STUDY OF GRINDING MACHINES

INTRODUCTION
Grinding is a metal removal operation in which the metal is removed with the
help of a rotating grinding wheel or abrasive wheel. The grinding wheels are made of
abrasive materials held together by a bonding material. Grinding process removes very little
amount of metal and also it gives very good surface finish with accuracy. This operation is
suitable for machining very hard metals.

TYPES OF GRINDING
1. Rough Grinding or non-precision
2. Finish or precision grinding
1. Rough Grinding
Chips, Sharp edges, burr, unwanted projections on the workplaces are
removed by Rough grinding process.
2. Precision Grinding
Precision grinding operation used for grinding the cutting tool materials. In
this method the grinding wheel with very thin abrasive is used for grinding. So the metal is
removed as very small particles. Due to this, the work piece can be machined accurately.
Grinding process is classified based on the grinding method. They are given below.
1. External cylindrical grinding
2. Internal surface grinding
3. Surface grinding
4. Form grinding
1. External cylindrical grinding
The grinding operation which is done on a straight or tapered cylindrical
workplace is called external cylindrical grinding. The work piece is rotated in its axis and
moved across the face of the grinding wheel for grinding the surface of the work piece.
2. Internal cylindrical grinding
The grinding operation which is done on the internal hole of the cylindrical
work piece and the inside taper surface of the cylindrical work piece is called internal
cylindrical grinding. In this method, the work piece is held in the chuck and rotated in its axis
then the rotating grinding wheel is passed inside the work piece for grinding.
3. Surface grinding
In this operation, the flat surface is produced by grinding the surface. For this,
the work piece is moved forward and backward under the rotating grinding wheel.
4. Form grinding
The required form of grinding wheel is used for grinding the work piece. So
this grinding operation produce the shape of grinding wheel used on the work piece for
grinding.
CLASSIFICATION OF GRINDING MACHINES
1. Cylindrical Grinding
1. Plain cylindrical grinder
2. Universal cylindrical grinder
3. Centreless grinder
2. Internal Grinders
1. Chucking type internal grinders
A. Plain internal grinders
B. Universal internal grinders
2. Planetory internal grinders
3. centreless internal grinders
3. Surface grinders
1. Reciprocating table type
A. Horizontal spindle type
B. Vertical spindle type
2. Rotating table type
A. Horizontal spindle type
B. Vertical spindle type
4. Tool and cutter grinders
1. Universal grinders
2. Special grinders
5. Special and single purpose grinding machines
CYLINDRICAL GRINDING MACHINE (CENTRE TYPE GRINDER)

Fig. Cylindrical Grinder

This is made of CI and rests on the floor and it supports the other parts which are
mounted on it. Horizontal guide ways are set on the top of the base. Table slides on these
guide ways are set on the top of the base. The table slides on these guide ways for giving
traverse motion to the work piece. The driving mechanism for the table is housed inside the
base.
2. Table
This machine has two tables such as upper table and lower table. The lower table
slides on the bad guide ways to give the longitudinal feed of the work past the grinding
wheel. The table can be moved by hand or by power. The dogs are provided at the side table
to reverse the table at the end of the stroke. The upper table is mounted on the lower table.
Head stock and tail stock are mounted on the upper table. The table can be swivelled for the
maximum angle up to 100 on either side
3. Head stock
The head stock has dead centre on which the work piece is supported. The work piece
is driven by head stock through a dog and driving pin. A separate motor is used in the head
stock for rotating the workspace
4. Tail Stock
Different length of work piece is clamped between head stock and tail stock by
adjusting the distance through tail stock. The work piece is held between head stock and tail
stock.
5. Wheel head
The grinding wheel is held in the wheel head and it is driven by a motor housed in the
head stock. The wheel head is placed over the bed at the back side. It can be moved
perpendicular to the table guide ways by hand or power.
6. Working
The required work piece is held between centres. It is rotated by a dog or a face plate.
Then the grinding wheel is made to rotate in its own axis in the opposite direction of work.
Then the grinding wheel is fed by hand or automatically towards the work piece.

