2.

0 : GRINDING MACHINE (ADVANCED)

2.1: Three types of manufacturing grinding machine and the concept :a) Surface Grinding Machine Surface grinding machine is use to produced a smooth finish 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 workpiece, making a face of it flat or smooth. The surface grinder is composed of an abrasive wheel, a workholding device known as a chuck, and a reciprocating table. The chuck holds the material in place while it is being worked on. It can do this one of two ways: ferromagnetic pieces are held in place by a magnetic chuck, while non-ferromagnetic and nonmetallic pieces are held in place by vacuum or mechanical means. A machine vise (made from ferromagnetic steel or cast iron) placed on the magnetic chuck can be used to hold non-ferromagnetic workpieces if only a magnetic chuck is available. Factors to consider in surface grinding are the material of the grinding wheel and the material of the piece being worked on.

Diagram 2.1 (a) : Example of Surface Grinding Machine

Type of Surface Grinding Machine : Horizontal Spindle (Peripheral) Surface Grinder :- The periphery (flat edge) of the wheel is in contact with the workpiece, producing the flat surface. Peripheral grinding is used in high-precision work on simple flat surfaces, tapers or angled surfaces, slots, flat surfaces next to shoulders, recessed surfaces, and profiles.

Vertical Spindle (Wheel-Face) Grinder :- The face of a wheel (cup, cylinder, disc, or segmental wheel) is used on the flat surface. Wheel-face grinding is often used for fast material removal, but some machines can accomplish high-precision work. The workpiece is held on a reciprocating table, which can be varied according to the task, or a rotary-table machine, with continuous or indexed rotation. Indexing allows loading or unloading one station while grinding operations are being performed on another.

Disc Grinder and Double Disc Grinder :- Disc grinding is similar to surface grinding, but with a larger contact area between disc and workpiece. Disc grinders are available in both vertical and horizontal spindle types. Double disc grinders work both sides of a workpiece simultaneously. Disc grinders are capable of achieving especially fine tolerances.

b) Cylinder Grinding Machine

Diagram 2.1 (b) : Cylinder Grinding Machine.

The cylindrical grinder is a type of grinding machine used to shape the outside of an object. The cylindrical grinder can work on a variety of shapes, however the object must have a central axis of rotation. This includes but is not limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft.

4 essential action of Cylinder Grinding Machine are shown below :-

i. ii. iii. iv.

The work (workpiece) must be constantly rotating. The grinding wheel must be constantly rotating. The grinding wheel is fed towards and away from the work. Either the work or the grinding wheel is traversed with the respect to the other.

Type of Cylindrical Grinding Machine : Outside Diameter Grinding (OD) Inside Diameter Grinding (ID) Plunge Grinding Creep Feed Grinding

c) Non-Central Grinding Machine

A method of material removal through grinding, similar to centered grinding except for the absence of the spindle. It has high throughput for example a large number of parts can be manufactured in a short time.

The workpiece is set up between the regulating wheel (or back up wheel) and the grinding wheel, and is supported by the work blade or work rest. The work rest is located between the wheels. The work is placed on the work rest, and the latter together with the regulating wheel is fed forward forcing the work against the grinding wheel. Axial movement of the work past the grinding wheel is accomplished by tilting the regulating wheel at a slight angle from horizontal. An angular adjustment of 0 to 8 or 10 degrees is provided in the machine for this purpose.

Classified into two types :i. Throughfeed grinding - the workpiece is fed into the machine along the work blade.

ii.

Plunge grinding - the workpiece is placed between the wheels on a work blade and the grinding wheel is plunged into the workpiece.

Diagram 2.1 (c) : Close up image of grinding wheel and backup wheel.

2.2: The main difference between horizontal spindle surface grinding machine and vertical spindle surface grinding machine. Vertical Spindle Cup shape grinding wheel Wheel face is used for fast material removal Wheel grinding using side to cut work piece High cutting feed Can be varied according work task Horizontal Spindle Disk shape grinding wheel Using surface wheel grinding to cut workpiece Use in high-precision work Low cutting feed Just work on simple flat surface

2.3 : Working Principle Of Chuck Magnet

A chuck is a specialized type of clamp used to hold an object usually an object with radial symmetry, especially a cylindrical object. It is most commonly used to hold a rotating tool such as the drill bit in a power tool or a rotating workpiece such as the bar or blank in the headstock spindle of a lathe machine.

Some chucks can also hold irregularly shaped objects ones that lack radial symmetry. In some applications, the tool or workpiece being held by the chuck remains stationary while another tool or workpiece rotates for example, a drill bit in the tailstock spindle of a lathe, or a round workpiece being milled by a milling cutter.

Chuck Magnet - used for holding ferromagnetic workpieces, a magnetic chuck consists of an accurately centered permanent magnet face. Electromagnets or permanent magnets are brought

into contact with fixed ferrous plates, or pole pieces, contained within a housing. These pole pieces are usually flush with the housing surface. The part (workpiece) to be held forms the closing of the magnetic loop or path, onto those fixed plates, providing a secure anchor for the workpiece.

Diagram 2.3 (a) : Permanent Magnetic Chuck

Diagram 2.3 (b) : Rectangular Permanent Magnetic Chuck.

