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Grinding
Grinding material removal by an abrasive
bonded grinding wheel rotating a high
speed.
Grinding Wheel basic parameters:
Abrasive material
Grain size
Bonding material
Wheel grade
Wheel structure
http://www.youtube.com/watch?v=RnTNqSccW-M&feature=PlayList&p=3AFB507B668AF162&index=41
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Grinding Wheel
Abrasive materials
Aluminum oxide: grinding ferrous and highstrength alloys (Knoop hardness ~ 2100)
Silicon carbide: grinding aluminum, brass, and
stainless steel, cast irons and certain ceramics
(Knoop hardness ~ 2500)
Cubic boron nitride: grinding hardened steels
and aerospace alloys (Knoop hardness ~ 5000)
Diamond: grinding ceramics, cemented
carbides, and glass (Knoop hardness ~ 7000)
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Grinding Wheel
Grain size size of the abrasive particles
Typical grain size: 8-250 (mesh size: lines/in)
Grit size 8: coarse grain for harder material
Grit size 250: fine grain for soft material, and for
lapping and superfinishing
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Grinding Wheel
Bonding materials requires strength,
toughness, hardness, and temperature
resistance.
Vitrified bond: baked clay and ceramics, most
common
Silicate: low heat generation, tool grinding
Rubber: flexible, cutoff operation
Resin: thermosets, rough grinding and cuttoff
Shellac: Varnish, strong but not rigid, good finish
Metallic: Usually bronze, diamond of cubic boron
nitride wheels
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Grinding Wheel
Wheel structure and Wheel grade
Wheel structure relative spacing of the abrasive
grains in the wheel
Vg+ Vb+ Vp = 1.0
Vg - proportion of abrasive grain in the wheel
Vb - proportion of bond material in the wheel
Vp - proportion of pores in the wheel
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Grinding Analysis
Material removal rate, MRR
= vwwd
vw = work speed
w = cutting width
d = depth of cut
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Grinding Process
Specific energy is much greater than
conventional machining
Most of the energy in grinding results in
high work surface temperature
Workpiece temperature can be lowered by
grinding fluid.
http://www.efunda.com/processes/machining/grind.cfm
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Surface Grinding
http://www.witherstool.com/surfacegrinding.html
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Cylindrical Grinding
http://www.youtube.com/watch?v=bhjuM85fx8c
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Centerless Grinding
http://www.youtube.com/watch?v=k557Zoeu38s&NR=1
http://www.youtube.com/watch?v=K_E7lZMkuw4&feature=related
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Honing
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Lapping
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Superfinishing
Similar to honing
Shorter stroke ~ 4.5 mm up to 1500 strokes / minute
Lower pressure between tool and workpiece
http://www.youtube.com/watch?v=RiNmLHBR7dk
Lower work speed ~ 0.25 m/s
Smaller grit size ~ up to 1000
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Polishing
Polishing
Removing scratches and burrs by means of
abrasive grains attached to a polishing wheel
rotating at high speed of around 38 m/s.
Abrasive grains are glued to the outside
periphery of flexible wheel.
Grit size ranges from 20 to 120.
http://www.youtube.com/watch?v=wcYFOH09_w4
http://www.youtube.com/watch?v=Xkm4KRJQV2s&feature=related
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Buffing
Buffing
Similar to polishing but used to form high
luster surface
Wheels are softer
Very fine grit size mixed in buffing compound
Speed 40 to 85 m/s
Perform manually
http://www.youtube.com/watch?v=lIsc1nDzLak
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Ultrasonic Machining
Ultrasonic machining
Abrasive slurry driven over the workpiece by an
ultrasonic vibration tool at about 20kHz
Amplitude vibration of 0.076mm
Tool materials soft steel and stainless steel
Abrasive materials boron nitride, boron carbide,
aluminum oxide, silicon carbide, diamond
Grit size 100 to 2000
Gap size about 2 times grit size
Adobe Acrobat
Document
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Ultrasonic Machining
The grit size determines the surface finish
The concentration of abrasive in the water-based slurry
is between 20% to 60%.
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http://www.youtube.com/watch?v=tJYSn9yDSzg
http://www.youtube.com/watch?v=XNGrVxQFrdI
http://www.youtube.com/watch?v=_iqJouVi4NU
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Electrochemical
Deburring and Grinding
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http://www.youtube.com/watch?v=wDOXQkHvl4g&feature=PlayList&p=3AFB507B668AF162&index=32
Electrochemical
Deburring and Grinding
Electrochemical grinding
(ECG)
A rotating grinding wheel
with conductive bonding
material to augment anodic
dissolution of metal
workpiece surface
Deplating 95%
Grinding 5%
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http://www.youtube.com/watch?v=fDYuSleApiQ
http://www.youtube.com/watch?v=qBOoyfuO5rM&feature=related
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Chemical Machining
Chemical Milling
Chemical Blanking
Chemical Engraving
Photochemical Machining
Tolerance as close as 0.0025 mm
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Chemical Milling
Sequence of processing steps in chemical milling (1) clean raw part, (2) apply maskant, (3) scribe, cut, and peel the
maskant from areas to be etched, (4) etch, and (5) remove maskant and clean to yield finished part.
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Chemical Blanking
Sequence of processing steps in chemical blanking (1) clean raw part, (2) apply resist (maskant) by painting through
screen, (3) etch (shown partially etched), (4) etch (completed), and (5) remove resist and clean to yield finished part.
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Chemical blanking
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Chemical Engraving
Process similar to the other chemical
processes except:
Filling to apply paint or other coating into the
recessed area
Panel immersed in a solution to dissolves the
resist but not the coating material
Resist is removed highlighting the coating
pattern
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Sequence of processing steps in photochemical machining (1) clean raw part, (2) apply resist (maskant) by dipping,
spraying, or painting, (3) place negative to resist, (4) expose to ultraviolet light, (5) develop to remove resist from areas
to be etched, (6) etch (shown partially etched), (7) etch (completed), (8) remove resist and clean to yield finished part.
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Application Considerations
Very small holes below 0.125 mm diameter. (Laser beam
machining, LBM)
Holes with large depth-to-diameter ratio, d/D>20. (ECM or
EDM)
Holes that are not round (ECM or EDM)
Narrow slots in slabs or plates (ECM, LBM, EDM, water jet,
abrasive jet)
Micromachining (PCM, LBM, EBM)
Shallow pockets and surface details in flat parts (Chemical
machining)
Special contoured shapes for mold and die applications
(EDM or ECM)
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Application Considerations
Special shapes for which the non traditional processes are appropriate (a) very small diameter holes, (b) holes with
large depth-to-diameter ratios, (c) nonround holes, (d) narrow, non-straight slots, (e) pockets, and (f) die sinking
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Materials Consideration
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Machining Characteristics
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Measurement
Packaging
Maintenance