5. 5
The author would like to thank all the bibliographic references and videos that
have contributed to the elaboration of these presentations.
For bibliographic references, please refer to:
• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)
• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)
For videos, please refer to:
• www.symbaloo.com/mix/manufacturingtechnology
BIBLIOGRAPHY
by Endika Gandarias
7. 7
INTRODUCTION
• Usually brought into play after machining, casting, forging, sheet metal forming, etc.
• It can be used on all type of materials.
• A variety of abrasive machining processes and machinery is available.
• Abrasive machining is necessary and economical when:
• Hard materials
• Brittle materials
• Excellent surface finish and dimensional tolerances are required.
by Endika Gandarias
Rz: Maximum height of the
roughness profile
Ra: Arithmetical mean deviation
of the roughness profile
Rq: Root mean square deviation
of the roughness profile
Roughness 2D Parameters
9. 9
• All abrasive operations can be considered as material removal processes with geometrically
undefined cutting edges. Each abrasive grain acts like a single cutting tool with undefined
geometry but usually with high negative rake angle.
INTRODUCTION
by Endika Gandarias
10. 10
Sharping with
stones
Rotary stone
Pedal with shank
and connecting rod
CHARLES MOSELEY
Cylindrical grinding
machine
SWEN PULSON
Extra-strong
grinding wheel
BROWN & SHARPE
Universal grinding
NORTON
Horizontal grinding
tool holder
ACHESON
Carborundum
(Silicon carbide)
CINCINNATI
Centerless
grinding machine
GENERAL ELECTRIC
Synthetic diamond
INTRODUCTION
by Endika Gandarias
11. 11
INTRODUCTION
ABRASIVEMACHINING
TECHNOLOGIES
Grinding Flat or surface grinding
Creep feed grinding
Cylindrical grinding
Centerless grinding
Bench grinding
Blasting
Wire brushing
Mass finishing
Coated abrasive
Honing
Polishing and buffing
Lapping
Superfinishing
Others
Abrasive flow machining
Electro-polishing
Electrolytic grinding
Chemical mechanical polishing
Polishing using magnetic fields
by Endika Gandarias
COARSEMEDIUMFINE
13. 13
GRINDING
Introduction
It is an abrasive technology in which abrasive particles are contained in bonded grinding wheel.
The feed (F) and depth of cut (ap) in grinding are small, while the cutting speed (Vc) is high.
Dimensional accuracy: 0,3 – 0,5 µm
Surface finish (Ra) ~ 0,1 – 1,6 µm
Specific cutting energy: 50 J/mm3
by Endika Gandarias
VIDEO
14. 14
Introduction
GRINDING
A grinding wheel consists of:
Hard abrasive grains called grits perform the cutting or material removal Hardness
Bonding material holds particles in place and gives the profile to the wheel Toughness
Conventional abrasive wheel materials:
• Aluminium oxide (Al2O3)
• Silicon carbide wheels (SiC)
Superabrasive wheels:
• Diamond
• CBN (Cubic Boron Nitride)
Conventional abrasive wheels Superabrasive wheels
by Endika Gandarias
15. 15
1 14192 250 X 25 X 25 51-A-36-L-5-V-23 40m/s
GEOMETRY DIMENSIONS COMPOSITION Max SPEED
PRODUCT
NUMBER
Grinding wheel specification
It is needed to be specified:
• Wheel diameter (D)
• Width and depth of rim (T)
• Bore diameter (H)
GRINDING
GEOMETRY
DIMENSIONS
by Endika Gandarias
16. 16
Standard Marking System for Aluminum-Oxide and Silicon-Carbide Bonded Abrasives
GRINDING
Grinding wheel specification
COMPOSITION
by Endika Gandarias
17. 17
ABRASIVE TYPE:
Al2O3 (2000-3000) high tensile strength materials, ductile materials “corundum”
SiC (2100-3000) low tensile strength, brittle and non metallic materials “carborundum”
CBN (4000-5000) very hard materials “borazon”
Diamond (7000-8000) carbide & very hard non ferrous materials
ABRASIVE GRAIN SIZE:
Coarse Soft & ductile materials or poor Ra = roughing
Fine Hard & brittle materials or excellent Ra = finishing
GRADE (abrasive grain-bonding joining strength):
Soft wheel hard materials machining (to have fresh abrasive) or poor Ra = roughing
Hard wheel soft materials machining or excellent Ra = finishing
STRUCTURE (porosity):
Open Soft & ductile materials
High removal rate or poor Ra = roughing
Dense Long wheel life & precise wheel forms/profiles or excellent Ra = finishing
BOND TYPE:
Vitrified: most common, brittle bond
Resinoid: more flexible bond
Rubber: very flexible bond
GRINDING
Grinding wheel specification
COMPOSITION
by Endika Gandarias
VIDEO
18. 18
Grinding wheel specification
GRINDING
by Endika Gandarias
MAX.SPEED
The heavy point of the grinding
wheel is marked with an arrow.
