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Name :- Vala Vivek B.
Enrolment no.:- 150210119123
Sem :- 3rd (third)
Year :- 2016
Subject :- manufacturing process-1
Branch :- mechanical –B
Design Considerations:
- Design parts so that they can be held securely
- Avoid interrupted surfaces if high dimensional accuracy
is required because they can cause vibrations
- Ensure cylindrical parts are balanced and thick enough to
minimize deflections
- Short pieces may be difficult to grind accurately in
centerless grinding because of limited support by the
blade
- Parts requiring high accuracy form grinding should be
kept simple to prevent frequent wheel dressing
- Avoid small deep or blind holes or include a relief
Grinding
- Grains have irregular shapes and random
spacing
- Average rake angle is very negative (about
-60° or lower)
- Radial positions of grains vary
- Cutting speed is very high (ca. 600 ft/min)
Grinding machine
Types:
Attritious Grain Wear
Grains develop a wear flat
Grain Fracture
Necessary to produce sharp grain
edges
Bond Fracture
Allows dull grains to be dislodged
from the wheel
Grinding machine
Grinding machine
- Remove heat
- Remove chips, grain fragments and
dislodged grains
- Are usually water-based emulsions
- Are added by flood application
Uses fine abrasive grains in a slurry to
remove material from brittle workpieces by
microchipping and erosion
The tool vibrates at 20 kHz and a low
amplitude (.0125-.075 mm) which
accelerates the grains to a high velocity
Can create very small holes and slots
Design Considerations:
- Avoid sharp profiles, corners and radii; the
slurry erodes corners off
- Allow for slight taper for holes made this
way
- Support the exit end of holes being formed
with a backup plate to prevent chipping of
the holder
Grinding machine
Uses a rotating and vibrating tool to remove
material, as in face milling
Diamond abrasives are embedded in the
tool surface
Effective at producing deep holes in ceramic
parts at high MRR
Coated Abrasives
Abrasive grains are deposited on flexible
backing; they are more pointed than those
in grinding wheels
Common examples: sandpaper, emery
Grinding machine
Belt Grinding
Uses coated abrasives in the form of a
belt; cutting speeds are about 2500-6000
ft/min
Micro replication
Abrasives with a pyramid shape are placed
in a predetermined regular pattern on the
belt
Grinding machine
Clat
Crad
a
h
Plastic zone
Lateral cracks – remove material
Radial cracks – surface damage
Used mainly to improve the surface finish of
holes
Bonded abrasives called stones are
mounted on a rotating mandrel; also used
on cylindrical or flat surfaces and to
remove sharp edges on tools
Hole defects correctible by honing
Uses very low pressure and short strokes
Used to enhance surface finish and dimensional
accuracy of flat or cylindrical surfaces;
tolerances are on the order of .0004 mm; surface
finish can be as smooth as .025-.1 μm; this
improves the fit between surfaces
Abrasive particles are embedded in the lap or
carried in a slurry
Pressures range from 7-140 kPa depending on
workpiece hardness
Grinding machine
Grinding Lapping
Polishing
Produces a smooth, reflective surface
finish; done with disks or belts with fine
abrasive grains
Electro-polishing
Produces mirror-like surfaces on metals;
the electrolyte removes peaks and raised
areas faster than lower areas; also used
for deburring
Grinding machine
Polished disk drive heads compared to the size of a dime
Magnetic Float Polishing
A magnetic field pulls on the magnetic abrasive
fluid, floating the workpieces and pressing them
against a drive shaft; forces are very small and
controllable so the polish is very fine
Magnetic Field Assisted Polishing
The workpiece is rotated on a spindle and the
magnetic field oscillates, producing vibrations in
the magnetic abrasive fluid
Grinding machine
Burrs
Thin ridges (usually triangular) that form on
the workpiece edges during production;
can be detrimental to the part or its
function
Traditionally removed manually; can
account for up to 10% of the part
manufacturing cost
Vibratory and Barrel Finishing
Abrasive pellets are placed in a container
with the workpiece; the container is
vibrated or tumbled
Shot Blasting
Abrasive particles are propelled at the
workpiece at high velocity by an air jet or a
wheel
Abrasive Flow Machining
An putty-like substance with abrasive grains is
forced around and through the workpiece;
especially useful for pieces with internal spaces
that cannot be reached by other means
Thermal Energy
The workpiece is exposed to an instantaneous
combustion reaction; the burrs heat up much
more rapidly than the solid part and melt away
=>Manufacturing identification no.:-indicate the use
of abrasive
=>types of Abrasive :- eg. ‘A’ denoted by aluminum
oxide….
=>Grit size :- it’s between 6-600,fine grit-very fine
grit
=>Hardness of wheel :- it’s between A-Z,softest
grade-hardest grade
=>Structure / porosity of wheel :-it’s between 1-
20,high porosity-low porosity
=> materials :- eg.-
bondmaterial(V),rubber(R),shellac(E)…..etc.
