IES 1996

Grinding & FinishingBy S K MondalProcessFeaturesGrindingUses wheels, accurate sizing, finishing, low MRR; can be done at high speeds .Creep feed grindingUses wheels with long cutting arc, very slow feed rate and large depth of cutAbrasive machiningHigh MRR, to obtain desired shapes and approximate sizesAbrasive water jet MachiningWater jets with velocities up to 1000 m/sec carry abrasive particles (silica and garnet)Honing"Stones" containing fine abrasives; primarily a hole - finishing processLappingFine particles embedded in soft metal or cloth; primarily a surface-finishing processAbrasive Machining ProcessesVideo3GrindingGrinding is the most common form of abrasive machining. It is a material cutting process which engages an abrasive tool whose cutting elements are grains of abrasive material known as grit. These grits are characterized by sharp cutting points, high hot hardness, and chemical stability and wear resistance. The grits are held together by a suitable bonding material to give shape of an abrasive tool. Grinding can be compared with milling with an infinite number of cutting edge.4

Fig- cutting action of abrasive grainsWhy is high velocity desired in grinding?It is desired to off set the adverse effect of very high negative rake angle of the working grit, to reduce the force per grit as well as the overall grinding force.6Advantages of GrindingDimensional accuracyGood surface finishGood form and locational accuracyApplicable to both hardened and unhardened material

7Applications of Grinding Surface finishingSlitting and partingDescaling, deburringStock removal (abrasive milling)Finishing of flat as well as cylindrical surfaceGrinding of tools and cutters and resharpening of the sameConventionally grinding is characterized as low material removal process capable of providing both high accuracy and high finish. However, advent of advanced grinding machines and grinding wheels has elevated the status of grinding to abrasive machining where high accuracy and surface finish as well as high material removal rate can be achieved even on an unhardened material.8Video9On which factors does the transverse roughness of workpiece depend during grinding?It mainly depends on the shape of the grits and overlap cuts made by the grits in the transverse direction. Lateral plastic flow of the material as a result of ploughing also influences the surface roughness.

10GrindingIf each abrasive grain is viewed as a cutting tool then in grinding operation.HighRake angle can be positive, zero, or negative ranging from +45o to -60o, dull, rounded grits has large negative rake angleCutting speed is very high Very high specific energy of cuttingLowLow shear angleLow feed rateLow depth of cut

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Interaction of the grit with the workpieceShape of grit is very important because it determines the grit geometry e.g. rake and clearance angle.The grits do not have definite geometry unlike a cutting tool.12

Interaction of the grit with the workpieceGrit with favourable geometry can produce chip in shear mode.However, grits having large negative rake angle or rounded cutting edge do not form chips but may rub or make a groove by ploughing leading to lateral flow of the workpiece material.

Fig- Grits engage shearing, ploughing and rubbing

13How is chip accommodation volume is related to material removal rate?Volume of chip accommodation space ahead of each grit must be greater than the chip volume produced by each grit to facilitate easy evacuation of the chip from the grinding wheel.

14Specific energy consumption in grinding

15How may the specific grinding energy vary with material removal rate in grinding?Specific grinding energy will start decreasing with material removal rate because rake angle of the grit becomes more favourable with increase of grit depth of cut. However, if increase of material removal rate causes chip accommodation problem in the available inter-grit space then specific energy may increase.

16G RatioThe grinding ratio or G ratio is defined as thee cubic mm of stock removed divided by the cubic mm of wheel lost.

In conventional grinding, the G ratio is in the range 20: 1 to 80: 1.

The G ratio is a measure of grinding production and reflects the amount of work a wheel can do during its useful life.

As the wheel losses material, it must be reset or repositioned to maintain workpiece size.

The lass of grains from the wheel means that the wheel is changing size. The grinding ratio or G ratio is defined as thee cubic mm of stock removed divided by the cubic mm of wheel lost.

In conventional grinding, the G ratio is in the range 20: 1 to 80: 1.

The G ratio is a measure of grinding production and reflects the amount of work a wheel can do during its useful life.

As the wheel losses material, it must be reset or repositioned tomaintain workpiece size.

17GATE -2011 (PI)Grinding ratio is defined as

Ans. (b)18Parameters for specify a grinding wheel 1)The type of grit material2)The grit size3)The bond strength of the wheel, commonly known as wheel hardness4)The structure of the wheel denoting the porosity i.e. the amount of inter grit spacing5)The type of bond material6)Other than these parameters, the wheel manufacturer may add their own identification code prefixing or suffixing (or both) the standard code.

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The number 51 is manufacturers identification number indicating exact kind of abrasive used. The letter A denotes that the type of abrasive is aluminium oxide. In case of silicon carbide the letter C is used. The number 60 specifies the average grit size in inch mesh. For a very large size grit this number may be as small as 6 where as for a very fine grit the designated number may be as high as 600. The letter K denotes the hardness of the wheel, which means the amount of force required to pull out a single bonded abrasive grit by bond fracture. The letter symbol can range between A and Z, A denoting the softest grade and Z denoting the hardest one. The number 5 denotes the structure or porosity of the wheel. This number can assume any value between 1 to 20, 1 indicating high porosity and 20 indicating low porosity. The letter code V means that the bond material used is vitrified. The codes for other bond materials used in conventional abrasive wheels are B (resinoid), BF (resinoid reinforced), E(shellac), O(oxychloride), R(rubber), RF (rubber reinforced), S(silicate) The number 05 is a wheel manufacturers identifier.

