Machining

• Machining: A subtractive
process used to get desired What is it?
shape, size, and finish by
removing surplus material in
the form of chips by a cutting
tool and by providing suitable
relative motion between the
workpiece and cutting tool
• Cutting tool: removes excess
material through direct
mechanical contact
• Machine tool: provides
necessary relative motion
between the work-piece and
tool
 Basics of shape generation by machining
• Two relative motions (between work and tool)
generally needed to produce surfaces
– Cutting speed: line generated by it is called
generatrix: Primary cutting motion
– Feed speed: line generated by it is called
directrix: Secondary cutting motion
 Relative motions needed for
various types surface generation
Surface Machini Generatrix Directrix
Obtained ng (cutting) (feed)
Process
Planar Shapin Straight Straight
Surface g, Line Line
Planing
Cylindrica Turning Circular Straight
l Line
Planar Milling Circular Straight
Surface Line
Surface of Contour Plain Circular
Revolutio Turning Curve
n ,Boring
 TYPES OF MACHINING PROCESSES
BASED ON ANGLE BETWEEN CUTTING
EDGE and CUTTING VELOCITY
Oblique Machining Orthogonal Machining
➢ Cutting edge of the tool ➢ Cutting edge of the tool is
is inclined with normal perpendicular to the
to the cutting velocity. direction of cutting velocity
➢ Cutting Forces Act ➢ Cutting Forces Act Along x
along All Three and z Directions Only i.e.
Directions i.e. x, y, and z No Cutting Force along y
Axes. Direction
➢ Examples: ➢ Examples:
Turning, Sawing,
Milling, Broaching,
Drilling, Parting-Off of Tube Wall
Shaping
MI-102: Manufacturing Techniques I. I. T.
ACCORDING to TYPE of CUTTING TOOL
Machining Processes

Using SINGLE-Point Using MULTI-Point Using ABRASIVES

Cutting Tools Cutting Tools as Cutting Tools

➢ Turning ➢ Milling ➢ Grinding

❖ Step Turning ➢ Drilling ➢ Honing
❖ Taper Turning ➢ Reaming ➢ Lapping
❖ Form Turning ➢ Knurling ➢ Super-Finishing
❖ Contour Turing ➢ Tapping ➢ Polishing
➢ Facing ➢ Hobbing ➢ Buffing
➢ Necking ➢ Broaching
➢ Parting-Off ➢ Sawing
➢ Boring
❖ Counter-
Boring
❖ Counter-
Sinking
➢ Shaping
➢ Planing
 LATHE MACHINE and its OPERATIONS
➢ Lathes are Machine Tools Designed Primarily to Do
Turning, Facing, and Boring.
➢ Because Lathes also can Do Facing, Drilling, and
Reaming, their Versatility Permits Several Operations

DESIGN and TERMINOLOGY of the ENGINE LATHE

The Essential Components of an Engine Lathe are
1. Bed
2. Headstock Assembly 5. Feed Rod
3. Tailstock Assembly 6. Leadscrew
4. Carriage Assembly 7. Quick Change Gearbox

MI-102: Manufacturing Techniques I. I. T.

 Tailstock

Bed
Schematic Diagram of an Engine Lathe
MI-102: Manufacturing Techniques I. I. T.
 Carriage
assembly
➢ Carriage
assembly
provides the
means for
mounting and
moving cutting
tools.
➢ Carriage
assembly
consists of
carriage, cross
slide,
compound rest,
tool post

MI-102: Manufacturing Techniques I. I. T.

 Feed rod
➢ provides
the
powered
movemen
t of the
carriage
and cross
slide for
automatic
movement
of tool
used in
turning Leadscrew
operation ➢ for cutting threads, a leadscrew is
used to provide automatic
movement to carriage.
SIZE DESIGNATION of LATHES
➢ Size of a Lathe is Designated by Two Dimensions:
1. Swing diameter: shows maximum diameter of work-
piece that can be rotated on a lathe.

