Grinding wheel

SHAPES AND SIZE OF A GRINDING WHEEL

Straight Wheel

These are generally used for cylindrical, internal, centreless and surface grinding operations. These wheels vary in size, diameter and width of the face.

It is also a straight wheel but its free is slightly tapered to facilitate the grinding of threads an gear teeth.

Type 5. It is used for surface grinding, i.e. production of flat surfaces. Grinding takes place with the help of face of the wheel.

Type 6. It is used for grinding flat surfaces with the help of face of grinding wheel.

Type 7 used in grinding of tools in tool room.

Type 8. It is used for sharpening of circular or band saw.

Type 9. These are normally on vertical spindle, rotary type and reciprocating type surface grinders

Type 10. It is also used for grinding of tools in tool room. It is capable to grind very narrow places due to its thinners.

Coding of a Grinding Wheel

The Indian Standard Coding system of grinding wheel is IS : 551-1954. It providesuniform system of coding of grinding wheels to designate their various characteristics. It gives a general indication of the hardness and grit size of any wheel as compared with another. Coding of a grinding wheel consists of six symbols as described below

Generally abrasive properties like hardness, toughness and resistance to fractureuniformly abrasives are classified into two principal groups :(a) Natural abrasives, and(b) Artificial abrasives.

Natural Abrasives

sand stone (solid quartz) These are relatively soft. These cannot be used for grinding of hard material and at faster speed.

Emery is a natural aluminium oxide containing 55 to 65% alumina, rest are iron oxide and impurities.

Corundum : If percentage of aluminium oxide is more, ranging from 75 to 95% then it is called corundum.

Diamond is not recommended to use as abrasive due to its cost in effectiveness.

Artificial Abrasives

Silicon Carbide

It is also called carbornudum. It is manufactured from 56 parts of silica sand, 34 parts of powdered cake, 2 pats of salt, 12 parts of saw dust in a long rectangular electric furnace of resistance type

There are two types of silicon carbide abrasive, green grit with approximately 97% silicon carbide black grit with approximately 95% silicon carbide. It is less harder than diamond and less tough than aluminium oxide.

It is used for grinding of material of low tensile strengthlike cemented carbide, stone and ceramic, gray cast iron, brass, bronze,aluminium vulcanized rubber, etc.

Aluminium Oxide

It is prepared by heating mineral bauxite, a hydrated aluminum oxide clay containing silica, iron oxide, titanium oxide mixed with ground coke and iron borings in a arc type electric furnace.

preferred for grinding of materials of higher tensile strengths like steel; high carbon and high speed steel and tough bronze

Coarse 10 12 14 16 20 24 -

Medium 30 36 46 54 60 - -

Fine 80 100 120 150 180 - -

Very Fine 220 240 280 320 400 500 600

Grits: The grain or grit number indicates in a general way the size of the abrasive grains used in making a wheel, or the size of the cutting teeth, since grinding is a true cutting operation.

Grain size is denoted by a number indicating the number of meshes per liner inch (25.4 mm) of the screen through which the grains pass when they are graded after crushing.

The following list ranging from very coarse to very fine includes all the ordinary grain sizes commonly used in the manufacture of grinding wheels.

Grade: The term "grade" as applied to a grinding wheel refers to the tenacity or hardness with which the bond holds the cutting points or abrasive grains in place. It does not refer to the hardness of the abrasive grain. The grade shall be indicated in all bonds and processes by a letter of the English alphabet. A denoting the softest and the letter Z denoting the hardest grade. The term "soft" or "hard" refer to the resistance a bond offers to disruption of the abrasives. A wheel from which the abrasive grains can easily be dislodged is called soft whereas the one which holds the grains more securely is called hard. The grades are denoted below.

Structure: Abrasive grains are not packed tightly in the wheel but are disturbedThrough the bond. The relative spacing is referred to as the structure and denoted by the number of cutting edges per unit area of wheel face as well as by number and size of void spaces between grains.

The primary purpose of structure is to provide clearance of chip and it may be open or dense.

The structure commonly used is denoted by numbers as follows.

BondsA bond is an adhesive material used to held abrasive particals together; relatively stable that constitute a grinding wheel. Different types of bonds are :(a) Vitrified bond,(b) Silicate bond,(c) Shellac bond, (d) Resinoid bond,(e) Rubber bond, and(f) Oxychloride bond.

Vitrified BondThis bond consists of mixture of clay and water. Clay and abrasives arethoroughly mixed with water to make a uniform mixture. The mixture is mouldedto shape of a grinding wheel and dried up to take it out from mould. Perfectlyshaped wheel is heated in a kiln just like brick making. It this way clay vitrifiesand fuses to form a porcelain or glass grains. High temperature also doesannealing of abrasive. This wheel posses a good strength and porosity to allowhigh stock removal with coal cutting. Disadvantage of this type of wheel are, it issensitive for heat, water, oil and acids. Their impact and bending strengths are also low. This bond is denoted by symbol ‘V’ in specification.

