TOOL POST GRINDER

ABSTRACT
 CHAPTER I

ABSTRACT

In modern manufacturing and assembling, high dimensional accuracy and

fine surface finish play an important role. The grinding process is commonly used
as finishing operation which makes the process distinguished from other
machining processes. One of the best low cost methods of producing such parts
is by a cylindrical grinding attachment on a lathe machine. In the present study
heavy duty lathe was retrofitted with a grinding attachment. A mounting plate
was loaded on a cross slide after removing the tool post. AC motor is employed
for driving the grinding wheel. The grinding wheel was mounted on ball bearings
with an overhang. The grinding wheel chosen is with aluminum oxide abrasives.
The required speed can be attained by arranging pulley drives.

The prepared work mounted between the centers of the lathe machine
chosen. Cylindrical grinding with traverse feed is used for finishing components
turned on a lathe. The surface finish obtained on the heavy duty lathe was
modeled against various parameters, such as work speed; traverse feed rate and
depth of cut. The improvement in surface finish on the work pieces leads to higher
corrosion resistance, fatigue strength and reduced power loss due to friction. The
optimization of the parameters is done by Regression Analysis. The outputs are
subjected to Regression Analysis and the optimal values are attained.
INTRODUCTION
 CHAPTER II

INTRODUCTION

Grinding is the process of removing metal by the application of abrasives

which are bonded to form a rotating wheel when the moving abrasive particles
contact the work piece, they act as tiny cutting tools, each particle cutting a tiny
chip from the workpiece. In cylindrical grinding, the workpiece rotates about a
fixed axis and the surfaces machined are concentric to that axis of rotation The
cylindrical grinder development took place during industrial revolution (Lewis et
al.,1959). In 1830, modern day cylindrical grinder was first built by Jonathan
bridges and James Wheaton (Robert et al.,1964). Joseph brown made first attempt
was a small lathe with a grinding wheel mounted on air displayed at 1876
centennial exposition and subsequent patent (Lewis et al.,1959; and Robert et al.,
1964). Norton improved the cylindrical grinder to use faster rpm values and more
precise grinding tolerances on April 18, 1925 (Day et al.,1996). Integrating CNC
and the PC into one dynamic system allowed for even further control of the
manufacturing process that required little to no human supervision (Arnold et al.,
2001). Two surfaces will be moving opposite directions when contact is made
which allows for a smoother operation (Kocherovsky et al.). Krabacher (1959)
investigated machining parameters on material removal rate and surface
roughness, noticed that surface quality was found to improve with decreased
material removal rate. Heaker and Liang (Hecker et al., 2003) predicated surface
roughness due to mainly chip thickness in grinding. The work piece surface
roughness dependence on wheel wear and feed is investigated in early 70’s by
Vickers taff (Vickerstaff, 1973). The influence of feed and depth of out on wheel
wear and surface finish have been investigated using regression analysis and
mathematics models and development by Rama Chandran (Ramachandran,
1976). Prediction of surface finish along with normal force are modelled against
various process parameters by buttery (Hamed, 1979). However, the study of
roughness on the work pieces carried out by a cylindrical grinding attachment on
a lathe machine is scarce and nor reported neither to. Hence the present
investigation makes the prominence. In the following, the basic concept of
cylindrical grinding is introduced the fabrication of cylindrical grinding
attachment and regression analysis are described next. The succeeding section
illustrates the effects of the grinding parameters on the surface roughness of wet
and dry condition. BASIC CONCEPT OF CYLINDRICAL Grinding The basic
components of a cylindrical grinder include a wheel head, which incorporate the
spindle and drive motor, a cross slide, that moves the wheel head to end from the
workpiece, a head stock, which locates, holds, and drives the work piece, and a
tailstock, which holds the other end of the work as shown in (Figure 1). The
present study relates to a grinder attachment for a lathe. Attachment is motor
driven for isolating the grinding wheel from vibrations. For best results in many
cases, the grinding operation should immediately follow the turning operation
without removing the rotor from the lathe spindle. In order to provide a smooth
surface on rotors, such as brake drums, brake discs, clutch plates and fly wheels,
it is desirable to finish grinding the brake surface to level off any hard spots in
the rotor. Cylindrical grinding attachment is defined as having four essential
actions. The work must be constantly rotating. The grinding wheel must be
constantly rotating. The grinding wheel is fed towards and away from the work,
Either the work or the grinding wheel is traversed with the respect to the other.
The attachment can be fixed on a lathe with or without tailstock. The abrasive
material is on a grinding wheel that rotates in a direction such that rolling or
sliding contact occurs where the in wheel and workpiece touch as shown in
(Figure 2).
COMPONENT
DESCRIPTION
 CHAPTER IV

COMPONENT DESCRIPTION

The components used in the attachment are listed below.

• Motor

• Grinding Wheel

• Mounting plate

• Shafts

• Bearings

• Pulleys and Belt

Motor

Motor is a device that creates motion, not an engine; it usually refers to

either an electrical motor or an internal combustion engine.

It may also refer to:

• Electric motor, a machine that converts electricity into a mechanical

motion.

