Surface Grinding

SURFACE
GRINDING
Surface grindingis used to produce a smooth finish

on flatsurfaces. It is a widely used abrasive
machining process in which a spinning wheel
covered in rough particles (grinding wheel) cuts
chips of metallic or non-metallic substance from a
work piece, making a face of it flat or smooth.
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Work piece is secured on a chuck attached to

the worktable of the grinder
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The surface grinder is composed of

abrasive wheel,
a work holding device known as a chuck,
a reciprocating or rotary table.
The chuck holds the material in place while it is being worked on. It can
do this one of two ways:magnetic pieces are held in place by a magnetic
chuck, while non-magnetic and non-metallic pieces are held in place by
vacuum or mechanical means. Amachine vise placed on the magnetic
chuck can be used to hold non-ferromagnetic work pieces if only a
magnetic chuck is available.
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TYPES OF SURFACE
GRINDING
RECIPROCATING GRINDING
CREEP FEED GRINDING
HIGH SPPED GRINDING
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RECIPROCATING GRINDING
reciprocating grinding is a peripheral longitudinal grinding

process with a back-and-forth feed motion, in which the feed
motion takes place gradually in small steps with a relatively high
feed rate.
Reciprocating grinding is used for generating plain surfaces of

usually large lateral dimensions. The grinding spindle is parallel
to the work piece surface to be machined, the work piece material
being cut mainly with the circumferential side of the grinding
5wheel. The grinding wheel is fed orthogonally to the work piece
surface
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Specific Removal Rate

The specific material removal rate for reciprocating grinding is calculated from the
product of infeed a and feed rate v:
Q = av
Non-productive Time
depends on table speed and acceleration and the non grinding time can be because
of the grinding wheel running beyond the work piece, and also because of the
reversing table motion.
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contact length between work piece and wheel is small and the grinding forces
are relatively small. There are only a few cutting edges engaged at the same
time
Increasing the feed rate results in higher average chip thickness and length,
and thus in an increase of grinding forces and thermal stress.
In feed and feed rate (work speed) crucially determine the total machining time
in reciprocating grinding. An increase of in feed increases grinding forces and
thermal stress. The work piece surface roughness decreases with a higher
number of engaged cutting edges.
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ECONOMICS
Low thermal, static, and dynamic stresses are advantages of reciprocating
grinding, in contrast to creep feed grinding.
They allow for a more simple machine design in terms of drive capacity,
rigidity, and auxiliary units, thus accounting for lower purchase and operating
costs.
The generally high total machining times are a disadvantage for the workpiece,
as well as higher surface roughness of the workpiece ,
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CREEP GRINDING
The total grinding stock being cut in one or only a few passes.
In this method, the grinding spindle is parallel to the work piece surface to be
machined, the work piece material being mainly cut with the grinding wheel
circumferential side. The grinding wheel is fed orthogonally to the work piece
surface
creep grinding is usually characterized by in feeds larger than 0.5 mm and
feed rates smaller than 40 mm/s
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HIGH-EFFICIENCY DEEP GRINDING
High-performance deep grinding, with increased wheel peripheral speed and

increased feed rate, is a special case requiring a cooling lubricant supply system
The advantages of high-speed grinding are higher surface quality, shorter
machining times, lower wheel wear, and low grinding forces.
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Due to the large contact length and large infeed in creep feed grinding,
grinding forces tend to be high, which, in turn, lead to high thermal stress
in the working zone
An increase of the specific material removal rate by increasing the infeed
or the feedrate involves higher grinding forces and elevated thermal stress
due to a higher chip thickness
The chip thickness and thus the cutting force at the single grain are smaller
during creep feed grinding than during reciprocating grinding.
Additionally, there are no repeat impact loads on the grinding wheel, so
that the abrasive grains can be held longer by the bond matrix before the
grains are broken out.
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Higher cutting forces require significantly higher static and dynamic rigidity
and higher drive performance of the grinding machine and its ancillary units
than necessary in the case of reciprocating grinding.
The high thermal stress during creep feed grinding does not only represent a
high load for tool and grinding machine, but also damages the workpiece
material causing cracks and structural changes.
In creep feed grinding, surface roughnesses are much smaller due to the
engagement of a higher number of cutting edges and due to smaller
feedrates than in the case of reciprocating grinding.
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ECONOMICS OF CREEP FEED GRINDING

Lower grinding times and high achievable surface quality with a high removal
rate argue for creep feed grinding in contrast to reciprocating grinding
High process temperatures and large contact lengths require cooling lubricant
pumps with increased volume flow and pressure, adapted cooling lubricant
nozzles
High-dimensional accuracy and high forces require high-precision and rigid
bearings and guidance, shock-free and precise drives.
High concentricity and adjustable grinding wheel topography require integrated
auxiliary conditioning equipment for diamond grinding wheels
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SPEED-STROKE GRINDING
An innovation of surface grinding driven by the Japanese in the 1980s is a process

called Speed Stroke Grinding that involves very high table speeds of 50 to 100
m/min and shallow depth of cuts of the order of 1 m or less
Offers the ability to remove stock faster and with lower forces and less risk of burn,
but roughness will be higher and compensation must be made in bond/grit
strength for increased force/grit
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FACE GRINDING
Face grinding is surface grinding using the face of a grinding wheel.
These include segment grinding, double- and single-disc grinding, and doubleand single-sided fine grinding
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Surfacegrinding segmentsare generally used togrindflat stock or flat

surfaces within a workpiece. Thesegmentmoves over the workpiece in a flat
plane or vice versa. Applications can vary from heavy, rapid stock removal to
precision tolerance operations.
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vertical and horizontal double disc grinding machines and single disc
grinding machines is available
Double disc grinding is an abrasive machining process that removes material

from two sides of a part simultaneously. In a typical double disc grinding
machine, the grinding discs are side-mounted on a pair of opposed spindles.
Because the process grinds both sides at the same time, it offers a high
degree of accuracy and parallelism and reduces stress on the part. The
process is suitable for a wide range of materials, including stainless steel,
sintered metal parts and high-strength alloys.
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Surface Grinding

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SURFACE

Surface grindingis used to produce a smooth finish

Work piece is secured on a chuck attached to

The surface grinder is composed of

reciprocating grinding is a peripheral longitudinal grinding

Reciprocating grinding is used for generating plain surfaces of

Specific Removal Rate

HIGH-EFFICIENCY DEEP GRINDING

High-performance deep grinding, with increased wheel peripheral speed and

ECONOMICS OF CREEP FEED GRINDING

An innovation of surface grinding driven by the Japanese in the 1980s is a process

Surfacegrinding segmentsare generally used togrindflat stock or flat

Double disc grinding is an abrasive machining process that removes material

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