Grinding machine

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Grinding machine

  • 1. Name :- Vala Vivek B. Enrolment no.:- 150210119123 Sem :- 3rd (third) Year :- 2016 Subject :- manufacturing process-1 Branch :- mechanical –B
  • 2. Design Considerations: - Design parts so that they can be held securely - Avoid interrupted surfaces if high dimensional accuracy is required because they can cause vibrations - Ensure cylindrical parts are balanced and thick enough to minimize deflections - Short pieces may be difficult to grind accurately in centerless grinding because of limited support by the blade - Parts requiring high accuracy form grinding should be kept simple to prevent frequent wheel dressing - Avoid small deep or blind holes or include a relief
  • 3. Grinding - Grains have irregular shapes and random spacing - Average rake angle is very negative (about -60° or lower) - Radial positions of grains vary - Cutting speed is very high (ca. 600 ft/min)
  • 5. Types: Attritious Grain Wear Grains develop a wear flat Grain Fracture Necessary to produce sharp grain edges Bond Fracture Allows dull grains to be dislodged from the wheel
  • 8. - Remove heat - Remove chips, grain fragments and dislodged grains - Are usually water-based emulsions - Are added by flood application
  • 9. Uses fine abrasive grains in a slurry to remove material from brittle workpieces by microchipping and erosion The tool vibrates at 20 kHz and a low amplitude (.0125-.075 mm) which accelerates the grains to a high velocity Can create very small holes and slots
  • 10. Design Considerations: - Avoid sharp profiles, corners and radii; the slurry erodes corners off - Allow for slight taper for holes made this way - Support the exit end of holes being formed with a backup plate to prevent chipping of the holder
  • 12. Uses a rotating and vibrating tool to remove material, as in face milling Diamond abrasives are embedded in the tool surface Effective at producing deep holes in ceramic parts at high MRR
  • 13. Coated Abrasives Abrasive grains are deposited on flexible backing; they are more pointed than those in grinding wheels Common examples: sandpaper, emery
  • 15. Belt Grinding Uses coated abrasives in the form of a belt; cutting speeds are about 2500-6000 ft/min Micro replication Abrasives with a pyramid shape are placed in a predetermined regular pattern on the belt
  • 17. Clat Crad a h Plastic zone Lateral cracks – remove material Radial cracks – surface damage
  • 18. Used mainly to improve the surface finish of holes Bonded abrasives called stones are mounted on a rotating mandrel; also used on cylindrical or flat surfaces and to remove sharp edges on tools
  • 20. Uses very low pressure and short strokes
  • 21. Used to enhance surface finish and dimensional accuracy of flat or cylindrical surfaces; tolerances are on the order of .0004 mm; surface finish can be as smooth as .025-.1 μm; this improves the fit between surfaces Abrasive particles are embedded in the lap or carried in a slurry Pressures range from 7-140 kPa depending on workpiece hardness
  • 24. Polishing Produces a smooth, reflective surface finish; done with disks or belts with fine abrasive grains Electro-polishing Produces mirror-like surfaces on metals; the electrolyte removes peaks and raised areas faster than lower areas; also used for deburring
  • 26. Polished disk drive heads compared to the size of a dime
  • 27. Magnetic Float Polishing A magnetic field pulls on the magnetic abrasive fluid, floating the workpieces and pressing them against a drive shaft; forces are very small and controllable so the polish is very fine Magnetic Field Assisted Polishing The workpiece is rotated on a spindle and the magnetic field oscillates, producing vibrations in the magnetic abrasive fluid
  • 29. Burrs Thin ridges (usually triangular) that form on the workpiece edges during production; can be detrimental to the part or its function Traditionally removed manually; can account for up to 10% of the part manufacturing cost
  • 30. Vibratory and Barrel Finishing Abrasive pellets are placed in a container with the workpiece; the container is vibrated or tumbled Shot Blasting Abrasive particles are propelled at the workpiece at high velocity by an air jet or a wheel
  • 31. Abrasive Flow Machining An putty-like substance with abrasive grains is forced around and through the workpiece; especially useful for pieces with internal spaces that cannot be reached by other means Thermal Energy The workpiece is exposed to an instantaneous combustion reaction; the burrs heat up much more rapidly than the solid part and melt away
  • 32. =>Manufacturing identification no.:-indicate the use of abrasive =>types of Abrasive :- eg. ‘A’ denoted by aluminum oxide…. =>Grit size :- it’s between 6-600,fine grit-very fine grit =>Hardness of wheel :- it’s between A-Z,softest grade-hardest grade =>Structure / porosity of wheel :-it’s between 1- 20,high porosity-low porosity => materials :- eg.- bondmaterial(V),rubber(R),shellac(E)…..etc.