Depending of the wheel
manufacturer, it needs to be
mounted with the arrow pointing
downwards or upwards.
VIDEO
19. 19
Truing is the process of making a grinding wheel round and concentric with the
grinding wheel spindle axis. Truing is also the process of forming a specific shape
on the face of the wheel.
Dressing is the process of conditioning the surface of a trued wheel to expose
the grain for efficient grinding action.
GRINDING
Truing and dressing a grinding wheel
After truing
After dressing
Truing and dressing can often be performed at the same time, even using
the same tool.
WHEEL OR GRINDING
DRESSERS
by Endika Gandarias
VIDEO
20. 20
GRINDING
• It is used to remove material from flat surfaces.
• Spindle position can be horizontal or vertical.
• Dimensional tolerance ~ IT5 – IT6
• Surface finish (Ra) ~ 0,15 – 0,6 µm
Grinding technology classification
Flat or surface grinding
by Endika Gandarias
VIDEO
21. 21
ALTERNATIVE
WORKTABLE
ALTERNATIVE
WORKTABLE
ROTATIVE
WORKTABLE
ROTATIVE
WORKTABLE
• Long and narrow surfaces.
• Worse efficiency than the frontal grinding.
• Better finishing than the frontal grinding.
• High material start-up rate.
• Worse finishing than the tangential grinding.
• Tools: rings, cups, segments
GRINDING
Flat or surface grinding
TANGENTIAL GRINDING WHEEL FRONTAL GRINDING WHEEL
VIDEO VIDEO
Grinding technology classification
by Endika Gandarias
VIDEO
22. 22
PropsGuide
Engine Cutting blade
GRINDING
Flat or surface grinding
APPLICATIONS
Gear
Other
Grinding technology classification
by Endika Gandarias
TANGENTIAL
FRONTAL FRONTAL
TANGENTIAL TANGENTIAL
VIDEO
23. 23
GRINDING
Creep feed grinding
It uses large depth of cuts (typically ap on the order of 1 - 6 mm) and low feed rates (F).
The wheel is often continuously dressed.
It is essential to use a high pressure coolant system and soft wheels with open structure to keep
temperature low.
Advantages: High material removal rates and productivity (the wheel is continuously cutting).
Grinding technology classification
Conventional grinding contrasted to creep feed grinding
by Endika Gandarias
25. 25
Cylindrical grinding
GRINDING
Grinding technology classification
• It is used to remove external or internal cylindrical surfaces.
• It is also known as Universal grinding.
• The workpiece is usually held in a rotating chuck in the headstock or between centers.
• The wheel rotates at very high rotational speed (N).
• Dimensional tolerance ~ IT6 – IT8
• Surface finish (Ra) ~ 0,8 – 1,6 µm
by Endika Gandarias
VIDEO
28. 28
Cylindrical grinding
GRINDING
Grinding technology classification
SPECIAL OPERATIONS
STEPPED SHAPE GRINDING WHEEL THREAD GRINDING
(a) traverse grinding (b) plunge grinding
by Endika Gandarias
VIDEO
GEAR GRINDING
VIDEO
29. 29
Crankshaftgrinding
Cylindrical grinding
GRINDING
Grinding technology classification
SPECIAL OPERATIONS
The part rotation and the distance x between centers
is varied and synchronized to grind the particular
workpiece shape.