20Abrasive MaterialComments and UsesAluminium oxide

Softer and tougher than silicon carbide; use on steel, iron, brassSilicon carbide

Used for brass, bronze, aluminum, stainless steel and cast ironcBN (cubic boron nitride)

For grinding hard, tough tool steels, stainless steel, cobalt and nickel based superalloys, and hard coatingsDiamond

Used to grind nonferrous materials, tungsten carbide and ceramics21IES 20092 marks

Why is aluminium oxide preferred to silicon carbide in grinding steel? Al2O3 is tougher than SiC. Therefore it is preferred to grind material having high tensile strength like steel. Moreover, Al2O3 shows higher chemical inertness than SiC towards steel leading to much improved wear resistance during grinding.

23Grit sizeThe grain size affects material removal rate and the surface quality of workpiece in grinding.Large grit- big grinding capacity, rough workpiece surfaceFine grit- small grinding capacity, smooth workpiece surface

24Why does single layer grinding wheel show progressive rise of force during grinding of high speed steel?The geometry of grit undergoes irreversible change in the form of rounding or flattening due to wear caused by rubbing action of hard carbides present in high speed steel.

25GradeThe worn out grit must pull out from the bond and make room for fresh sharp grit in order to avoid excessive rise of grinding force and temperature. A soft wheel should be chosen for grinding hard material. A hard wheel should be chosen for grinding soft material.

On the other hand, during grinding of low strength soft material grit does not wear out so quickly. Therefore, the grit can be held with strong bond so that premature grit dislodgement can be avoided.26Structure / concentrationThe structure should be open for grinding wheels engaged in high material removal to provide chip accommodation space. The space between the grits also serves as pocket for holding grinding fluid. Dense structured wheels are used for longer wheel life, for holding precision forms and profiles.

27Why is coarse grain and open structured wheel is preferred for stock removal grinding?Coarse grit allows large grit protrusion and open structure provides large inter grit chip space. Thus in combination those two provide large space for chip accommodation during stock removal grinding and risk of wheel loading is minimized.

28Bonding Materials for Grinding wheelsType of BondAttributesVitrified bondsComposed of clays and other ceramic substances, porous, strong, rigid, and unaffected by oils, water, or temperature. Brittle and can not be used for high wheel speed.Resinoid, or phenolic resinsPlastic bond, replaced shellac and rubber wheels, not with alkaline grinding fluid.Shellac bondFor flexible cut off wheels, replaced by resin bond.29Bonding Materials for Grinding wheelsType of BondAttributesRubber bondFor use in thin wheels, replaced by resin bond.Oxychloride bondLimited use.Metal bondExtensively used with super abrasive wheels, high toughness, high accuracy, large stock removal.Electroplated bondUsed for small wheel, form wheel and thin super abrasive wheels, for abrasive milling and ultra high speed grinding. Replace by electroplated bond 30Bonding Materials for Grinding wheelsVitrified bondsThey are composed of clays and other ceramic substances. Vitrified wheels are porous, strong, rigid, and unaffected by oils, water, or temperature over the ranges usually encountered in metal cutting. The operating speed range in most cases is 1500 to 5000 m/min.

Bonding material is a very important factor to be considered in selecting a grinding wheel. It determines the strength of the wheel, thus establishing the maximum operating speed. It determines the elastic behavior or deflection of the grits in the wheel during grinding. The wheel can be hard or rigid, or it can be flexible. Finally, the bond determines the force required to dislodge an abrasive particle from the wheel and thus plays a major role in the cutting action. Bond materials are formulated so that the ratio of bond wear matches the rate of wear of the abrasive grits. Bonding materials in common use are:

Vitrified bonds. They are composed of clays and other ceramic substances. The abrasive particles are mixed with the wet clays so that each grain is coated. Wheels are formed from the mix, usually by pressing, and then dried. They are then fired in a kiln, which results in the bonding material's becoming hard and strong, having properties similar to glass. Vitrified wheels are porous, strong, rigid, and unaffected by oils, water, or temperature over the ranges usually encountered in metal cutting. The operating speed range in most cases is 1500 to 5000 m/min.

Vitrified bond is suitable for high stock removal even at dry condition. It can also be safely used in wet grinding. It can not be used where mechanical impact or thermal variations are like to occur. This bond is also not recommended for very high speed grinding because of possible breakage of the bond under centrifugal force.

31What is the main short coming of vitrified bond?Vitrified bond is brittle and can not with stand high impact loads. This bond can not be used for high wheel speed due to risk of wheel breakage under centrifugal force.

