Abrasive

Objectives
At the end of this unit, the student/trainee should be able to:
• Select the proper grinding wheel to be used for each type

of work material
• True and dress grinding wheel
Abrasive
• An abrasive grain is a hard, tough substance containing
many sharp projecting cutting edges or points.
• It is used as a cutting tool to penetrate and cut away
material that is softer than itself.
• Abrasive products such as grinding wheels, coated
abrasives, sharpening stones, and abrasive sticks are
composed of many abrasive grains which have been
bonded together.
(Technology of Machine Tools 4th Edition by Steve F. Krar & J. William Oswald)
Types of Abrasives
❖Abrasives may be divided into two classes: NATURAL
and ARTIFICIAL.
❑Natural abrasives, such as sandstone, emery, quartz, and
corundum were used extensively prior to the early part of
the twentieth century.
• Natural abrasives contain impurities and the quality and
hardness vary.
• These natural abrasives have been totally replaced by
manufactured abrasives with their inherent advantages.
Types of Abrasives
• One of the best natural abrasives is diamond, but
because of the high cost of industrial diamonds (bort), its
use in the past was limited mainly to grinding cemented
carbides and glass, and sawing concrete, marble,
limestone, and granite.
Types of Abrasives
❑Manufactured abrasives are used extensively because
their grain size, shape, and purity can be closely
controlled.
• This uniformity of grain size and shape, which ensures
that each grain does its share of work is not possible with
natural abrasives.
Types of Abrasives
➢There are several types of manufactured abrasives:
o Aluminum oxide
o Silicon carbide
o Boron carbide
o Cubic boron nitride
o Manufactured diamond
• This uniformity of grain size and shape, which ensures
that each grain does its share of work is not possible with
natural abrasives.
Types of Abrasives
o Aluminum oxide
▪ Probably the most important abrasive since about 75%
of the grinding wheels manufactured are made from it.
▪ It is generally used for high-tensile strength materials
including all ferrous metals except cast iron.
Types of Abrasives
o Aluminum oxide
(hindustanabrasives.com)
(paxtonpatterson.shop)
(shop.ehayes.co.nz)
Types of Abrasives
o Silicon carbide
▪ It is suited for grinding materials which have low tensile
strength and high density, such as cemented carbides,
stone, and ceramics.
▪ It is also used for cast iron and most nonferrous and
nonmetallic materials.
▪ It is harder and tougher than aluminum oxide.
▪ It may vary in color from green to black.
Types of Abrasives
o Silicon carbide
▪ It may vary in color from green to black.
✓Green silicon carbide is used mainly for grinding
cemented carbide and other hard materials.
✓Black silicon carbide is used for grinding cast iron
and soft nonferrous metals, such as aluminum, brass,
and copper.
Types of Abrasives
o Silicon carbide
(www.axminstertools.com)
Types of Abrasives
o Boron carbide
▪ One of the newer abrasives.
▪ It is harder than silicon carbide and next to the
diamond.
▪ It is the hardest material manufactured.
▪ It is not suitable for use in grinding wheels.
▪ It is used only as a loose abrasive and a relatively
cheap substitute for diamond dust.
Types of Abrasives
o Boron carbide
▪ Because of its extreme hardness, it is used in the
manufacture of precision gauges and sand-blast
nozzles.
Types of Abrasives
o Boron carbide
(www.iamashley.xyz)
(www.gaugeindia.net)
Types of Abrasives
▪ One of the more recent developments in the abrasive
field has been the introduction of cubic boron nitride.
▪ This manufactured abrasive has hardness properties
between silicon carbide and diamond.
▪ This material can grind high-speed steel with ease and
accuracy and is superior to diamond in many
applications.
Types of Abrasives
▪ It is about twice as hard as aluminum oxide and is
capable of withstanding high grinding temperatures up
to 2500°F before breaking down.
▪ These wheels require very little dressing and can
remove a constant amount of material across the face
of a large work surface without having to compensate
for wheel wear.
Types of Abrasives
(www.andmax.rs)
Types of Abrasives
▪ Diamond, the hardest substance known to human
beings, was primarily used in machine shop work for
truing and dressing grinding wheels.
▪ Because of the high cost of natural diamonds, industry
began to look for cheaper, more reliable sources.
▪ In 1954, they come out with a man-made diamond.
▪ And in 1957, after researching and testing, they began
to produce commercial diamonds.
Types of Abrasives
▪ Because the temperature, pressure, and catalyst-
solvent can be varied, it is possible to produce
diamonds of various sizes, shapes and crystal structure
best suited to a particular need.
Types of Abrasives
(www.tradeindia.com)
Grinding Wheels
• They are the most important product made from
abrasives.
• They are composed of abrasive materials held together
with a suitable bond.
Grinding Wheels
• The basic functions of grinding wheels in a machine shop
are:
o Generation of cylindrical, flat, and curved surfaces
o Removal of stock
o Production of highly finished surfaces
o Cutting-off operation
o Production of sharp edges and points
Grinding Wheels
• The material components of a grinding wheel are the
abrasive grain and the bond;
• however, there are other physical characteristics, such as
grade and structure, that must be considered in grinding
wheel manufacture and selection.
Grinding Wheels
• Grain Size
o After crushing, the abrasive grains are sized by passing them
over screens having a certain number of meshes per linear
inch.
o The grain size is determined by the number of openings per
linear inch in the screen through which the abrasive particles
just pass.
o Grain sizes ranging from 4 to 240 grit are the most common
sizes used in the manufacture of grinding wheel.
o Sizes finer than 240 grit are commonly referred to as flour.
Grinding Wheels
• Grain Size
Relative abrasive grain sizes: (A) 8-grain; (B) 24-grain; (C) 60-grain.
Grinding Wheels
• Bonds
o Grinding wheels are composed of abrasive grains held together
by a bond.
o The amount of bond used determines the hardness (grade) of
the wheel.
Grinding Wheels
• Bonds
o Standards grinding wheels may used one of the following
bonds:
▪ Vitrified
▪ Resinoid
▪ Rubber
▪ Shellac
▪ Silicate
▪ Oxychloride
Grinding Wheels
• Bonds
o The most common bonds and are used in over 90% of the
grinding wheels manufactured are:
▪ Vitrified
▪ Resinoid
▪ Rubber
Grinding Wheels
• Wheel Grade and Structure
o Although the abrasive grains and the bond are the only tangible
components used in the grinding wheel, there are other
characteristics which greatly affect the grinding wheel.
o These are the grade and structure of the wheel.
Grinding Wheels
• Grade
o It indicates the strength with which the bond holds the abrasive
particles together in the wheel.
o In other words, the grade refers to the hardness of the wheel.
o It is indicated by a letter ranging from “A” for the softest wheel
(weakest bond post) to “Z” for the hardest wheel (strongest
bond post).
Grinding Wheels
• Grade
Grinding wheel grades: (A) weak bond posts;