Camshaftgrinding
GRINDING A NON-CYLINDRICAL PART
VIDEO
by Endika Gandarias
VIDEO
32. 32
Centerless grinding
GRINDING
Grinding technology classification
• It is used for high length to diameter ratio parts.
• Workpiece is NOT supported by centers or chucks,
but by a blade or between rollers.
• Easy to be automatizated.
• Dimensional tolerance ~ IT4 – IT6
• Surface finish (Ra) ~ 0,4 – 0,8 µm
(a) Through-feed grinding (b) Plunge grinding
EXTERNAL GRINDING OPERATIONS
VIDEOVIDEO
by Endika Gandarias
(a) Through-feed grinding
VIDEO
VIDEO
36. 36
The work is held (usually manually) against the flat surface of the wheel to accomplish the
grinding operation.
It can be a bench grinder or pedestal grinder.
Surface finish (Ra) ~ 0,2 - 1,6 µm
BENCH GRINDING
by Endika Gandarias
VIDEO
38. 38
This is the finishing method by spraying blasting abrasives from a nozzle with the force of
compressed air to workpieces.
It is used for:
Cleaning
Deburring
Descaling
Finishing
Peening (increases hardness and eliminates residual stresses)
Surface finish (Ra) ~ 1,5 µm
BLASTING
by Endika Gandarias
VIDEOVIDEO
40. 40
WIRE BRUSHING
It produces a fine and controlled surface texture.
Wire brushing is typically used for:
removal of rust or corrosion from metal objects.
rough-polishing castings, hot-rolled steel,…
Brushes can be made of nylon, steel or brass filaments, and may contain abrasives.
Surface finish (Ra) ~ 0,1 – 1,5 µm
by Endika Gandarias
VIDEOVIDEO
42. 42
MASS FINISHING
Mass finishing is a surface improving mass-production system. A mixture of parts, abrasive
media (vitrified, alumina, plastic, organic or metallic) and compounds (liquid or powder) are placed
into a container or barrel, and rotated at a predetermined speed.
It is used for:
Deburring
Radiusing
Smoothing
Descaling
Luster and mirror finishing.
There are several types of barrel motion:
Centrifugal barrel
Centrifugal disc
Vibratory bowl
Rotary tumbling
Surface finish (Ra) ~ 0,05 – 1,6 µm
MATERIAL
REMOVAL
RATE
HIGH
LOW
Centrifugal barrel Centrifugal disc
Vibratory bowl Barrel / Rotary tumbling
by Endika Gandarias
VIDEO
VIDEO VIDEO
VIDEO VIDEO
VIDEO
VIDEO
44. 44
COATED ABRASIVE
Sandpaper and emery cloth are common examples of coated abrasives.
They are available in multiple geometries: sheets, belts, disks,…
The precision of the surface finish depends primarily on the grain size.
Abrasive grains (mostly Al2O3, ZrO2, SiC) are uniformly distributed on flexible backing
material (paper, cotton, rayon polyester) with the tips upward. Matrix or make coat is made
of resins.
by Endika Gandarias
VIDEO
45. 45
COATED ABRASIVE
by Endika Gandarias
FEPA P
GRAIN DIAMETER
(µm)
VERY COARSE
P12 1815
P16 1324
P20 1000
P24 764
COARSE
P30 642
P36 538
P40 425
P50 336
MEDIUM
P60 269
P80 201
P100 162
FINE
P120 125
P150 100
P180 82
P220 68
FEPA P
GRAIN DIAMETER
(µm)
VERY FINE
P240 58.5
P280 52.2
P320 46.2
EXTRA FINE
P360 40.5
P400 35.0
P500 30.2
P600 25.8
P800 21.8
SUPER FINE
P1000 18.3
P1200 15.3
P1500 12.6
P2000 10.3
P2500 8.4
P3000 7
P5000 5
Obtained surface roughness (Ra) depends on the workpiece material.
46. 46
Coated abrasives are also used as belts for high material removal rate and good surface finish.