32Resinoid, or phenolic resinsBecause plastics can be compounded to have a wide range of properties, such wheels can be obtained to cover a variety of work conditions. They have, to a considerable extent, replaced shellac and rubber wheels. Resin bond is not recommended with alkaline grinding fluid for a possible chemical attack leading to bond weakening.Resinoid, or phenolic resins. Because plastics can be compounded to have a wide range of properties, such wheels can be obtained to cover a variety of work conditions. They have, to a considerable extent, replaced shellac and rubber wheels. Composite materials are being used in rubber-bonded or resinoid-bonded wheels that are to have some degree of flexibility or are to receive considerable abuse and side loading. Various natural and synthetic fabrics and fibers, glass fibers, and nonferrous wire mesh are used for this purpose.

Conventional abrasive resin bonded wheels are widely used for heavy duty grinding because of their ability to withstand shock load. This bond is also known for its vibration absorbing characteristics and finds its use with diamond and cBN in grinding of cemented carbide and steel respectively. Resin bond is not recommended with alkaline grinding fluid for a possible chemical attack leading to bond weakening. Fiberglass reinforced resin bond is used with cut off wheels which requires added strength under high speed operation.

33Shellac bondAt one time this bond was used for flexible cut off wheels. At present use of shellac bond is limited to grinding wheels engaged in fine finish of rolls.

Shellac-bonded wheels are made by mixing the abrasive grains with shellac in a heated mixture, pressing or rolling into the desired shapes, and baking for several hours at about 300F This type of bond is used primarily for strong, thin wheels having some elasticity. They tend to produce a high polish and thus have been used in grinding such parts as camshafts and mill rolls.

34Rubber bondIts principal use is in thin wheels for wet cut-off operation. Rubber bond was once popular for finish grinding on bearings and cutting tools.

Rubber bonding is used to produce wheels that can operate at high speeds but must have a considerable degree of flexibility so as to resist side thrust. Rubber, sulfur, and other vulcanizing agents are mixed with the abrasive grains. The mixture then is rolled out into sheets of the desired thickness, and the wheels are cut from these sheets and vulcanized. Rubber-bonded wheels can be operated at speeds up to 5,000 m/min. They commonly are used for snagging work in foundriesand for thin cutoff wheels.

35Oxychloride bondIt is less common type bond, but still can be used in disc grinding operation. It is used under dry condition.

36Metal bondMetal bond is extensively used with super abrasive wheels. Extremely high toughness of metal bonded wheels makes these very effective in those applications where form accuracy as well as large stock removal is desired.

37Electroplated bondThis bond allows large (30-40%) crystal exposure above the bond without need of any truing or dressing. This bond is specially used for making small diameter wheel, form wheel and thin super abrasive wheels. Presently it is the only bond for making wheels for abrasive milling and ultra high speed grinding.38Brazed bondThis is relatively a recent development, allows crystal exposure as high 60-80%. In addition grit spacing can be precisely controlled. This bond is particularly suitable for very high material removal either with diamond or cBN wheel. The bond strength is much greater than provided by electroplated bond. This bond is expected to replace electroplated bond in many applications.

39GlazingWith continuous use a grinding wheel becomes dull with the sharp abrasive grains becoming rounded.This condition of a dull grinding wheel with worn out grains is termed as glazing.40LoadingSome grinding chips get lodged into the spaces between the grits resulting in a condition known as loaded wheel.Loading is generally caused during the grinding of soft and ductile materials.A loaded grinding wheel cannot cut properly and need dressing.41DressingDressing is the conditioning of the wheel surface which ensures that grit cutting edges are exposed from the bond and thus able to penetrate into the workpiece material. In dressing attempts are made to splinter the abrasive grains to make them sharp and free cutting and also to remove any residue left by material being ground. Dressing therefore produces micro-geometry. DressingDressing is the conditioning of the wheel surface which ensures that grit cutting edges are exposed from the bond and thus able to penetrate into the workpiece material. Also, in dressing attempts are made to splinter the abrasive grains to make them sharp and free cutting and also to remove any residue left by material being ground. Dressing therefore produces micro-geometry. The structure of micro geometry of grinding wheel determines its cutting ability with a wheel of given composition. Dressing can substantially influence the condition of the grinding tool.

Dressing of super abrasive wheelDressing of the super abrasive wheel is commonly done with soft conventional abrasive vitrified stick, which relieves the bond without affecting the super abrasive grits.

However, modern technique like electrochemical dressing has been successfully used in metal bonded super abrasive wheel. The wheel acts like an anode while a cathode plate is placed in front of the wheel working surface to allow electrochemical dissolution.

Electro discharge dressing is another alternative route for dressing metal bonded super abrasive wheel. In this case a dielectric medium is used in place of an electrolyte.Touch-dressing, a new concept differs from conventional dressing in that bond material is not relieved. In contrast the dressing depth is precisely controlled in micron level to obtain better uniformity of grit height resulting in improvement of workpiece surface finish.

42GATE-2014Match the Machine Tools (Group A) with the probable Operations (Group B):

PQRSPQRS(a)1243(b)2143(c)3142(d)3421Group AGroup BP: Center Lathe1: SlottingQ: Milling2: Counter-boringR: Grinding3: KnurlingS: Drilling4: DressingAns. (c)

43Can a resin bonded cBN wheel be electrochemically dressed?Electrochemical dressing is not possible with resin bonded wheel because it is not electrically conducting.