• AC motor, an electric motor that is driven by alternating current.

• In this present attachment we use and AC motor for rotating the

Grinding Wheel.

Grinding Wheel

In this present attachment we use Aluminium Oxide Abrasive Grinding

Wheel, the grinding wheel is shown below with specifications

• Abrasive Grinding Wheel

• Carborundum Universal Company

 • Aluminum Oxide Abrasive

• 200 mm Diameter

• 20 mm Thickness

• 31.75 Bore

• Max.Speed 3150 Rpm

Mounting Plate

A MS plate of 12" × 6" is employed for this attachment. The plate is placed
on the lathe after removing Tool post from it. The plate bears the whole weight
of the attachment. It is used for moving the grinding wheel and motor constantly
with the movement of the carriage. Shafts There are two types of Shafts are used
in this attachment,

• Fixed shaft 76 mm Diameter, 40 mm Inside Bore

• Rotating shaft 17 mm Diameter

The Rotating shaft is used for the rotation of the Grinding wheel; the power
from the motor is transmitted to the rotating shaft through Pulleys and Belt, the
rotating shaft is inserted into the fixed shaft through Ball Bearings. The fixed
shaft is attached to the mounting plate by Welding and makes it immovable. The
Ball Bearings are used for the rotation of the Rotating shaft inside of the fixed
shaft. The grinding wheel is mounted on to the Rotating shaft and tightened with
nuts so that the grinding wheel rotates with the shaft.

BEARINGS

There are two types of bearings used in this Attachment,

• Ball Bearings

• Thrust Bearings
Ball Bearing:

A ball bearing is a type of rolling-element bearing which uses balls to

maintain the separation between the moving parts of the bearing The purpose of
a ball bearing is to reduce rotational friction and support radial and axial loads. It
achieves this by using at least two races to contain the balls and transmit the loads
through the balls. Usually one of the races is held fixed. As one of the bearing
races rotates it causes the balls to rotate as well. Because the balls are rolling they
have a much lower coefficient of friction than if two flat surfaces were rotating
on each other. Ball bearings tend to have lower load capacity for their size than
other kinds of rolling-element bearings due to the smaller contact area between
the balls and races. However, they can tolerate some misalignment of the inner
and outer races. Compared to other rolling-element bearings, the ball bearing is
the least expensive, primarily because of the low cost of producing the balls used
in the bearing.

Thrust Bearing

A thrust bearing is a particular type of rotary bearing. Like other rotary

bearings they permit rotation between parts, but they are designed to support a
high axial load while doing this. The two bearing are with Outside diameter 40
mm and inside diameter 17 mm.

Belt and Pulley Systems

A belt and pulley system is characterized by two or more pulleys in

common to a belt. This allows for mechanical power, torque, and speed to be
transmitted across axes and, if the pulleys are of differing diameters, a mechanical
advantage to be realized. A belt drive is analogous to that of a chain drive,
however a belt sheave may be smooth (devoid of discrete interlocking members
as would be found on a chain sprocket, spur gear, or timing belt) so that the
mechanical advantage is approximately given by the ratio of the pitch diameter
of the sheaves only, not fixed exactly by the ratio of teeth as with gears and
sprockets. In the case of a drum-style pulley, without a groove or flanges, the
pulley often is slightly convex to keep the flat belt centered.

Though once widely used in factory line shafts, this type of pulley is still
found driving the rotating brush in upright vacuum cleaners. The below (Figure
8) shows the pulley and belt attachment used in our attachment. These are the
components we use in our Cylindrical Attachment on Lathe. The components are
made useful with so many other operations Turning, Boring, Drilling, etc. The
assembling of the above components to make our attachment is given below
SELECTION OF
MATERIALS
 CHAPTER V

SELECTION OF MATERIALS

1.Properties:

The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface
finish, rigidity, ability to withstand environmental attack from chemicals, service
life, reliability etc. The following four types of principle properties of materials
decisively affect their selection

 Physical

 Mechanical

 From manufacturing point of view

 Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc. The various Mechanical
Properties Concerned are strength in tensile, Compressive shear, bending,
torsional and buckling load, fatigue resistance, impact resistance, elastic limit,
endurance limit, and modulus of elasticity, hardness, wear resistance and sliding
properties. The various properties concerned from the manufacturing point of
view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage
2. Manufacturing Case

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may demand
the use of special materials.

3. Quality Required

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less number
of components which can be fabricated much more economically by welding or
hand forging the steel.

4. Availability of Material

Some materials may be scarce or in short supply, it then becomes

obligatory for the designer to use some other material which though may not be
a perfect substitute for the material designed. The delivery of materials and the
delivery date of product should also be kept in mind.

5. Space Consideration

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. Cost

As in any other problem, in selection of material the cost of material plays

an important part and should not be ignored. Sometimes factors like scrap
utilization, appearance, and non-maintenance of the designed part are involved in
the selection of proper materials.
WORKING PRINCIPLE
 CHAPTER VI
WORKING PRINCIPLE
This attachment is used on centre lathes. This whole arrangement is fixed
on the carriage where the component rests. A grinding wheel is mounted on the
spindle which is supported by two bearings, and is rotated by a motor through ‘V’
rope in high revolution.