Typical applications: surgical implants, medical & dental instruments, golf clubs, firearms, turbine
blades.
Dimensional tolerance ~ IT10 – IT11
Surface finish ~ 0,4 – 0,8 µm
COATED ABRASIVE
Belt grinding
by Endika Gandarias
VIDEOVIDEO
48. 48
HONING
Honing is used to improve the surface finish and roundness of bored or ground holes.
It creates a characteristic cross-hatched surface that retains lubrication.
As it is a slow rotation operation, no heat affected zone (HAZ) appears.
Typical application: bores of internal combustion engines.
Dimensional tolerance ~ IT4 – IT5
Surface finish (Ra) ~ 0,05 – 0,2 µm
BEFOREAFTER
(Al2O3 or SiC)
by Endika Gandarias
OscillationVa
Slow rotation
Vu
VIDEOVIDEO
51. 51
POLISHING AND BUFFING
Abrasive particles are glued to the outside periphery of the polishing wheel and it rotates at
high speeds.
Polishing is used to remove scratches and burrs.
Polishing operations are often accomplished manually.
The polishing wheel is made of fabrics, leather or felt.
Surface finish (Ra) ~ 0.02 – 0.4 μm
BEFOREAFTER
Polishing
by Endika Gandarias
VIDEOVIDEO
52. 52
It is very similar to polishing, in which abrasive particles are not glued to the wheel but are
loose. Buffing is a finer operation than polishing.
Ideal for enhancing and brightening existing finishes, taking out stains in metals and
bringing out a new lustre in work surfaces.
Polishing operations are often accomplished manually.
The buffing wheel is made of linen, cotton, bleached muslin, flannel, or other soft cloth
materials.
Surface finish (Ra) ~ 0.01 – 0.2 μm
Buffing
POLISHING AND BUFFING
by Endika Gandarias
54. 54
LAPPING
(b) lapping on cylindrical surfaces(a) lapping on flat surfaces
It is a low speed, low ablading process.
Lapping uses fluid suspension of very small abrasive particles between
workpiece and lap. Lap usually made of cast iron, copper, leather, or
cloth.
Typical application: optical lenses, metallic bearing surfaces, gages.
Dimensional tolerance ~ IT4 – IT5
Surface finish (Ra) ~ 0.025 – 0.1 μm
by Endika Gandarias
VIDEO VIDEO
56. 56
SUPERFINISHING
It is similar to honing (also called “microhoning”):
Shorter strokes (<5 mm)
Higher frequencies (>400 cycles/min)
Lower pressures (10-40 psi)
Smaller grit size
Copious amount of low viscosity lubricant-coolant is used and it establishes a continuous film between
the stone and the workpiece and separates them.
Stroke paths controlled so that a single grit never traverses the same path twice.
Dimensional tolerance ~ IT3 – IT4
Surface finish (Ra) ~ 0.01 – 0.04 μm
(a) cylindrical microhoning (b) centerless microhoning
by Endika Gandarias
VIDEOVIDEO
VIDEO
58. 58
OTHERS
A putty of abrasive grains (SiC or diamond) is forced back and forth through the workpiece.
It is particularly suitabe for workpieces with internal cavities.
It is used for:
Deburring
Radiusing
Polishing
Dimensional tolerance ~ ± 0,005mm
Surface finish (Ra) ~ 0,05 – 0,4 µm
Abrasive Flow Machining
by Endika Gandarias
VIDEO
59. 59
This polishing method melts the surface of a workpiece by applying an electrolytic solution and
an electric DC current to workpiece.
Mirrorlike finishes can be obtained on metal surfaces. It is very suitable for irregular geometries.
This process is also used for deburring operations.
Typical application: medical instrumentation, bone screws, stainless steel surfaces.
Surface finish (Ra) ~ 0.1 – 0.8 μm
OTHERS
Electropolishing
by Endika Gandarias
VIDEOVIDEO
60. 60
It is a variant of ElectroChemical Machining (ECM), and it is also known as electrochemical
grinding.
It is a process that combines electrochemical energy with mechanical energy to remove
material by grinding with a negatively charged abrasive grinding wheel, an electrolyte fluid, and
a positively charged workpiece.