44Is dressing necessary for single layer wheel?Conventional macro level dressing is not required because the wheel inherently has an open structure. However, touch dressing is carried out to obtain better uniformity in grit height in order to improve surface finish of the workpiece.

45TruingTruing is the act of regenerating the required geometry on the grinding wheel.Truing is also required on a new conventional wheel to ensure concentricity with specific mounting system.Truing and dressing are commonly combined into one operation for conventional abrasive grinding wheels, but are usually two distinctly separate operation for super abrasive wheel.

TruingTruing is the act of regenerating the required geometry on the grinding wheel, whether the geometry is a special form or flat profile. Therefore, truing produces the macro-geometry of the grinding wheel.

Truing is also required on a new conventional wheel to ensure concentricity with specific mounting system. In practice the effective macro-geometry of a grinding wheel is of vital importance and accuracy of the finished workpiece is directly related to effective wheel geometry.

Truing and dressing are commonly combined into one operation for conventional abrasive grinding wheels, but are usually two distinctly separate operation for super abrasive wheel.

46Balancing Grinding WheelsBecause of the high rotation speeds involved, grinding wheels must never be used unless they are in good balance. Grinding wheel must be balanced Statically and Dynamically.A slight imbalance will produce vibrations that will cause waviness in the work surface. It may cause a wheel to break, with the probability of serious damage and injury. Because of the high rotation speeds involved, grinding wheels must never be used unless they are in good balance. A slight imbalance will produce vibrations that will cause waviness in the work surface. It may cause a wheel to break, with the probability of serious damage and injury. The wheel should be mounted with proper bushings so that it fits snugly on the spindle of the machine. Rings of blotting paper should be placed between the wheel and the flanges to assure that the clamping pressure is evenly distributed. Most grinding wheels will run in good balance if they are mounted properly and trued. Most machines have provision for compensating for a small amount of wheel imbalance by attaching weights to one mounting flange. Some have provision for semiautomatic balancing with weights that are permanently attached to the machine spindle.47

Creep feed grindingThis machine enables single pass grinding of a surface with a larger down feed but slower table speed than that adopted for multi-pass conventional surface grinding. In creep-feed grinding, the entire depth of cut is completed in one pass only using very small in-feed rates.

Creep feed grinding machineThis machine enables single pass grinding of a surface with a larger down feed but slower table speed than that adopted for multi-pass conventional surface grinding. This machine is characterised by high stiffness, high spindle power, recirculation ball screw drive for table movement and adequate supply of grinding fluid. A further development in this field is the creep feed grinding centre which carries more than one wheel with provision of automatic wheel changing. A number of operations can be performed on the work piece. It is implied that such machines, in the view of their size and complexity, are automated through CNC

High efficiency deep grinding machineThe concept of single pass deep grinding at a table speed much higher than what is possible in a creep feed grinder has been technically realized in this machine. This has been made possible mainly through significant increase of wheel speed in this new generation grinding machine.

48State the basic advantage of a creep feed grinder over a conventional surfaceProductivity is enhanced and life of the grinding wheel is extended.

49IES 2011 ConventionalWhat is creep feed grinding? Discuss its salient features, advantages, and application. [10 marks]Cylindrical GrindingCenter-type cylindrical grinding is commonly used far producing external cylindrical surfaces.The grinding wheel revolves at an ordinary cutting speed, and the workpiece rotates on centers at a much slower speed.Grinding machines are available in which the workpiece is held in a chuck for grinding both external and internal cylindrical surfaces.51

What are the characteristic features of a universal cylindrical grinder?Characteristic features of a universal cylindrical grinder not possessed by plain cylindrical grinder are:Swivelling wheel headSwivelling wheel head slideSwivelling head stock

53Centerless GrindingCenterless grinding makes it possible to grind both external and internal cylindrical surfaces without requiring the workpiece to be mounted between centers or in a chuck. This eliminates the requirement of center holes in some workpieces and the necessity for mounting the workpiece, thereby reducing the cycle time.Two wheels are used. The larger one operates at regular grinding speeds and does the actual grinding. The smaller wheel is the regulating wheel. It is mounted at an angle to the plane of the grinding wheel.

54Centerless GrindingThe regulating wheel controls the rotation and longitudinal motion of the workpiece and usually is a plastic- or rubber-bonded wheel with a fairly wide face.The workpiece is held against the work-rest blade by the cutting forces exerted by the grinding wheel and rotates at approximately the same surface speed as that of the regulating wheel.

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Centerless GrindingVideoCenterless Grinding

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Centreless internal GrindingThis machine is used for grinding cylindrical and tapered holes in cylindrical parts (e.g. cylindrical liners, various bushings etc). The workpiece is rotated between supporting roll, pressure roll and regulating wheel and is ground by the grinding wheel.

59State the disadvantages of centreless cylindrical grinding machine?It does not grind concentrically with centres.Large diameter short workpiece are difficult to control in the processIt may not improve workpiece perpendicularity.

60Surface Grinding MachinesSurface grinding machines are used primarily to grind flat surfaces.However formed, irregular surfaces can be produced on some types of surface grinders by use of a formed wheel. Four basic types of surface grinding machines are:1. Horizontal spindle and reciprocating table2. Vertical spindle and reciprocating table3. Horizontal spindle and rotary table4. Vertical spindle and rotary table

Video63Is transverse feed provided in vertical spindle reciprocating table surface grinder?Usually no transverse feed is provided in such machine. The wheel diameter is kept larger than the width of the workpiece surface to be ground.