2. Maximum Distance Between Centers: Indicates the

Maximum Length of Workpiece that can be Mounted
Between Centers.

Example: A 14 x
48 Lathe
designates that
the swing is 14
in. and the
maximum
distance
between centers
is 48 in.
• Engine lathe,
• Speed lathe, Type of
• Tool room lathe,
• Turret lathe,
lathes
• Automatic lathe,
• Numerical control lathe
 ENGINE LATHE
• Most frequently used in
manufacturing
• They are heavy duty
machine tools with all the
components have power
drive for all tool
movements except on
compound rest.
• Most engine lathes are
equipped with chip pans
and a built-in coolant
circulating system.
SPEED LATHE
➢ Speed lathes usually
have only a
headstock, a
tailstock, and a
simple tool post
➢ Usually three or four
speeds
➢ Mainly used for
wood turning,
polishing, or metal
spinning
➢ Spindle speeds up to
4000 rpm.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Tool room lathe
• Greater accuracy and
usually a wider range
of speeds and feeds
than engine lathes.
• Designed to have
greater versatility to
meet the requirements
of tool and die work
• Generally used for
machining smaller
parts
 Turret lathe
• Hexagon Turret Replaces
the Tailstock
• Turret used for mounting
tools and feed into the work
piece
• Turret Lathes Use the 11 RAM TYPE
Station Tooling and so as
to increase production
rate by reducing tool
changing time .
• SIX Tools can be Mounted
on the Hexagon Turret
• Turret can be Rotated
about the Vertical Axis to
Bring Each Tool into the
Operating Position
Ram and saddle SADDLE
TYPE
type turret lathe
• Primary difference is
in mounting and size
of two types.
• Ram type is light,
less rigidity and so
for small jobs using
RAM TYPE
fine cuts
• Saddle type heavy,
more rigid, large
jobs and heavy cuts
Turning is the process of Machining external
cylindrical and conical surfaces.
– Straight turning: for producing cylindrical shapes
– Taper turning: for producing conical shapes
– Facing: making edges square and clear
– Chamfering: slightly tapering and rounding off of
edges Operations of
– Threading: for producing threads lathe
– Drilling: for creating /producing hole
– Boring: for enlarging hope and correcting shape
– Parting off or necking: separating or making square
groove
– Knurling: making impression for firm gripping
– Reaming: finishing purpose
 Straight/cylindrical turning

Orthogonal turning Oblique turning

TAPER TURNING

➢ Cutting tool is fed at an angle to the axis

of rotation producing an
external/internal conical surface.
➢ Tapers generally specified in degrees of
included angle between the sides (or rate
of change in diameter along the length
mm/mm)

➢ FOUR Methods for Taper turning:

➢ Swiveling the Compound Rest: Only for
Short and steep Tapers
➢ Taper turning attachment: for fine taper-ness
less than 0.5mm/mm
➢ Setting over tailstock: low taper in long jobs
➢ NC lathe with programmed both movements of
movement of tool
MI-102: Manufacturing Techniques I. I. T.
Swiveling the compound rest
• Tool is set
at half of
taper angle
w.r.t. lathe
axis and
moved with
compound
rest only
Taper turning
attachment
• Cross
slide is
made free
and tool
is moved
with help
of
attachme
nt at an
angle
Off setting the tail stock

Tool is moved with help

of carriage parallel to the
lathe axis
 Contour turning

➢ The tool follows a contour

creating a contoured form on
the turned part instead of
parallel to the axis. Cross slide
is made free to follow the path
of contour.

FORM TURNING

➢ Cutting edge of Tool has a Specific

Form or Shape and is fed radially
inward towards the axis of rotating
work piece.
FACING

➢ Cutting tool is fed radially inwards

(at 90° w.r.t. the axis of rotation) into
the rotating work piece.

➢ End facing: facing by tool moving

radially outward from the center

➢ Shoulder facing: facing the stepped

cylindrical work piece
Chamfering
➢ The tool is fed radially inward
used to cut an angle on the
corner of the cylinder,
forming a chamfer to avoid
sharp edges.