(B) medium bond posts; (C) strong bond posts.
Grinding Wheels
• Structure
o indicates the density (grams per cubic inch) of the wheel, or the
relationship of the abrasive grain and bonding material to the
voids that separate them.
o The primary function of the void or space is to provide chip
clearance for the metal removed from the work by the grain.
o The variations in wheel structure or density range from 1- 8
(dense) to 9-15 (open).
o A wheel with open structure has more chip clearance than a
dense structure.
Grinding Wheels
• Structure
Grinding wheel structure: (a) dense; (b) medium; (c) open.
Straight Grinding Wheel Marking System Chart (cac-7.top)
Selecting a Grinding Wheel for a Specific Job
❑Example
• It is required to rough surface grind a piece of SAE 1045 steel

using a straight wheel. Coolant is to be used.
o Type of abrasive: Because steel is to be ground, aluminum oxide
should be used.
o Size of grain: Since the surface is not precision- finished, a
medium grain can be used – about 46 grit.
❑
o Grade: A medium-grade wheel which will break down reasonably
well should be selected. Use grade J.
o Structure: Since this steel is of medium hardness, the wheel
should be of medium density – about 7.
o Bond type: Since the operation is standard surface grinding and
since coolant is to be used, a vitrified bond should be selected.
✓ After the various factors have been considered, an A46-J7-V
grinding wheel should be selected to rough-grind SAE 1045 steel.
❑Example
• It is required to finish-grind a high-speed steel milling cutter on the