64Finishing Processes

LappingLapping is basically an abrasive process in which loose abrasives function as cutting points finding momentary support from the laps. Material removal in lapping usually ranges from .003 to .03 mm but many reach 0.08 to 0.1mm in certain cases.

66Video67Characteristics of lapping processUse of loose abrasive between lap and the workpieceUsually lap and workpiece are not positively driven but are guided in contact with each otherRelative motion between the lap and the work should change continuously so that path of the abrasive grains of the lap is not repeated on the workpiece.Cast iron is the mostly used lap material. However, soft steel, copper, brass, hardwood as well as hardened steel and glass are also used.68Abrasives of lappingAl2O3 and SiC, grain size 5 ~100 mCr2O3, grain size 1 ~ 2 mB4C3, grain size 5 - 60 mDiamond, grain size 0.5 ~ 5 m69Vehicle materials for lappingMachine oilRapeside oilgrease70Technical parameters affecting lapping processes areunit pressurethe grain size of abrasiveconcentration of abrasive in the vehiclelapping speedLapping is performed either manually or by machine. Hand lapping is done with abrasive powder as lapping medium, whereas machine lapping is done either with abrasive powder or with bonded abrasive wheel.Centreless lapping is carried out in the same principle as that of centreless grinding. The bonded abrasive lapping wheel as well as the regulating wheel are much wider than those used in centreless grinding. This technique is used to produce high roundness accuracy and fine finish, the workpiece requires multi-pass lapping each with progressively finer lapping wheel. This is a high production operation and suitable for small amount of rectification on shape of workpiece. Therefore, parts are to be pre-ground to obtain substantial straightness and roundness. The process finds use in lapping piston rings, shafts and bearing races.

71HoningHoning is a finishing process, in which a tool called hone carries out a combined rotary and reciprocating motion while the workpiece does not perform any working motion. Most honing is done on internal cylindrical surface, such as automobile cylindrical walls. The honing stones are held against the workpiece with controlled light pressure. The honing head is not guided externally but, instead, floats in the hole, being guided by the work surface.72HoningIt is desired that1. Honing stones should not leave the work surface2. Stroke length must cover the entire work length.3. In honing rotary and oscillatory motions are combined to produce a cross hatched lay pattern.

The honing stones are given a complex motion so as to prevent every single grit from repeating its path over the work surface.

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Fig. Honing toolFig. Lay pattern produced by combination of rotary and oscillatory motionHoningVideo75The critical process parameters are1. rotation speed2. oscillation speed3. length and position of the stroke4. honing stick pressure

With conventional abrasive honing stick, several strokes are necessary to obtain the desired finish on the work piece. However, with introduction of high performance diamond and cBN grits it is now possible to perform the honing operation in just one complete stroke. Advent of precisely engineered microcrystalline cBN grit has enhanced the capability further. Honing stick with microcrystalline cBN grit can maintain sharp cutting condition with consistent results over long duration.Superabrasive honing stick with monolayer configuration, where a layer of cBN grits are attached to stick by a galvanically deposited metal layer, is typically found in single stroke honing application.With the advent of precision brazing technique, efforts can be made to manufacture honing stick with single layer configuration with a brazed metal bond. Like brazed grinding wheel such single layer brazed honing stick are expected to provide controlled grit density, larger grit protrusion leading to higher material removal rate and longer life compared to what can be obtained with a galvanically bonded counterpart.The important parameters that affect material removal rate (MRR) and surface roughness (R) are:(i) unit pressure, p(ii) peripheral honing speed, Vc(iii) honing time, T

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BuffingBuffing is a polishing operation in which the workpiece is brought into contact with a revolving cloth wheel that has been charged with a fine abrasive, such as polishing rough. The wheels are made of disks of linen, cotton, broadcloth, or canvas, and achieve the desired degree of firmness through the amount of stitching used to fasten the layers of cloth together. Negligible amount of material is removed in buffing while a very high luster is generated on the buffed surface.The dimensional accuracy of the parts is not affected by the buffing operation.

BuffingBuffing is a polishing operation in which the workpiece is brought into contact with a revolving cloth wheel that has been charged with a fine abrasive, such as polishing rough. The wheels are made of disks of linen, cotton, broadcloth, or canvas, and achieve the desired degree of firmness through the amount of stitching used to fasten the layers of cloth together. When the operation calls for very soft polishing or polishing into interior corners, the stitching may be totally omitted, the centrifugal force of the wheel rotation being sufficient to keep the layers in the proper position. Various types of polishing compounds are also available, with may consisting of ferric oxide particles in some form-of binder or carrier. Negligible amount of material is removed in buffing while a very high luster is generated on the buffed surface. The dimensional accuracy of the parts is not affected by the buffing operation.

78Video79Super Finishing

Fig. super finishing of end faceof a cylindrical work piece in radial modeIn this both feeding and oscillation of the super finishing stone is given in the radial direction.