Silicate BondSilicate bonds are made by mixing abrasive particals with silicate and soda orwater glass. It is moulded to required shape, allowed to dried up and then takenout of mould. The raw moulded wheel is baked in a furnace at more than 200oCfor several days. These wheel exhibits water proofing properly so these can beused with coolant. These wheels are denoted by ‘S’ in specification.

Shellac BondThese are prepared by mixing abrasive with shellac than moulded by rolling andpressing and then by heating upto 150oC for several hours. This bond exhibitgreater elasticity than other bonds with appreciable strength. Grinding wheelshaving shellac bond are recommended for cool cutting on hardened steel and thin sections, finishing of chilled iron, cast iron, steel rolls, hardened steel cams and aluminium pistons. This bond is denoted by ‘E’ in specifications

Resinoid BondThese bonds are prepared by mixing abrasives with synthetic resins like backeliteand redmanol and other compounds. Mixture is moulded to required shape andbaked upto 200oC to give a perfect grinding wheel. These wheels have good grinding capacity at higher speed. These are used for precision grinding of cams, rolls and other objects where high precision of surface and dimension influence the performance of operation. A resinoid bond is denoted by the letter ‘B’.

Rubber BondRubber bonded wheels are made by mixing abrasives with pure rubber andsulpher. After that the mixture is rolled into sheet and wheels are prepared bypunching using die and punch. The wheels are vulcanized by heating then infurnace for short time. Rubber bonded wheels are more resilient and have largerabrasive density. These are used for precision grinding and good surface finish.Rubber bond is also preferred for making thin wheels with good strength andtoughness. The associated disadvantage with rubber bond is, these are lesser heatresistant. A rubber wheel bonded wheel is denoted by the letter ‘R’.

Oxychloride BondThese bonds are processed by mixing abrasives with oxides and chlorides ofmagnesium. The mixture is moulded and baked in a furnace to give shape of agrinding wheel. These grinding wheels are used for disc grinding operations. Anoxychloride bonded wheel is specified the letter ‘O’.

Selection of Grinding Wheel

1.Type of metal on which grinding is required Abrsasive

Metal of low tensile strength – Silicone carbide Metal of high tensile strength- Aluminium oxide

Grain Size

Low cut /Better surface finish – fine grainRough cut/ deep cut- Coarse / Medium grain

• Grade Soft metals- High grade Hard metals – Low grade • StructureSoft metals- open structure Hard metals – Dense structure

• Bond high cut – vitrified bond High finish – shellac bond parting – resinoid / Rubber

2.Amount of metal to be removed High cut – Rough / coarse – medium Grain Low cut – Fine grain/ Dense structure

3. Accuracy of size & finish - On grain size/bond- Rough cut / low finish – coarse grain/ vitrified

bond- High finish – Resonoid / shellac / Rubber bond

4.Area of contact Greater area – Soft Grade Smaller area – High grade / Soft grade

5. Types of machine Heavy Machine – Low vibration – Soft wheelSmall machine – hard wheel6. Speed of wheel200m/s or lesser – vitrified bondHigher speed – resinoid bond

GLAZING AND LOADING, THEIR EFFECTS, CAUSES AND REMEDIES

When the surface of a grinding wheel develops a smooth and shining appearance, it is said to be glazed. (Fig 1)

This indicates the abrasive particles on the wheel face are not sharp.

These are worked down to bond level

• Loading When soft materials like

aluminium, copper, lead, etc. are ground the metal particles get clogged between the abrasive particles. This condition is called loading. (Fig 2)

The effects of a glazed or a loaded grinding wheel are almost the same.

MOUNTING THE GRINDING WHEELS

1. All wheels should be closely inspected just before mounting to make sure that they have not been damaged in transit, storage, or otherwise.

The wheel must first be subjected to the ringing test. For this purpose, the grinding wheel is put on an arbor while it is subjected to slight hammer blows. A clear, ringing, vibrating sound must be heard. If a grinding wheel contains fine cracks, discordant sound that fail to vibrate will be emitted. This test is applicable to vitrified and silicate wheels. Shellac, resinoid or rubber loaded wheels will not ring distinctly.

2. The abrasive wheels should have an easy fit on their spindles or locating spigots. They should not be forced on.

3. The hole of grinding wheels mostly is lined with lead. The lead liner bushes should not project beyond the side of wheels.

4. There must be a flange on each side of the wheel. The mounting flanges must be large enough to hold the wheel properly, at least the flange diameter must be equal to the half of the grinding wheel diameter. Both the flanges should be of the same diameter, other-wise the wheel is under a bending stress which is liable to cause fracture.

5. The sides of the wheel and the flanges which clamp them should be flat and bear evenly all round

6. All flanges must be relieved in the center so that the flanges contact the wheel only with the annular clamping area. If they are not properly relieved, the pressure of the flanges is concentrated on the sides of the wheel near the hole, a condition which should be avoided.

