GRINDING PROCESS
Meaning
Is the act of removing extra unwanted material from the parent material by action of
friction between the two contact surfaces i.e. between the wheel/disk and the
workpiece.
Application of grinding
sharpening of cutting tools
smoothening of too hard surfaces which cannot be handled by other machining
processes.
Types of grinding processes
1. Tool grinding
- Involves machining using abrasive or grinding wheels to re-sharpen a workpiece.
2. Surface grinding
- Used to produce a smooth finish on flat surfaces. It is a machining process in which a
spinning wheel cuts chips of metallic substance from workpiece making a face of it
flat or smooth.
3. Cylindrical grinding
Is a machining process used to create to create precise cylindrical shapes or surfaces
on workpieces
The workpiece rotates about a fixed axis against a grinding wheel, the surfaces are
concentric to that axis of rotation.
Types of grinding machine
1. Pedestal grinder
It consists of a larger motor driven grinding wheel mounted on one side of the
pedestal and a smaller wheel of fine grinding.
Used to sharpen high –speed cutting tools, shaping metals and grinding surfaces.
2. Hand grinder (portable or angle grinder)
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A light-weight hand operated machine tool. It can be powered electrically or
pneumatically depending on model selected.
3. Cylindrical grinder
Used primarily to grind cylindrical surfaces although tapered and simple format
surfaces may also be ground.
4. Surface grinder
Designed to grind flat or plane surfaces.
Parts of pedestal grinding machine
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Parts of portable grinding machine
The procedure of operating a grinding wheel
1. Before using the grinder read thoroughly the manufacturer's manual. This will provide specific
instructions and safety precautions for your particular model.
2. Check the machine for any damage or defects. Ensure all guards are in place and functioning
properly. Also, inspect the grinding wheel for any cracks or damage.
3. Always wear appropriate personal protective equipment (PPE) such as safety glasses, gloves, and
hearing protection. If you're grinding metal, consider wearing a face shield.
4. Clear the area around the grinder of any obstructions. Make sure there is adequate ventilation to
prevent the buildup of dust and fumes.
5. Secure the Workpiece using clamps or a vise.
6. Adjust the tool rest to the proper distance from the grinding wheel. Ensure the wheel guard is in
place and adjusted to the appropriate position.
7. Follow the manufacturer's instructions for starting the grinder.
8. Guide the grinding smoothly across the face of the grinding wheel. Apply steady pressure
without forcing the workpiece into the wheel. Periodically cool the workpiece using a coolant to
avoid overheating.
9. Periodically stop grinding to inspect the workpiece and make sure you're achieving the desired
result. Make any necessary adjustments to the grinding wheel or the workpiece setup.
10. Once grinding is over turn off the machine and wait for the grinding wheel to come to a complete
stop before removing the workpiece. Clean up any debris or swarf from the work area.
11. Once you've finished grinding, clean the grinder and inspect it for any damage or wear. Follow the
manufacturer's guidelines for routine maintenance and storage.
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Parts of surface grinding machine
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Parts of cylindrical grinding machine
Parts of centerless grinding machine
Principal parts and their functions
1. Base – Robust and heavily ribbed box-section casting to ensure rigidity and complete
freedom from vibration.
2. Headstock – Located at the left hand end of the swivel table and is equipped with a
variable speed motor to rotate the work at the desired speed.
3. Tailstock – Mounted at the right hand end of the swivel table and supports the other end
of the work being ground
4. Column – Carries the wheel head at its top end and contains the motor and belt drive to
the wheel spindle.
5. Wheel head – Carries the wheel spindle which is mounted in precision bearings.
6. Wheel – Is the cutting tool.
7. Coolant system – Reduces heat and friction created by the deformation of metal and chip
sliding along the chip-tool interface.
8. Saddle – Fitted on top of the base in the two vee slideways and provides the cross-
traverse movement.
9. Table – Guided by vee and flat slideway on saddle and can be operated manually with a
handwheel.
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Classification of grinding wheels
1. Cup wheel – Used in tool and cutter grinders where orientation of the wheel and a slim
profile are required. Have the advantage of producing a truly flat surface on the side of
lathe tools.
2. Straight wheel – Used on the periphery only and therefore produce a slightly concave
surface (hollow ground) on the part. Have the advantage of producing many tools such as
chisel.
3. Cylinder wheel – Provides a long wide surface with no center mounting support
(hollow). Used only in vertical or horizontal spindle grinders.
4. Tapered wheel – Is stronger than straight wheel and can accommodate higher lateral
loads.
5. Straight cup – Is an alternative to cup wheels in tool and cutter grinders, where having
an additional radial grinding surface is beneficial.
6. Dish cup – A very shallow cup-style grinding wheel. Used primarily in cutter and jig
grinding for slots and crevices.
7. Saucer wheel – Used to grind milling cutters and twist drills. Most common in non-
machining areas.
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Safety precautions when using grinding machine
(Action taken to minimize or eliminate injuries)
Always wear appropriate PPE especially safety goggles
Coolant should oftenly be used to cool the work piece
Keep hands clear of wheels
The wheel guard must always be securely fixed in place
Belt and pulley guards must always be in place
Stop all motors before making adjustment
Test grinding wheel for possible cracks
Only one person should operate the machine
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Care and maintenance of grinding machine
Cleaning – Keep equipment clean
Disconnect power and brush or wipe off dust and sludge.
Make sure screws and bolts are in place and tightened
Tip back the grinder, remove tooling and wipe off the heads
Inspect plates and shrouds