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Fig. super finishing operation in plunge modeSuper FinishingIn this case the abrasive stone covers the section of the workpiece requiring super finish. The abrasive stone is slowly fed in radial direction while its oscillation is imparted in the axial direction. It reduce surface roughness and increase bearing load capacity.

Super finishing can be effectively done on a stationary workpiece. In this the abrasive stones are held in a disc which oscillates and rotates about the axis of the workpiece.Internal cylindrical surfaces can also be super finished by axially oscillating and reciprocating the stones on a rotating workpiece81State the specific application of a planetary internal grinder.Planetary internal grinders find application for grinding holes in workpieces of irregular shape or large heavy workpieces.

82Video83

GATE - 1995Among the conventional machining processes, maximum specific energy is consumed in(a)Turning (b)Drilling(c)Planning(d)Grinding

Ans. (d)85GATE - 1998Ideal surface roughness, as measured by the maximum height of unevenness, is best achieved when, the material is removed by(a)An end mill(b)A grinding wheel(c)A tool with zero nose radius(d)A ball mill.

Ans. (b)86GATE - 1998In machining using abrasive material, increasing abrasive grain size (a)Increases the material removal rate(b)Decreases the material removal rate(c)First decreases and then increases the material removal rate(d)First increases and then decreases the material removal rateAns. (d)87GATE - 2000Abrasive material used in grinding wheel selected for grinding ferrous alloys is(a)Silicon carbide(b)Diamond(c)Aluminium oxide(d)Boron carbideAns. (c)88GATE - 2002The hardness of a grinding wheel is determined by the(a)Hardness of abrasive grains(b)Ability of the bond to retain abrasives(c)Hardness of the bond(d)Ability of the grinding wheel to penetrate the work pieceAns. (b)89GATE - 2006If each abrasive grain is viewed as a cutting tool, then which of the following represents the cutting parameters in common grinding operations?(a)Large negative rake angle, low shear angle and high cutting speed(b)Large positive rake angle, low shear angle and high cutting speed(c)Large negative rake angle, high shear angle and low cutting speed(d)Zero rake angle, high shear angle and high cutting speedAns. (a) Grinding(i) Rake angle vary from a positive to a large negative value, rounded i.e. dull grits has large negative rake, So here large negative rake angle is choice, (b) & (d) out

(ii) Cutting speed is very high. (c) is out. So our choice (a)

90GATE - 1997List I List II(A)Grinding 1.Surface for oil retention(B)Honing 2.Surface for max. load capacity(C)Super-finishing 3.Surface of limiting frictionD)Burnishing 4.Surface of matte finish5.Surface for pressure sealing6.Surface for interference fit.

Ans. (A) -3, (B) -1, (C)-2, (D)-5

91IES - 2005Consider the following statements in respect of grinding?The pitch of the grit cutting edges is larger than the pitch of the milling cutter.The cutting angles of the grits have a random geometry.The size of the chip cuts is very small for grinding.Which of the statements given above are correct?(a)1 and 2 (b)2 and 3 (c)1 and 3 (d)1, 2 and 3Ans. (b)92IES - 2009Which one of the following is NOT used as abrasive material in grinding wheels?(a)Aluminium oxide(b)Silicon carbide(c)Cubic boron nitride(d)Manganese oxide

Ans. (d)93IES - 1997Which one of the following materials is used as the bonding material for grinding wheels?(a)Silicon carbide(b)Sodium silicate(c)Boron carbide(d)Aluminum oxide

Ans. (b)

94IES - 1996Grinding wheel is said to be loaded when the(a)Metal particles get embedded in the wheel surface blocking the interspaces between cutting grains.(b)Bonding material comes on the surface and the wheel becomes blunt.(c)Work piece being ground comes to a stop in cylindrical grinding.(d)Grinding wheel stops because of very large depth of cutAns. (a)95IES - 2001Specific cutting energy is more in grinding process compared to turning because(a)Grinding (cutting) speed is higher(b)The wheel has multiple cutting edges (grains)(c)Plaguing force is significant due to small chip size(d)Grinding wheel undergoes continuous wear

Ans. (b)96IES - 1996Specific energy requirements in a grinding process are more than those in turning for the same metal removal rate because of the(a)Specific pressures between wheel and work being high.(b)Size effect of the larger contact areas between wheel and work.(c)High cutting velocities(d)High heat produced during grinding.

Ans. (d)97IES - 1994The ratio of thrust force to cutting force is nearly 2.5 in(a)Turning (b)Broaching (c)Grinding(d)Plain millingAns. (c)98IES - 1992Assertion (A): Vitrified bond is preferred for thin grinding wheels.Reason (R): Vitrified bond is hard brittle.(a)Both A and R are individually true and R is the correct explanation of A(b)Both A and R are individually true but R is not the correct explanation of A (c)A is true but R is false(d)A is false but R is trueAns. (a) Both A and R are true but R is NOT the correct explanation of A99IES - 2000Assertion (A): The ratio of cutting force to thrust force is very high in grinding process as compared to other machining processes.Reason (R): Random orientation and effective negative rake angles of abrasive grains increase the cutting force and adversely affect the cutting action and promote rubbing action.(a)Both A and R are individually true and R is the correct explanation of A(b)Both A and R are individually true but R is not the correct explanation of A (c)A is true but R is false(d)A is false but R is trueAns. (d) The mean grinding coefficient, which is the ratio of the cutting force to the thrust force for grinding, to be 0.47 (or the ratio of the thrust force to the cutting force of about 2.12) .