Parting off & necking

➢ Tool is fed perpendicular to

the rotational axis
➢ Necking is a making partial
cutoff

MI-102: Manufacturing Techniques I. I. T.

DRILLING
➢ The tool (Drill) mounted on the
tailstock of the engine lathes
is fed by hand against a
rotating work piece along the
axis of lathe.

BORING

➢ Tool mounted to tailstock is

fed parallel to the lathe axis
after giving suitable depth of
cut

MI-102: Manufacturing Techniques I. I. T.

 REAMING
➢ It is semi-finishing
operation that enlarges
an existing hole. Tool is
rotated and fed along
rotational axis.
knurling
➢ Roughening the surface of work
piece for better gripping.
➢ No machining operation only cold-
forming takes place
➢ Process involves pressing of
two hardened rolls against the
rotating work piece with sufficient
force to form impression (the knurl)
like raised diamond pattern.
• Face plate: for holding irregular
Work holding
shape w/p
devices
• Lathe centers: for holding long
jobs
• Chuck:
– 3 jaw chuck for circular or
hexagonal section
– 4 jaw chuck for irregular
shapes
– Magnetic chuck for holding
soft metal
 Mandrel: for
Mandrel holding hollow disc
shape w/p for
machining of side
faces

Collet: for holing

small diameter tool
and work pieces

Collet
CUTTING TOOLS USED In a LATHE
➢ Single Point Cutting Tools
➢ Bit-Type Cutting Tools
➢ Form Tools (tapering and Threading Tool)

common cutting tool materials

❖ For conventional machining processes, cutting
tool material must be at least 35% to 50%
harder than work material at the actual
temperature of machining
1. tool steels
2. high speed steel (hss)
3. cemented carbides
4. coated carbides
5. ceramics
6. cermets (ceramic material in a metallic binder)
7. sintered polycrystalline cubic boron nitride
(cbn)
8. sintered polycrystalline diamond (pcd)
MI-102: Manufacturing Techniques I. I. T.
Geometry of
single point
cutting tool
FUNDAMENTALS of DRILLING OPERATIONS

➢ Drilling is a machining operation of creating a hole in a

work-piece which can be through holes or blind holes,
performed with a rotating cylindrical tool having TWO
cutting edges called a twist drill.

➢ Rotating drill is fed into the stationary work-piece to

form a hole whose diameter is determined by the drill
diameter.

MI-102: Manufacturing Techniques I. I. T.

OPERATIONS RELATED to DRILLING

REAMING: A Semi-Finishing Operation to

➢ Slightly Enlarge an Existing Hole
➢ To Provide Better Tolerance on Hole Diameter
➢ To Improve Surface Finish

TAPPING: To Make INTERNAL

Threads on an Existing Hole Using
Taps

MI-102: Manufacturing Techniques I. I. T.

 COUNTER-BORING:
➢ Making of INTERNAL STEPPED HOLE in
which a Lager Diameter Follows a
Smaller Diameter Partially into the
Hole

COUNTER-SINKING:
➢ Similar to Counter-Boring, Except
that the Step in the Hole is Cone
Shaped for Flat-Head Screws and
Bolts.
CENTERING or CENTER-DRILLING:
➢ Drilling of a Starting Hole to
Accurately Establish its Location for
Subsequent Drilling.
TYPICAL SEQUENCE of
OPERATIONS in a
HOLE MAKING

MI-102: Manufacturing Techniques I. I. T.

CUTTING TOOLS USED in DRILLING

➢ A Twist Drill has THREE Basic Parts: Body, Point, and

Shank
➢ A Twist Drill has TWO Helical Grooves Called Flutes
Separated by Lands.
➢ Flutes Act as Passageways for Extraction of Chips From
the Hole
➢ Point of the Twist Drill has the General Shape of a Cone
having a Typical Value of 1180.

MI-102: Manufacturing Techniques I. I. T.

