
Decreasing
material
removal rate
Kalpakjain p 1060
PROSANDCONSOFALLABRASIVEPROCESSES
Advantages
Veryprecisematerialremovepossible
Hightolerances
Verysmoothsurfaces
Disadvantages
Lowmaterialremovalrates
Complexshapesnotpossible