While we are introducing the rotating grind wheel inside the bore of a job
which is also rotating on the chuck, Material will be removed according to the cut
which we select. The operation is similar to grinding operation. In turning, a
single point tool removes the material, but in this process, a grinding wheel is
used to super finish the jobs, where high accuracy is necessary.

WORKING OF UNIT

This attachment is fixed on the lathe carriage, where the compound rest
rests. The spindle of the attachment will be parallel to the lathe spindle. It is just
like a boring bar on tool post. Where the motor is on, the spindle and the grinding
wheel will be rotated, on the RPM of about. Job is held on the lathe chuck, for
example, if we grind a bore of a body, the body will be rotating in lower RPM on
lathe spindle, and the grinding wheel will be rotating on higher RPM. The rotation
of the grinding wheel will be opposite to the job rotation.

Depth of cut may be given by cross slide, and the longitudinal movement will be
given by automatic feed. Normally depth per cut will be 0.02 to 0.05 MM.
DIAGRAM
CHAPTER VII

DIAGRAM
COST ESTIMATION
 CHAPTER VIII

COST ESTIMATION

S.No Component Qty Price

1 Pulley 2 Rs.380

2 Belt 1 Rs. 120

3 Motor 1 Rs.1450

4 Mounting shaft 1 Rs. 120

5 Grinding wheel 1 Rs.250

5 Frame - Rs. 300

Total Rs. 2620

LABOUR COST

 Welding

 Grinding

 Power hacksaw
  gas cutting cost

OVERGHEAD CHARGES:

The overhead charges are arrived by ”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

= Rs. 2620 + Rs. 1500

= Rs. 4120

Overhead Charges = 20%of the manufacturing cost

= Rs. 824

TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

= 2620 + 1500 + 824

= Rs.4944/-

Total cost for this project = Rs. 4944 /-

FEATURES
 CHAPTER IX
FEATURES
ADVANTAGES

 The attachment is compact and rigid in size.

 Maintenance is less.
 It can be used on any lathe by small change in centre heights.

APPLICATIONS

 Grinding inside the bore in any size of body can be done.

 As the feed is given automatic, 0.8 micron finish may be achieved.
 By changing the grades of grinding wheels it can be used to grind
the carbon steel, Alloy steel and stainless steel etc.

FIELD OF APPLICATION

Wherever grinding finish is required it can be used. For example, bore of

industrial valves, outer dia of spindle of varies machines.
CONCLUSION
 CHAPTER X
CONCLUSION

As compared to other grinding machines it requires less initial and

maintenance cost. It is compact in size and handy to use. Can be easily moved
from one location to other without any special means of transportation. Accuracy
and surface finish of this grinder is same as conventional grinding machine. Large
size work piece can be easily surface finish with this grinder by providing base
plate to supporting body. Accuracy up to 0.002mm can be achieved. As initial
investment is less, one can easily afford this attachment. Also the maintenance
cost and operation cost of this attachment is low as compared to conventional
grinding machines. Hence, if kept idle in absence of jobs there is no any
considerable loss to the owner.
REFERENCES
 CHAPTER XI
REFERENCES
[1] Z.W. Zhong, V.C. Venkatesh, Recent Developments in Grinding of Advanced
Materials, International Journal of Advanced Manufacturing and Technology,
41(2009) 468- 480.
[2] S. Malkin, C. Guo, Theory and applications of machining with abrasives, 2nd
ed. Published by Industrial Press, Inc. New York, 2008.
[3] R.L. Hecker, S.Y. Liang, Predictive Modeling of Surface Roughness.
[4] R. Alberdi, J.A.Sanchez, I.Pombo, N.Ortega, Strategies for optimal use of
fluids in grinding, International Journal of Machine Tools & Manufacture, 2011
[5] Users Manual, MITUTOYO Surftest SJ-400
[6] Sijo M.T and Biju N, 2010, “Taguchi method for optimization of cutting
parameters in Turning Operations” AMAE.2010.01.536pp-103-105.
[7] Prof J.S. Colton, Manufacturing processes and systems, Georgia Institute of
Technology 2009, version 1 pp. 21–39.
[8] Jayakrishnan J and Suraj R, Effect of Roller Burnishing Process on Tool Steel
Material Using CNC Lathe. International Journal of Design and Manufacturing
Technology (IJDMT), 7(4), 2016, pp. 281– 288.
[9] Phan Bui Khoi, Do Duc Trung and Ngo Cuong, A Study on Multi-Objective
Optimization of Plunge Centerless Grinding Process. International Journal of
Mechanical Engineering and Technology, 5(11), 2014, pp. 140–152.
[10] Gunwant D. Shelake, Harshal K. chavan, Prof. R. R. Deshmukh, Dr. S. D.
Deshmukh, Model For Prediction of Temperature Distribution in Workpiece for
Surface Grinding Using Fea. International.
CHAPTER XII
PHOTOGRAPHS