100IES - 1995Soft materials cannot be economically grind due to(a)The high temperatures involved(b)Frequent wheel clogging(c)Rapid wheel wear(d)Low work piece stiffnessAns. (b)101IES 2010In relation to the peripheral or surface speeds of the grinding wheel and that of the workpiece in cylindrical grinding of alloy steel workpieces, the grinding wheel speed is(a) Less than the speed of the workpiece(b) Same as the speed of the workpiece(c) Double the speed of the workpiece(d) 65 to 75 times the speed of the workpiece.Ans. (d)102

IES - 2009Given that the peripheral speed of the grinding wheel of 100 mm diameter for cylindrical grinding of a steel work piece is 30 m/s, what will be the estimated rotational speed of the grinding wheel in revolution per minute (r.p.m.)?(a)11460(b)5730(c)2865(d)95

Ans. (b)103IES - 2002Which of the following materials are used in grinding wheel?1.Aluminium oxide2.Cubic boron nitride3.Silicon carbideSelect the correct answer using the codes given below:(a)1, 2 and 3(b)1 and 2(c)2 and 3 (d)1 and 3Ans. (a)104IES 2001, ISRO-2009The marking on a grinding wheel is '51 A 36 L 5 V 93'. The code '36' represents the(a)Structure (b)Grade (c)Grain- size (d)Manufacturer's number

Ans. (c)105IES - 2000The sequence of markings "S 14 K 14 S" on a grinding wheel represents respectively(a)Bond type, structure, grade, grain size and abrasive type(b)Abrasive type, grain size, grade, structure and bond type(c)Bond type, grade, structure, grain size and abrasive type(d)Abrasive type, structure, grade, grain size and bond typeAns. (b)106IES - 1995In the grinding wheel of A 60 G 7 B 23, B stands for(a)Resinoid bond(b)Rubber bond(c)Shellac bond (d)Silicate bond.

Ans. (a)107IES - 1993Tool life in the case of a grinding wheel is the time(a)Between two successive regrinds of the wheel(b)Taken for the wheel to be balanced(c)Taken between two successive wheel dressings(d)Taken for a wear of 1mm on its diameter

Ans. (c) 108IES - 2001Assertion (A): Hard wheels are chosen for grinding hard metals.Reason (R): In hard wheels only the abrasive grains are retained for long time.(a)Both A and R are individually true and R is the correct explanation of A(b)Both A and R are individually true but R is not the correct explanation of A (c)A is true but R is false(d)A is false but R is trueAns. (d) Soft wheels are chosen for grinding hard metals.109IES - 1994Consider the following statements regarding grinding of high carbon steel:1.Grinding at high speed results in the reduction of chip thickness and cutting forces per grit.2.Aluminium oxide wheels are employed.3.The grinding wheel has to be of open structure.Of these statements(a)1, 2 and 3 are correct (b)1 and 2 are correct (c)1 and 3 are correct(d)2 and 3 are correctAns. (b) 110IES - 1999Consider the following reasons:1.Grinding wheel is soft 2.RPM of grinding wheel is too low3.Cut is very fine 4.An improper cutting fluid is usedA grinding wheel may become loaded due to reasons stated at(a)1 and 4 (b)1 and 3 (c)2 and 4 (d)2 and 3Ans. (c)111IES - 2001Dry and compressed air is used as cutting fluid for machining(a)Steel (b)Aluminium(c)Cast iron(d)BrassAns. (c)112IES - 1993In centre less grinding, the work piece centre will be(a)Above the line joining the two wheel centres(b)Below the line joining the two wheel centres(c)On the line joining the two wheel centres(d)At the intersection of the line joining the wheel centres with the work plate plane.Ans. (a) In centreless grinding, the work piece centre will be above the line joining the two wheel centres. (Usually about half the diameter of work piece)113IES - 2000Consider the following advantages:1.Rapid process2.Work with keyways can be ground 3.No work holding device is required.Which of these are the advantages of centre less grinding?(a)1, 2 and 3 (b)1 and 2 (c)2 and 3 (d)1 and 3Ans. (d) 2. Work with keyways can be ground is wrong114IES - 1996A grinding wheel of 150 mm diameter is rotating at 3000 rpm. The grinding speed is

115

IES - 1993Consider the following parameters:1.Grinding wheel diameter.2.Regulating wheel diameter.3.Speed of the grinding wheel.4.Speed of the regulating wheel.5.Angle between the axes of grinding and regulating wheels.Among these parameters, those which influence the axial feed rate in centreless grinding would include(a)2, 4 and 5 (b)1, 2 and 3 (c)1, 4 and 5 (d)3, 4 and 5

Ans. (a) The rate of longitudinal feed = x diameter of regulating wheel x rpm of regulating wheel x sin (angle of inclination of regulating wheel)Thus parameters 2, 4 and 5 given in (a) influence the axial feed rate in centreless grinding.