7. Washers of compressible materials such as card board, leather, rubber, etc. not over 1.5 mm thick should be fitted between the wheel and its flanges. In this way any unevenness of the wheel surface is balanced and a tight joint is obtained. The diameter of washers may be normally equal to the diameter of the flanges.

8. The inner fixed flange should be keyed or otherwise fastened to the spindle, whereas the outer flange should have an easy sliding fit on the spindle so that it can adjust itself slightly to give a uniform bearing on the wheel and the compressible washers.

9. The nut should be tightened to hold the wheel firmly. Undue tightness is unnecessary and undesirable as excessive clamping strain is liable to damage the wheel.

10. The wheel guard should be placed and tightened before the machine is started for work.

Dressing removes loading and breaks away the glazed surface so that sharp abrasive particles are again presented to the work. This is done with various type of dressers. A common type of wheel dresser, known as the star-dresser,

Dressing

• For precision and high finish grinding, small industrial diamonds, known in the trade as bors, are used. The diamond or group of diamonds is mounted in a holder. The diamond should be kept pointed, since only the point can be used for cutting. This is done by the holder down at a 15° angle and using a new surface each time the wheel is dressed. A good supply of coolant should be used when dressing with a diamond, as overheating can cause the diamond to fracture or drop out of its setting. Very light cuts only may be taken with diamond tools.

• Truing : Truing is the process of changing the shape of

the grinding wheel as it becomes worn from an original shape, owing to the breaking away of the abrasive and bond. This is done to make the wheel true and concentric with the bore, or to change the face contour for form grinding. Truing and dressing are done with the same tools, but not for the same purpose

The only satisfactory method of truing a wheel is by the use of a diamond tool in a similar manner as explained before. In turning a wheel with a diamond, the feed rate must not exceed 0.02 mm, otherwise grooves may be cut into the wheel

BALANCING GRINDING WHEELS If wheels become out of balance through wear

and cannot be balanced by truing or dressing, they should be removed from the machine and discarded. Wheels should be tested for balance occasionally and re balanced if necessary-Wheels that are out of balance not only produce poor work but may put undue strains on the machine. Small wheels may be balanced by milling a short recess on the inside of the flanges and filling with lead.

Large wheels should be placed on a balancing stand and balanced by moving weights around a recessed flange. Now-a-days, grinding wheel mounts are provided with devices to enable balancing to be done whilst the wheel is running and between grinding operations

COMMON DEFECTS (FAULTS) IN GRINDING AND THEIR REMEDIES

Fault Symptom Caused by Remedies

Chtter marks Intermittent

sparking Uneven

sound.

Wheel out of balance Re-balance the

wheel

Glazing of wheel Incorrect grade of

wheel

Change the wheel

Work piece (or) work

hold ing device loose.

Secure both properly.

Wheel in correctly

dressed.

Re-dress the wheel

Loose pulley on

spindle.

Tighten the pulley.

Uneven cutting

and irregular

sparking.

Feed too coarse. Decrease the feed

rate.

Machine vibration. Improper bedding

down.

Report to your

supervisor.


Scratched

surface.

Incorrect grain size of

wheel.

Change to correct

grain size

Dirty coolant. Clean the tank and

replace.

Poor Surface finish. Surface

burnished.

Incorrect wheel grade Fit a correct wheel

Feed too coarse. Reduce the feed.

Cut too deep. Decrease the depth

of cut.

Insufficient coolant. Increase the supply

of the coolant.


Ridges Wheel damaged/not

properly dressed.

Change the wheel if

necessary or dress

the wheel

Wheel wearing

out

Wheel size reduced Wheel is too soft Use harder wheel.

Grinding wheel speed

lower than that

recommended.

Increase the wheel

speed to the

recommended

speed

Wrong rate of traverse

or work speed.

Reduce the rate of

traverse and work

speed and.

decrease slightly

the depth of cut

CUTTING FLUIDS

Recommended cutting fluidsSoluble mineral oil and pure water are mixed in the ratio of 1:40 or 50 (depending upon the grinding wheel) and is used for grinding the following materials.

oCast iron or hardened steeloSoft steeloConnected carbide tools (using silicon wheel)

In India we use IOC Servocut oils as cutting fluid.There is a special grade oil manufactured by IOC for grinding alone. It is called Servocut - clear.

Important points to be noted while using cutting fluids•Always add pure water to soluble oils•Always the coolant should be kept clean Periodically clean the coolant tank.•Do not allow soluble oil to mix with other oils. •Always mix water to the oil in correct proportion and not oil to the water.•It should be kept cool under normal temperature.Use suitable splash guard so that the operator is protected from the splash of the fluid.

Grinding allowance

Machine parts are processed in different machines such as lathes,

shaping machines, milling machines, etc. in such a way that their final dimensions have some stock left, which is finished during the grinding operation. The amount of this stock left is called the 'grinding' allowance. No definite value of the grinding allowance can be given as a general rule because this depends upon too many variable

factors. In general it varies from-0.2 mm to 0.50 mm.