PRECISION GRINDING

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 PRECISION GRINDING
Precision grinding is used in engineering to
produce very accurate and smooth surface
finishes on many different types of
components. Most grinding procedures can
produce work to an accuracy of one thousand
of a millimetre. (0.001mm)

Precision grinding is a finishing process, this

means that the work piece has being pre-
machined using other machines such as the
lathe or milling machine before being ground
to the finish dimensions
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 PRECISION GRINDING
There are four types of precision grinding
techniques that are commonly used

1. Surface grinding:

2. Cylindrical grinding:

3. Internal grinding:

4. Centreless Grinding:
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 SURFACE GRINDER
Surface grinding: is used to produce flat surfaces. The work is
usually held by a magnetic chuck, the table moves back & forth, in
& out while the grinding wheel rotates at a very high speed.

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 CYLINDRICAL
GRINDER
Cylindrical grinding: is used to produce cylindrical shapes. The
work is held either in a chuck or is held between centres, the work
rotates at a constant speed, the grinding wheel rotates at a very high
speed.

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 INTERNAL GRINDING
Internal Grinding: is used to produce internal diameters. The work is
held in a chuck which rotates at a constant speed, the grinding wheel
rotates at very high speed.

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 CENTRELESS
GRINDING
Centreless grinding, the work is not held
between centres or in a chuck. The work is
held against the face of the grinding wheel
by the combined action of a supporting rest
and a control wheel. Centreless grinding is
used to finish engine valves, morse tapers

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 GRINDING
Before any type of precision
grinding takes place, the
following should be done.
1. Select the correct type of
grinding wheel.
2. The grinding wheel has to be
balanced.
3. The grinding wheel should be
dressed.
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 GRINdING WHEEL
BALANCING
If the wheel is not balanced it will
cause the spindle that the wheel is
mounted on to vibrate which will give
a poor surface finish.
 WHEEL SELECTION
Grinding wheel selection depends on
the type of material being worked,
hard or soft material.
 GRINDING WHEELS
& DRESSING
The wheel is dressed by turning it on
and moving a diamond dressing tool.
Wheel dressing will renew a sharp
cutting face and correct irregularities
such as wheel concentricity, loaded
and glazed wheels.

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 GRINDING WHEEL
FAULTS
During the grinding process there are two main
faults that can occur:

Loading: occurs when small particles of the metal

being machined clog up the spaces (voids)
between the abrasive grains in the grinding wheel.

Glazing: occurs when abrasive particles which have

lost there cutting edge fail to break away and
remain trapped in the grinding wheel.

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 WHEEL MAKE-UP
There are basically three parts that
make up a grinding wheel:
The abrasive: does the actual
cutting
The bond: holds the abrasive
together in the form of a wheel.
The voids. Spaces within the wheel,
little air pockets

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 PARTS OF A GRINDING
WHEEL
Voids

Bond

Abrasive

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 WORK HOLDING
magnetic chuck
Most work is held firmly in place on
the surface grinder by using a
magnetic chuck.
To use the magnetic chuck, the
material has to be magnetic.
The work must have a flat surface
so that it will make good contact
with the surface of the magnetic
chuck.
Both the surface of the chuck
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MAGNETIC CHUCK

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 COOLANT
Coolant is nearly always used during
any of the precision grinding
processes mentioned.
It prevents the work from burning as
the wheel cuts the work piece.
It flushes away the waste material.

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Pedestal/Bench Grinding
Machine
Safety features include:

Large clear guard encloses

machining.
Machine will not run when guard is
not in place.
Emergency stop on the front of the
machine.
Programme must have test run
before machining.
 Question 7 (b) 2008

The process of grinding wheel dressing is illustrated below:

(i) Outline the reasons for wheel dressing a grinding wheel;
(ii) Differentiate between the loading and glazing of a grinding
wheel.
Question 7 (c) 2007

Describe, with the aid of a diagram, any one of the following:

(i) Surface grinding;
(ii) Cylindrical grinding.

Question 7 (c) 2006

(i) Explain the function of the bond in a grinding wheel;

(ii) Identify two safety features incorporated into a pedestal
grinding machine;

Question 7 (a) 2004

With reference to the diagram shown below:

(i) Name and describe the machining process;
(ii) Explain a method of work holding;
(iii) Give one suitable application.

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 Question 7(b) 2009

Cutting tool materials include high carbon steel, high speed steel and
tungsten carbide.
The effect of increased machining temperatures on the hardness of
cutting tool materials A and B is shown.
(i) Suggest a suitable cutting tool material for A and a suitable
cutting tool material B.
(ii) Outline two methods of prolonging cutting tool life.
(iii) State three advantages of using the cutting tool shown below in a
turning operation.

Question 7 (c) 2008

(i) Outline two factors that influence the amount of heat generated in a
machining operation;
(ii) Identify two safety issues associated with machining mild steel;
(iii) Rake angle and clearance angle;
(iv) Distinguish between orthogonal and oblique cutting forces.

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