This document discusses various abrasive machining and finishing operations. It begins by describing common bonded and superabrasive grinding wheels. It then explains different grinding processes like surface, cylindrical, plunge, thread, and internal grinding. It also covers grinding operations like centerless grinding, creep-feed grinding, ultrasonic machining, honing, superfinishing, lapping, polishing using magnetic fields, abrasive flow machining, and robot deburring. Diagrams are provided to illustrate the various abrasive processes and techniques.

1. CHAPTER 25
Abrasive Machining and
Finishing Operations

2. Examples of Bonded Abrasives
Fig: A variety of bonded abrasive used in abrasive machining processes

3. Workpiece Geometries
Fig: The types of work pieces and operations typical of grinding: (a) cylindrical surfaces, (b) conical surfaces,
(c) fillets on a shaft, (d) helical profiles, (e) concave shape, (f) cutting off or slotting with thin wheels, and (g)
internal grinding

4. Grinding Wheel
Fig: Physical model of a grinding wheel, showing is structure and wear and fracture patterns.

5. Common Grinding Wheels
Fig: Common Type of Grinding Wheels made with conventional abrasives. Note that each wheel has a
specific grinding face; grinding on other surfaces is improper and unsafe

6. Superabrasive Wheel Configuration
Fig: Examples of Superabrasive Wheel Configuration. The annular regions (rim) are superabrasive grinding
surfaces, and the wheel itself (core) is generally made of metal or composites. The bonding materials for the
super abrasives are: (a), (d), and (e) resinoid, metal, or vitrified, (b) metal, (c) vitrified, and (f) resinoid

7. Grinding Chips
Fig: (a) Grinding chip being produced by a single abrasive grain. (A) chip, (B) workpiece, (C) abrasive grain.
Note the large negative rake angle of the grain. The inscribed circle is 0.065mm in diameter. (b) Chip
formation by an abrasive grain with a wear flat. Note the negative rake angle of the grain and the small shear
angle

8. Grinding Wheel Surface
Fig: The surface of a grinding wheel
showing abrasive grains, wheel porosity,
wear flats on grains, and metal chips from
the workpiece adhering to the grains.
Note the random distribution and shape of
abrasive grains.

9. Surface grinding and Plowing
Fig: Surface grinding process, showing
various process variables.
Fig: Chip formation and Plowing of the workpiece surface
by and abrasive grain. This action is similar to abrasive
wear

10. Shaping using Computer Control
Fig: Shaping the grinding face of a wheel by
dressing it with computer control. Note that
the diamond dressing tool is normal to the
surface at point of contact with the wheel.

11. Surface Grinding Operations
Fig: Surface Grinding Operations. (a) Traverse grinding with a horizontal-spindle surface grinder. (b) Plunge
grinding with a horizontal-spindle surface grinder, producing a groove in the workpiece. (c) A vertical-spindle
rotary-table grinder (also known as the Blanchard type)

12. Surface Grinding
Fig: (a) Rough grinding of steel balls on a vertical-
spindle grinder; the balls are guided by a special
rotary fixture. (b) The balls are ground to within
0.013mm of their final size.
Fig: A Horizontal-spindle surface grinder

13. Cylindrical Grinding Operations
Fig: Examples of various cylindrical grinding operations. (a) Traverse grinding, (b) plunge grinding, and
(c) profile grinding.

14. Plunge and Noncylindrical Grinding
Fig: Plunge Grinding of a workpiece on a
cylindrical grinder with the wheel dressed to
a stepped shape.
Fig: Grinding a noncylindrical part on a
cylindrical grinder with computer controls to
produce the shape. The part rotation and the
distance x between centers is varied and
synchronized to grind the particular workpiece
shape.

15. Thread and Internal Grinding
Fig: Thread grinding by (a) traverse, and (b) plunge grinding
Fig: Internal grinding operations

16. Cycle Pattern in Cylindrical Grinding

17. Centerless Grinding
Fig: Centerless grinding operations: (a) through feed grinding.
(b) Plunge grinding. (c) A computer numerical control grinding
machine

18. Creep-Feed Grinding
Fig: (a) Creep-Feed Grinding process. Note the large wheel depth of cut, d. (b) A shape groove produced on
a flat surface by creep-feed grinding in one pass. Groove depth is typically on the orde of a few mm. (c) An
example of creep-feed grinding with a shaped wheel. This operation can also be performed by some of the
processes described .

19. Ultrasonic Maching and Coated
Abrasives
Fig: (a) Ultrasonic Maching process. (b) and (c) Types of parts made by this
process. Note the small size of holes produced
Fig: Structure of a coated
abrasive.Sandpaper, developed in the 16th
century, and emery cloth are common
examples of coated abrasives

20. Belt Grinding

21. Honing and Superfinishing
Fig: Honing tool used to improve the surface
finish or ground holes
Fig: The Superfinishing process for a
cylindrical part. (a) Cylindrical microhoning,
(b) Centerless microhoning

22. Lapping
Fig: (a) Lapping process. (b) Production lapping on flat surfaces. (c) Production lapping on cylindrical
surfaces.

23. Polishing Using Magnetic Fields
Fig: Polishing of balls and rollers using magnetic fields. (a) Magnetic float polishing of ceramic balls. (b)
Magnetic-field-assisted polishing of rollers.

24. Abrasive Flow Machining
Fig: Abrasive Flow Machining to deburr a turbine impeller.The arrows indicate movement of abrasive media.
Note the special fixture, which is usually different for each part design.

25. Robot Deburring
Fig: A Deburring operation on a robot-held die-cast part for an outboard motor housing, using a grinding
wheel. Abrasive belts or flexible abrasive radial-wheel brushes can also be used for such operations.