Geometry of Twist Drill.
DRILLING MACHINE
➢ Drilling is Most Commonly Performed on a Drill Press.
DRILL PRESS Consists
of Following Parts
1. Base,
2. Column
3. Power-Head
4. Spindle
5. Worktable
These may be bench
or floor mounted
depending on the
size
➢ Drill can be fed
manually or Upright Drill Press.
automatically
MI-102: Manufacturing Techniques I. I. T.
TYPES of DRILLING MACHINES

MAIN Applications
TYPE
1. BENCH Holes up to 0.5 in. Diameter
can be Drilled. Very High
Speed up to 30,000 rpm
2. Speeds Ranges from 60 to
UPRIGHT 3500 RPM
3. For Large Workpieces that
RADIAL Cannot Easily be Handled
Manually.
4. GANG Mass Production variety of
purposes such as Holes of
Different Sizes, Reaming,
Counterboring, on a Single
Part.
TYPES of DRILLING MACHINES

MAIN Applications, Designation

TYPE
5. MULTI- Mass Production Machines with as many
SPINDLE as 50 Spindles Driven by a Single
Power head and Fed Simultaneously
into Work.
6. DEEP- For Drilling Long (Deep) Holes in
HOLE Rifle Barrels, Connecting Rods, and
Long Spindles.
 UPRIGHT DRILLING MACHINE
BENCH TYPE
Milling
➢ Milling is a machining operation in which a work-
part is fed past a rotating cylindrical tool called
milling cutter is multi point cutting tool.
➢ In milling axis of rotation of the cutting tool is
perpendicular to the direction of feed.
➢ While in drilling, the cutting tool is fed in a
direction parallel to its axis of rotation.

HORIZONTAL TYPE VERTICAL TYPE

➢ Geometric form created by milling is a plane
surface and other geometries are created either by
controlled cutter path or the cutter shape.

➢ Typical feature of milling:

➢ it is an interrupted cutting operation

❖ the teeth of the milling cutter enter and exit the

work during each revolution.

❖ so cycle of impact force and thermal shock in

every rotation.

❖ the tool material and cutter geometry must be

designed to withstand these conditions.
TYPES of MILLING OPERATIONS
PERIPHERAL MILLING FACE MILLING
axis of tool is parallel to the axis of tool is perpendicular to the
surface being machined surface being machined
machining is performed by cutting machining is performed by cutting
edges on the outside periphery edges on both the end and
of the cutter. outside periphery of the cutter.
TYPES of PERIPHERAL or TYPES of FACE MILLING
PLAIN MILLING
(a) slab milling: basic form of (a) conventional face milling:
peripheral milling in which the cutter the diameter of the cutter is
width extends beyond the work- greater than the work-part
piece on both sides. width, so that the cutter
overhangs the work on both
sides.

(b) slot milling (slotting): the (b) partial face milling: the
width of the cutter is less than the cutter overhangs the work on
work-piece width. very thin cutter only one side.
can be used to mill narrow slots or to
cut a work-part in two, called saw
milling.
TYPES of PERIPHERAL MILLING TYPES of FACE MILLING

(c) side milling: cutter machines (c) end milling: the cutter
the side of the workpiece. diameter is less than the work
width, so a slot is cut into the
part.

(d) straddle milling: the same as (d) profile milling: this is a form
side milling, only cutting takes of end milling in which the outside
place on both sides of the work. periphery of a flat part is cut.

MI-102: Manufacturing Techniques I. I. T.

TYPES of PERIPHERAL TYPES of FACE MILLING
according to the rotation (e) pocket milling: another form
direction of the cutter two types: of end milling, this is used to mill
(e) up or conventional: the shallow pockets into flat parts.
direction of motion of the cutter
is opposite to the feed direction.

(f) down or climb milling: the (f) surface contouring: a ball-

direction of cutter motion is in nose cutter is fed back and forth
the feed direction across the work along a curvilinear
path at close intervals to create a
3-dimensional surface form.

MI-102: Manufacturing Techniques I. I. T.