2.9 Determine the manufacturing rate per hour for Non-central grinder when it is known that component length in (mm) and feed rate in (mm/s) : manufacturing rate per hour = (3600F)/L
Subject: Speeds and Feeds for Milling, Turing and Drilling This analysis of speeds and feeds are based on the class text "Machine Tool and Manufacturing Technology," Steve F.Krar, Mario Rapisarda, Albert F. Check. This review is not complete for it covers Speeds and Feeds for Milling only, Drilling and Turning will be added later. Milling calculation of Speeds and Feeds are the most complex. A full understanding how to develop these speeds and feed should help when reading the text and working Drilling and Turing computations (Ref. Pg. 193-196 Drilling, 234237 Turning). Whether the machine operation is Milling, Turing (Lathe), Drilling or Grinding the selection of the proper speed and feed is probably the most difficult thing for the machinist due to so many variables. An experienced machinist can often set speed and feed that will work and get the job done but this may not always be the most efficient. To be efficient the cutting speeds and feeds should be coordinated, using mathematic calculation as a "bench mark." For example during the machining process heat is generated. In proper machine practice the heat should be transfer to the chip away from the workpiece and the cutting tool. This can be accomplished by having the workpiece held rigid, a sharp tool, the speeds and feeds coordinated and coolant if needed. Also by calculating the feed "time estimates" can be made prior to scheduling and releasing the work to the shop. Before predetermine speed and feed are calculated the following items should be known. 1) The rigidity of the machine. 2) The horse power available at the cutter. 3) The RPM and Feed of the machine. The material type of the cutter, high speed steel (HSS) or carbide for example. 4) The type of material and the condition of the material to be machined. (Note: Raw ferrous material will often be harder on the outside and softer toward the center and the feeds and speeds may need to be adjusted).

5) The size of material to be machine (if the workpiece is thin or small the cutting speeds and feeds may need to be modified). The text does not include the above items in the mathematical calculations of speed and feed. They are theoretical and show computation that maybe greater than the machine scheduled to perform the work is capable of. For example the milling machines use in Cerritos College Machine Shop Lab maximum feeds is 9 to 12 inches per minute. Here the calculations need to be adjusted to match the designated machine feeds and speeds. If the calculated speed and feed are substantially more than the scheduled machine the possibly of a machine with faster speeds and feeds should be considered. It is machine shop practice that two types of cuts should be made; rough and finish cuts. Rough cuts should use maximum speeds, feeds and depth of cut. Finish cuts the RPM can remain the same but the feed slowed and the depth of cut set at minimum of material removal. Also smaller depth of cuts and additional passes may be needed to hold the required tolerances or surface finish. Often rough cuts are made by "Conventional milling." Two disadvantages to this type of machining, the tooth enters the cut at zero chip thickness in an upward direction and can lift the workpiece if not held securely. Also the conventional milling finish normally is not a clean cut. Finish cuts on the other hand are made by "Climb milling." Climb milling can also be used to take rough cuts but the machine must be in good condition and rigid to keep the table from jumping forward. For finish cuts the RPM can remain the same but the feed slowed and the depth of cut set at minimum of material removal. The cutting speed or surface speed is based on the peripheral linear speed of the mill cutter. This should not be confused with RPM. The cutting speed is a factor used to find the RPM. The larger the diameter of the cutter the greater (peripheral) surface speed of the tool. For example if two persons are at each end of a 6 foot pole and one starts to run in a circle, the other stays in the center the speed of the runner out side will be much faster speed than the one in the center. Review of the text formulas. Formula to Find r/min (revolutions Per Minute (RPM) of the mill cutter)

Formula to find the mill table feed in inches per minute.

Walking through the text example; Ref. Pg. 327. 1. Calculate the RPM (r/min) to machine a keyway on a shaft 1 wide. 2. Cutter 1 wide 4 diameter high-speed steel (HSS). Note: the authors do not note the exact type of cutter used to form the keyway and no illustration is given. A cutter 1 wide 4 diameter is more than likely to big to be a Woodruff Key cutter and maybe a Staggered-tooth or a Plain Side Milling cutter on a Stub arbor. Cutting Speed 80. Here the authors used a cutting speed of 80 which falls within the center of the Machine Steel 70100.

Ref. Text Example, to find the r/min do the following: 80 (CS) X 4 (Constant) = 320 4 (Dia.) =80 RPM

2nd example: 1. Calculate the RPM (r/min) to machine aluminum using a (.750) HSS end mill. 2. Cutting Speed 600. Here the authors used a cutting speed of 600 which falls within the lower part of the CS of the aluminum 500-1000. Ref. To find the r/min do the following: 600 (CS) X 4 (Constant) = 2400 .750 (Dia. 3/4) = 3200 RPM. To calculate the feed (Note: the authors only give one example for feed and this illustration may not be for the key cutter example).

The authors note that the cutter is a 4, 12-tooth helical HSS tool. Ref. To find the feed do the following: 12 (N) X 0.010 X 80 (RPM) = 9.6 in/min. Here the feed should be rounded to the machine feeds. The above text example is a simplified system of calculating and can be used for quick RPM and Feeds. For quantity productions runs and machine parts computer programming a more in depth calculations should be made. There are many sources that have made in depth studies on machining. Perhaps the most ready available is the Machinerys Handbook or SMEs Tool and Manufacturing Engineers Handbook. By no means are the above the last word on speeds and feeds, other resource should also be considered.