Typically 90% of the metal is removed by electrolysis and 10% from the abrasive grinding wheel
(the wheel lasts a longer time). Thus, difficult materials independent of their hardness or
strength can be machined.
The wheel and workpiece must be electrically conductive.
OTHERS
Electrolytic grinding (ECG)
by Endika Gandarias
VIDEO
61. 61
OTHERS
Chemical Mechanical Polishing/Planarization is a process of smoothing surfaces.
It is a combination of mechanical free abrasive polishing and chemical etching (increases
material removal rate).
It may contain 1 or more workpiece carriers.
Typical applications: silicon wafers and integrated circuits.
Surface finish (Ra) ~ 0.035 – 0.0005 μm
Chemical Mechanical Polishing (CMP)
by Endika Gandarias
VIDEOVIDEO
62. 62
OTHERS
A magnetic field is used to force a homogeneous mixture of magnetic particles and abrasive particles
against the target surface.
The particles can be introduced into areas which are hard to reach by conventional techniques.
Typical applications: medical components, fluid systems, optics, dies and molds, electronic
components, microelectromechanical systems, and mechanical components.
Surface finish (Ra) ~ 200 – 0.001 μm
(a) magnetic float polishing of ceramice balls (b) magnetic field assisted polishing of rollers
Polishing Using Magnetic Fields
by Endika Gandarias
VIDEOVIDEO
64. 64
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Ablading Abrasión Urratze
Abrasive Abrasivo Urratzaile
Accuracy Precisión Doitasun
Attrition Erosión Erosio
Axial cutting depth Profundidad de pasada axial Sakontze sakonera
Axle Eje Ardatz
Backing Sustrato / Apoyo Substratu
Barrel Barril / Tonel Upel / Barrika
Barrel finishing Tambor de pulido Leunketa danbor
Batch Lote Sorta
Bearing Rodamiento Errodamendu
Bed Base Oinarri
Belt Cinta / Banda Banda
Belt grinding Lijado con cinta/banda Banda bidezko lixatze
Bench grinding Esmerilado Esmerilaketa
Between centers Entre centros Zentru artean
Binder Aglutinante Aglutinatzaile
Blade Cuchilla Hortz
Blasting Chorreado Jariaketa
Bleached muslin Muselina blanqueada Muselina zuritua
Bond Enlace Lotura
Bone Hueso Hezur
Brittle Frágil Hauskor
Buffing Abrillantado Distiraketa
Burr Rebaba Bizar
Camshaft Arbol de levas Espeka ardatza
Carborundum Carborundo Karborundum
Carriage Carro Orga
65. 65
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Carrier Transportador / Portador Garraiatzaile
Casting Fundición Galdaketa
Centerless grinding Rectificado sin centros Zentrugabeko artezketa
Chip Viruta Txirbil
Chuck Amarre / Porta Amarratze / Porta
Coarse Basto Baldar
Coated abrasive Papel / telas abrasivas Paper / Oihal urratzaileak
Compound Mezcla / Compuesto Nahaste
Corundum Corindón Korindoi
Cotton Algodón Kotoi
Crankshaft Cigüeñal Birabarki
Creep feed grinding Rectificado de profundidad Sakonerako artezketa
Cross-hatched Estrías cruzadas Ildaska gurutzatuak
Cup Copa Kopa
Cutting speed Velocidad de corte Ebaketa abiadura
Cutting speed Velocidad de corte Ebaketa abiadura
Descaling Descascarillar / Desescamar / Desincrustar / Decapar
Azala kendu / Ezkata kendu / Inkrustazioak
kendu / Ugerra kendu
Dressing Reavivado Berpizketa
Drive spindle Cabezal motriz Buru eragilea
Emery Esmeril Esmeril
Emery cloth Paño de lija Lixa oihal
Engine Motor Motore
Fabric Tela Ohial
Face plate Plato plano Plater laua
Feed rate Avance por minuto Aitzinamendua minutuko
Felt Fieltro Feltro
Field Campo Eremu
Firearms Armas de fuego Su arma