 DIFFERENCES
UP Milling DOWN Milling
The direction of motion of The direction of cutter
the cutter is opposite to the motion is in the feed
feed direction. direction
It is milling “against the It is milling “with the feed."
feed."
Cutting force direction is Cutting force direction is
tangential to the periphery of downward, tending to hold
the cutter which tends to lift the work against the
the work piece as the cutter milling machine table.
exits the material.

MI-102: Manufacturing Techniques I. I. T.

TYPES of MILLING MACHINES

Type Applications
(a) column and → for slab, side, or straddle milling.
knee type → well suited for face and end
(general purpose) milling operations
→ for milling to produce twist
drills), milling cutters, and helical
gear teeth, etc.
(b) bed type → for making heavy cuts
(manufacturing) → simultaneous milling of two or
three surfaces in a single pass
(c) planer milling → for machining a wide variety of
machines surfaces on heavy workpiece in a
single setup.
MI-102: Manufacturing Techniques I. I. T.
 Milling cutter
➢ Milling cutters are classified on the basis of
methods of mounting and direction of rotation.
➢ Method of mounting
➢ arbor cutters have a center hole for mounting on
an arbor.
➢ shank cutters have either a tapered or a straight
shank.
❖tapered shanks cutters can be mounted
directly in the milling machine spindle.
❖straight shank cutters are held in a chuck.

MI-102: Manufacturing Techniques I. I. T.

➢ BASED ON DIRECTION OF ROTATION (Applies only to
Face and End Milling Cutters)
❖ A right-hand cutter must rotate counterclockwise
when viewed from the front end of the machine
spindle.
❖ A left-hand cutter must rotate clockwise.

Arbor for a Horizontal Spindle Milling

Typical geometry of milling cutter
GRINDING
➢ Grinding is a finishing process using abrasives (i.e. Al2O3,
SiC, B4C, Diamond, CBN, etc.) bonded in form of Wheel
operating at Very High Surface Speeds.
➢ Similar to the Milling, Cutting in grinding can be either the
Periphery or the Face of the Grinding Wheel.

Periphery

MI-102: Manufacturing Techniques I. I. T.

➢ Comparison between Grinding and Milling in terms of:
❖ Size: finer in grinding than milling
❖ number of Cutting teeth: more in grinding than
milling
❖ Orientation of cutting teeth: random in grinding
and the same is fixed in milling
❖ Cutting Speeds: Higher in grinding speed than
Milling
❖ Self-Sharpening Feature exists with grinding but
not with milling

MI-102: Manufacturing Techniques I. I. T.

TYPES of GRINDING OPERATIONS
➢ Grinding is mainly for Finish Parts of part Created by
Other Operations.
➢ Accordingly, Grinding Machines have been Developed
to Grind
❖ Plain Flat Surfaces,
❖ External and Internal Cylinders, and
❖ Contour Shapes such as Threads.
❖ Tool Rooms operations for processing Cutting
Tools.
➢ Main Types of Grinding Operations are
1. Surface Grinding,
2. Cylindrical Grinding,
3. Centerless Grinding,
4. Creep Feed Grinding,
5. Other Grinding Operations

MI-102: Manufacturing Techniques I. I. T.

 Surface Grinding
➢ Surface Grinding for Plain Flat Surfaces.
➢ Workpiece is Normally Held in a Horizontal Orientation.

➢ Peripheral Grinding:
Performed using
Periphery of the
Grinding Wheel
rotating the
Horizontal Axis,

➢ Face Grinding: Performed

using Flat Face of the wheel
which Rotates about the
Vertical Axis.

➢ In either case, the Relative Motion of the Workpiece is Achieved by

Reciprocating (Flat) or by Rotating (Circular) the Work Past the
Wheel.
Cylindrical Grinding
➢ Used for Rotational Parts.
➢ Cylindrical Grinding Operations can be Divide into TWO Basic Types:
(A) External Cylindrical Grinding; (B) Internal Cylindrical
Grinding.

External Cylindrical Grinding

➢ Also Called Center-Type Grinding to Distinguish it from
Centerless Grinding, is Performed much like a Turning
Operation.