tool and cutter grinder.
o Type of abrasive: Since the cutter is steel, an aluminum oxide
wheel should be used.
o Size of grain: Since milling cutter must have a smooth finish, a
medium to fine grain should be used. About 60 grit is
recommended for this type of operation.
❑
o Grade: It is important that a cool-cutting wheel be used to prevent

burning the cutting edge of the cutter. A wheel which breaks down
reasonably well will permit cool grinding. Use a medium-soft
grade as J.
o Structure: To produce a smooth cut, a medium-dense wheel
should be used. For this application, use a #6.
❑
o Bond type: Because most tool and cutter grinders are designed
for standard speeds, a vitrified bond should be used. When the
speed is excessive for the wheel size, a resinoid bond should be
used.
✓ The wheel selected for this job (disregarding the manufacturer’s
prefix and records) should be A60-J6-V.
NOTE: If the cutter is chipped or if considerable metal must be removed to

resharpen, it is advisable to first rough-grind using 46-grit wheel.
Common Grinding Wheel Shapes & Applications
Grinding Wheel Care
• To ensure the best results in any surface-grinding
operation, proper care of the grinding wheel must be
taken.
1. When not in use, all grinding wheels should be properly

stored.
Grinding Wheel Care
Storage of grinding wheel
(forturetools.com)
Grinding Wheel Care
2. Wheel should be tested for crack prior to use.
Testing a grinding wheel (familyhandyman.com)
Grinding Wheel Care
3. Select the proper type of wheel for the job.
4. Grinding wheel should be properly mounted and
operated at the recommended speed.
Balancing a Grinding Wheel
• Proper balance of a mounted grinding wheel is very
important:
o improper balance will greatly affect the surface finish
and accuracy of the work
o excessive imbalance creates vibration which will
damage the spindle bearings.
• There are two methods of balancing a wheel:
1. Static balancing
o On some grinders, the wheel is balanced off the
machine with the use of a balancing stand and arbor.
o Counterweights in the wheel flange must be correctly
positioned to balance the grinding wheel.
• There are two methods of balancing a wheel:
2. Dynamic balancing
o Most new grinding machines are equipped with ball-
bearing balancing devices, which automatically
balance a wheel in a matter of seconds while it is
revolving on the grinder.
To Balance a Grinding Wheel
1. Mount the wheel and adapter on the surface grinder
and true the wheel with a diamond dresser.
2. Remove the wheel assembly and mount a special

tapered balancing arbor in the hole of the adapter.
3. Place the wheel and arbor on a balancing stand which

has been leveled.
Grinding Wheel Balancing Stand

(technicaltrainingsolutions.co.uk)
4. Allow the wheel to rotate until it stops. This will indicate
that the heavy side is at the bottom. Mark this point with
chalk.
5. Rotate the wheel and stop it at three positions, one-

quarter, one-half, and three-quarters of a turn, to check
the balance. If the wheel moves from any of these
positions, it is not balanced.
6. Loosen the setscrews in the wheel counterbalances, in
the grooved recess of the flange, and move the
counterbalances opposite the chalk mark.
Adjusting counterbalance
to balance a grinding
wheel.
7. Check the wheel in the four positions mentioned in
steps 4 and 5.
8. Move the counterbalances around the groove an equal
amount on each side of the centerline and check for
balance again.
9. Continue to move the balances away from the heavy
side until the wheel remains stationary at any position.
10. Tighten the counterbalances in place.
Truing and Dressing a Grinding Wheel
❑After mounting a grinding wheel, it is necessary to true
the wheel to ensure that it will be concentric with the
spindle.
• Truing
o It is the process of making a grinding wheel round and
concentric with its spindle axis and producing the required
form or shape on the wheel.
o This procedure involves the grinding or wearing away of a
portion of the abrasive section of a grinding wheel to
produce the desired form or shape.
• Dressing
o It is the operation of removing dull grains and metal
particles.
o It exposes sharp cutting edges of the abrasive grains to
make the wheel cut better.
Truing makes the wheel round and true with its axis; dressing sharpens the wheel.
• A dull, glazed, or loaded wheel should be dressed for
the following reasons:
1. To reduce the heat generated between the work surfaces
and the grinding wheel.
2. To reduce the strain on the grinding wheel and the
machine.
3. To improve the surface finish and accuracy of the work.
4. To increase the rate of metal removal.
• An industrial diamond, mounted in a suitable holder on
a magnetic chuck, is generally used to true and dress a
grinding wheel.
A diamond dresser
used to dress a
grinding wheel.
To True and Dress a Grinding Wheel
1. Check the diamond for wear and, if necessary, turn it in
the holder to expose a sharp cutting edge to the wheel.
NOTE: Most diamonds are mounted in the holder at an angle of