METHODS OF CENTRELESS GRINDING

1. Through feed

2. In feed

3. End feed

1. Through feed
This method is suitable for grinding the long shaft or bars and rollers pins. In this
method, the regulating wheel is tilted at a small angle for moving the work piece axially
through the space between the grinding wheels and regulating wheel. Guides are provided at
both ends of the wheel for guiding the movement of the work piece.

Fig. 4.13. Methods of Centreless Grinding

2. In feed grinding

In this method, the work piece is placed on the work rest against an end stop. Due to
this, the axial movement of the work piece is avoided. Then the regulating wheel and the
work rest with the work piece are moved towards the grinding wheel by giving hand feed.
This method of grinding is similar to the plunge grinding. Shoulders and formed surfaces are
ground by this method.

3. End feed grinding

This method is suitable for producing tapered surface. So, the grinding wheel or
regulating wheel with required form of taper is used for grinding. The work piece is fed
axially between the wheels and ground. An end stop is provided at the rear end of the wheel
for stopping the work piece at the required length.

Advantages of centreless grinding

1. Fixtures and other clamping devices are not required for holding the work piece.
2. This is the faster process than the centre type grinding.
3. The size of the job can be controlled easily by the regulating wheel.
4. Skilled operators are not required
5. Suitable for mass production.

Limitations

1. Work piece with steps and multiple diameters as cannot be ground easily
2. The cylindrical surface with a keyway or holes cannot be ground.

SURFACE GRINDERS:

This machine is suitable for grinding flat and plane surface. Irregular, curved
and tapered surfaces also can be ground using this machine. Die, Valve, Piston rings,
surface plates are finished by this grinding machine.

HORIZONTAL SPINDLE – RECIPROCATING TABLE SURFACE GRINDER

1. Base

Base is made by casting with rectangular shape. Driving mechanism is housed inside
the base. A vertical column is mounted on the back side of base. Horizontal guide ways are
in the top of the base and these are perpendicular to the column.

2. Table and saddle

Saddle rests on the base. The saddle moves on the guide ways which are
perpendicular to the column and gives cross feed. The table moves on the horizontal guide
ways of the saddle. Longitudinal feed is given by moving the table. ‘T’ slots are provided on
the table for holding the work.

3. Wheel head

A separate motor is mounted at the top of the column for operating the wheel head.
The wheel head moves up and down on the vertical guide ways of the column.

Operation

Magnetic chuck or fixtures are used for holding the work piece on the table. The trip
dogs are adjusted suitably to get the correct stroke length of the table. Then the table with
work piece reciprocates and the periphery of the rotating grinding wheel grinds the work
piece. Depth of cut is given by lowering the wheel head or raising the table. Cross feed is
given to the work piece at the end of every stroke.

Fig. 4.16. Surface Grinder

HORIZONTAL SPINDLE – ROTARY TABLE SURFACE GRINDER

Rotary Table Surface Grinder

Fig. 4.17. Horizontal spindle Rotary table Surface Grinder

VERTICAL SPINDLE RECIPROCATING TABLE SURFACE GRINDER

The work piece is clamped on the reciprocating work table using a magnetic chuck or
a fixture. A grinding wheel rotates in its vertical axis. The face or side of the grinding wheel
cuts the metal. The wheel head is moved down for giving the depth of cut. The longitudinal
and cross feed are given through the table. This machine is useful for grinding the flat
surfaces of medium size work piece.

Fig. 4.18. Vertical spindle Reciprocating table Grinder

VERTICAL SPINDLE-ROTARY TABLE SURFACE GRINDER

The grinding spindle is mounted vertically on the face of a column and rotates in
fixed position. The grinding wheels are moved down for giving depth of cut and grinding the
work piece which are rotating with the rotary table. This grinding machine is used for
grinding large quantity of small work piece

GRINDING WHEEL:
Grinding Wheel

Fig. 4.19. Grinding wheel

Wheel Head

Fig. 4.20. Grinding wheel head

It is made up of small abrasive particles held together by a bonding material.