MI-102: Manufacturing Techniques I. I. T.

➢ There are Two Types of Feed Motion Possible,
❖ Traverse Feed: Grinding Wheel is Fed in a Direction Parallel to
the Axis of Rotation of the Workpiece (Fig. a)
✓ Infeed: Typical range from 0.0075 to 0.075mm.
✓ A Longitudinal Reciprocating Motion parallel to work axis is
sometimes to either the Work or the Wheel to Improve Surface
Finish.

❖ Plunge-Cut: Grinding Wheel is Fed Radially into the Work.

Formed Grinding Wheels use this type of Feed Motion (Fig. b)
APPLICATIONS:
➢ Parts Include Axles, Crankshafts, Spindles, Bearings and
Bushings, and Rolls for Rolling Mills

Internal Cylindrical Grinding

➢ The Workpiece is Usually held in a
Chuck and Rotated
➢ Wheel Diameter must be Smaller
than the Original Bore Hole so needs
High Rotational Speeds in Order to
Achieve the Desired Surface Speed.
➢ Grinding Wheel is Fed in either of Two
Ways: Traverse Feed or Plunge Feed
APPLICATIONS:

➢ Used to Finish the Hardened Surfaces

of Bearing Races and Bushing
Surfaces.
 Centerless Grinding
➢ The Workpiece is NOT Held Between Centers so Reduction in
Work Handling Time therefore for High volume Production.
➢ EXTERNAL Centerless Grinding: Consists of Two Wheels
❖ Grinding Wheel: Rotating at Surface Speeds of 1200 to
1800 m/min.
❖ Regulating Wheel: Rotating at Lower Speeds and is Inclined
at a Slight Angle to Control through Feed of the Work

Long Rods are Supported by a Rest Blade

and Fed through Between the Two Wheels
INTERNAL Centerless Grinding:
➢ Two Support Rolls are Used to Maintain the
Position of the Work in Place of the Rest Blade.
❖ The Regulating Wheel is Tilted at a Small
Inclination Angle to Control the Feed of the Work
Past the Grinding Wheel.
❖ ADVANTAGE: Provides Very Close Concentricity
Between Internal and External Diameters on a
Tubular Part Such as a Roller Bearing Race

MI-102: Manufacturing Techniques I. I. T.

Creep Feed Grinding (Developed Around
1958).
➢ Grinding using Very High Depths of Cut and
Very Low Feed Rates.
➢ Depths of Cut in Creep Feed Grinding are
1,000 To 10,000 Times Greater than in
Conventional Surface Grinding and Feed Rates
are Reduced by About the Same Proportion.

Conventional Surface Grinding Creep Feed Grinding

 Other Grinding Operations
➢ TOOL GRINDERS: used for Sharpen and Recondition Cutting
Tools.
➢ JIG GRINDERS: Used to Grind Holes in Hardened Steel Parts
to High Accuracies e.g. Press Working Dies and Tools.

➢ ABRASIVE BELT GRINDING: Uses Abrasive Particles

Bonded to a Flexible Cloth Belt Support by Roll or Platten
Located Behind the Belt, and Work is Pressed Against it.

TOOL GRINDERS ABRASIVE BELT GRINDING

MI-102: Manufacturing Techniques I. I. T.

GRINDING WHEEL
➢ Grinding Wheel is Usually Disk-shaped and is
Precisely Balanced for High Rotational Speeds.
➢ A Grinding Wheel Consists of Abrasive Particles held by
Bonding Material in position.
➢ Parameters of the Grinding Wheel used for
designation:
(1) Type of Abrasive Particle Material,
(2) Size of Abrasive Particles,
(3) Bonding Material,
(4) Wheel Grade,
(5) Wheel Structure
➢ All these parameters affect Desired Performance of
Grinding in terms of surface roughness and metal
removal rate i.e. rate of cutting.
Grinding Wheel Parameters