116IES - 2007Honing Process gives surface finish of what order?(a)10 m (CLA)(b)1.0 m (CLA)(c)0.1 m (CLA)(d)0.01 m (CLA)Ans. (c) Surface finish of the order of 0.05m Ra can be obtained by honing.117IES - 1992CLA value for Honing process is(a)6 (b)0.05 - 3.0 (c)0.05 - 1.0 (d)0.025 - 0.1Ans. (c)

118IES - 2012Statement (I): Honing is an abrading process to remove stock from metallic surfaces.Statement (II):Honing is commonly done on internal surfaces.(a) Both Statement (I) and Statement (II) are individually true and Statement (II) is the correct explanation of Statement (I)(b) Both Statement (I) and Statement (II) are individually true but Statement (II) is not the correct explanation of Statement (I)(c) Statement (I) is true but Statement (II) is false(d) Statement (I) is false but Statement (II) is true

Ans. (b)119IES - 2001Match List-I (Cutting Tools) with List-II (Applications) and select the correct answer using the codes given below the lists:List IList IIA.Trepanning tool1.For surface finishing by honingB.Side milling cutter2.For machining gearsC.Hob cutter3.For cutting keyways in shaftsD.Abrasive sticks4.For drilling large diameter holesCodes:ABCDABCD(a)1324(b)4321(c)1234(d)4231

Ans. (b)120IES - 1992A surface finish of 0.025 0.1 micrometer CLA values is to by produced. Which machining process would you recommend?(a)Grinding (b)Rough turning(c)Lapping (d)HoningAns. (c)121IES - 1992Buffing wheels are mode of(a)Softer metals(b)Cotton fabric(c)Carbon(d)Graphite

Ans. (b)122IAS - 2004The size effect refers to the increase in specific cutting energy at low values of under formed chip thickness. It is due to which one of the following?(a)Existence of ploughing force (b)Work hardening(c)High strain rate (d)Presence of high friction at chip-tool interface.

Ans. (a) that so why in grinding specific energy of cutting is maximum.123IAS - 2000Consider the following statements in respect of a grinding wheel of specification, 51-A- 36-L-7-R-23, using the standard alphanumeric codification:1.Abrasive used in the wheel is aluminum oxide2.The grain size of abrasive is medium3.The wheel grade is medium hard 4.It has an open structure5.It has resinoid as bonding agentWhich (If these statements are correct?(a)1, 2 and 3(b)1, 3 and 4 (c)2, 3 and 5(d)1, 4 and 5

Ans. (a)

124

IAS - 1999Assertion (A): The grade of a grinding wheel is a measure of hardness of the abrasive used for the wheel.Reason (R): Grading is necessary for making right selection of the wheel for a particular work.(a)Both A and R are individually true and R is the correct explanation of A(b)Both A and R are individually true but R is not the correct explanation of A (c)A is true but R is false(d)A is false but R is true

Ans. (d) The grade of a grinding wheel depends oni)Kind of bondii)Structure of wheeliii)Amount of the abrasive used for the wheel and not hardness of the abrasive used for the wheel.

125IAS - 2001Consider the following statements:The set-up for internal centreless grinding consists of a regulating wheel, a pressure roll and a support roll, between which the tubular workpiece is supported with the grinding wheel within the tube, wherein1.The grinding wheel, workpiece and regulating wheel centers must lie on one line2.The directions of rotation of workpiece and grinding wheel are same3.The directions of rotation of pressure roll, support roll and regulating wheel are same4.The directions of rotation of grinding wheel and regulating wheel are sameWhich of these statements are correct?(a)1, 2 and 3 (b)1, 3 and 4(c)2 and 3 (d)3 and 4

Ans. (a)126IAS - 1997Which of the following pairs are correctly matched?1.Drill press :Trepanning 2.Centreless grinding: Through feeding3.Capstan lathe: Ram type turretSelect the correct answer using the codes given below:Codes:(a)1 and 2(b)1, 2 and 3(c)1 and 3(d)2 and 3

Ans. (b)127IAS - 2007 Match List I with List II and select the correct answer using the code given below the Lists:List IList II(Machine Tool/ Cutting Tool)(Part/ Characteristics)A.Screw cutting lathe1.Self locking taperB.Drill2.Chasing dialC.End mill3.Wiper insertD.Grinding wheel4.Self releasing taper5.Balance weightsCode:A B CDA B CD(a) 4 5 3 1(b) 2 1 4 5(c) 4 1 3 5(d) 2 5 4 1

Ans. (b)128IAS - 1999Which one of the following processing sequences will give the best accuracy as well as surface finish?(a)Drilling, reaming and grinding(b)Drilling, boring and grinding(c)Drilling, reaming and lapping(d)Drilling, reaming and electroplating

Ans. (c)

129IAS - 2001Which one of the following grinding wheels (with Grade, Grit and Bond) is suitable for cutter grinding?(a)K 60 vitrified(b) K 320 vitrified (c)T 60 resinoid (d) T 320 resinoid

Ans.(a)130

Ch-9: GrindingQ. NoOptionQ. NoOption1D7A2D8A3A9A4A10C5B11A6B12D