1. ABRASIVE PARTICLE MATERIAL: Desired Properties

of an Abrasive Material Used in Grinding Wheels
Include
❖ High Hardness
❖ High Wear Resistance
❖ High Toughness
❖ Friability: Capacity of the Abrasive Material to
Fracture when the Cutting Edge of the Grain
Becomes Dull, thereby Exposing a New Sharp
Edge.
➢ Hardness, Wear Resistance, and Toughness are
Desirable Properties of Any Cutting Tool Material.
➢ Commonly Abrasives are
❖ Aluminum oxide (Al203),Silicon carbide (SiC),
Cubic Boron Nitride (CBN), Diamond
MI-102: Manufacturing Techniques I. I. T.
2. SIZE of ABRASIVE PARTICLES: (also called
Grit Size) affects Surface Finish and Material
Removal Rate.
➢ Small Particle Size Produces Better
Finishes, while Larger Particle Size Produce
Larger Material Removal Rates.
➢ Selection of Abrasive Particle Size also
Depends on the Type of Work Material.
➢ Harder Work Materials Require Smaller
Particle Size to Cut Effectively, while Softer
Materials Require Larger Particle Size.
MI-102: Manufacturing Techniques I. I. T.
3. BONDING MATERIALS: The Bonding Material Must
❖ Hold the Abrasive Grains Rigidly so as to get desired
the Shape and Structural Integrity of the Grinding
Wheel.
❖ Should be able to Withstand under
❖ the Centrifugal Forces
❖ High Temperatures generated during Grinding
❖ Good impact Resistance to avoid Shattering in
Shock Loading
❖ Allowing debonding of Worn Abrasive Grains so that
New Grains are Exposed.
➢ Commonly Bonding Materials in Grinding Wheels:
➢ Vitrified bond:
(A)Silicate Bond:.
(B) Rubber Bond:
(D) Resinoid Bond:
(E) Shellac Bond:
(F) Metallic Bond:
 4. GRINDING WHEEL STRUCTURE: Refers to the Relative Spacing of
the Abrasive Grains in the Wheel. A Grinding Wheel Contains Air
Gaps/Pores, Abrasives and Bond Material.
➢ The Volumetric Proportions of Grains, Bond Material, and Pores
can be Expressed as Pg + Pb + Pp = 1; Where
Pg = Proportion of Abrasive Grains; Pb = Proportion of Bond
Material, and Pp = Proportion of Pores (Air Gaps) in the Total
Wheel Volume
➢ Wheel Structure is termed as "Open" or "Dense” as per spacing
between abrasives
➢ An Open Structure has large Air Gaps than the Abrasives and
reverse is true for dense structure.
➢ A Dense Structure is One in Bond
which Pp is Relatively Small, And Material
Pg is Larger.
➢ Open Structures offers high MRR
and poor surface finish .
➢ Dense Structures are Used to
Obtain Better Surface Finish
and Dimensional Control.

MI-102: Manufacturing Techniques I. I. T.

5. GRINDING WHEEL GRADE: Indicates the Bond
Strength of the Grinding Wheel in Retaining the
Abrasive Grits during Cutting.
➢ Depends on the type and Amount of Bonding
Material.
➢ Grade is termed as “Soft”, medium, “Hard”.
➢ "Soft" Wheels Lose Grains Readily, while “Hard"
Wheels Retain their Abrasive Grains.

Selection of grade
➢ Soft Wheels are Generally Used for Applications
Requiring Low Material Removal Rates and
Grinding of Hard Work Materials.
➢ Hard Wheels are Typically Used to Achieve High
Material Removal Rates and for Grinding of
Relative Soft Work Materials.
MI-102: Manufacturing Techniques I. I. T.
Grinding Wheel Designation
➢ The Grinding Wheel Parameters are Concisely
Designated in a Standard Grinding Wheel
Marking System Defined by the American
National Standards Institute (ANSI).
➢ Designated Using Numbers and Letters to Specify:
in sequence of Abrasive Type, Abrasive Grit Size,
Wheel Grade, Wheel Structure, and Bond
Material.

Z
New scheme