5° to 15° from the vertical to prevent the possibility of chatter and
of the diamond digging into the wheel.
It also permits the diamond to wear on an angle so that a sharp
cutting edge may be obtained by merely turning the diamond in
the holder.
2. Clean the magnetic chuck thoroughly with a cloth and
wipe it with the palm of the hand to remove all grit and
dirt.
3. Place a piece of paper, slightly larger than the base of
the diamond holder, on the left-hand end of the magnetic
chuck.
o This prevents scratching of the chuck when the diamond
holder is being removed.
4. Place the diamond holder on the paper, covering as
many magnetic inserts as possible, and energize the
chuck.
o The diamond should be pointing in the same direction as the
grinding wheel rotation.
NOTE: The diamond dresser should be mounted on the left-hand

end of the chuck to prevent flying grit, created during the dressing
operation, from pitting and damaging the surface of the magnetic
chuck.
Proper positioning of the diamond dresser in relation to the grinding wheel.
5. Raise the wheel above the height of the diamond.
6. Move the table longitudinally so that the diamond is

offset approximately ¼ inch (6 mm) to the left of the
centerline of the wheel.
7. Adjust the table laterally so that the diamond is

positioned under the high point on the face of the
wheel.
o This is important since grinding wheels will wear more
quickly on the edges of the wheel, leaving the center
of the face higher than the edges.
Positioning of the diamond under the high point of the wheel.
8. Start the wheel revolving and carefully lower the wheel
until the high point touches the diamond.
9. Move the table laterally, using the crossfeed handwheel
to feed the diamond across the face of the wheel.
10.Lower the grinding wheel 0.001 to 0.002 inch (0.02 to
0.05 mm) per pass, and rough-dress the face of the
wheel until it is flat and has been dressed all around the
circumference.
11.Lower the wheel 0.0005 inch (0.01 mm) and take several
passes across the face of the wheel.
o The rate of crossfeed will vary with the structure of the wheel.
o A rule of thumb is to use a fast crossfeed with coarse wheels
and a slow, but regular, crossfeed for fine, closer spaced
grains.
• The following additional points may be helpful when
truing or dressing a grinding wheel:
1. To minimize wear on the diamond, rough-dress the
grinding wheel with an abrasive stick.
2. If coolant is to be used during the grinding operation, it
is advisable to use coolant when dressing the wheel.
o This will protect the diamond and the wheel from excessive
heat.
3. A loaded wheel is indicated by discoloration on the
periphery or grinding wheel face.
o When dressing the wheel, take off sufficient material to
remove completely any discoloration on the wheel face.
4. If rapid removal of metal is more important than the
surface finish, do not finish-dress the wheel.
o After the wheel has been rough-dressed, some operators
will take a final pass of 0.001 to 0.002 inch (0.02 to 0.05
mm) at a high rate of feed.
o The rough surface produced by this operation will remove
the metal more rapidly than a finish-dressed wheel.

Abrasive

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Objectives

At the end of this unit, the student/trainee should be able to:

• Select the proper grinding wheel to be used for each type

Grinding wheel grades: (A) weak bond posts;

Grinding wheel structure: (a) dense; (b) medium; (c) open.

• It is required to rough surface grind a piece of SAE 1045 steel

• It is required to finish-grind a high-speed steel milling cutter on the

o Grade: It is important that a cool-cutting wheel be used to prevent

NOTE: If the cutter is chipped or if considerable metal must be removed to

1. When not in use, all grinding wheels should be properly

Storage of grinding wheel

Testing a grinding wheel (familyhandyman.com)

2. Remove the wheel assembly and mount a special

3. Place the wheel and arbor on a balancing stand which

Grinding Wheel Balancing Stand

5. Rotate the wheel and stop it at three positions, one-

NOTE: Most diamonds are mounted in the holder at an angle of

NOTE: The diamond dresser should be mounted on the left-hand

Proper positioning of the diamond dresser in relation to the grinding wheel.

6. Move the table longitudinally so that the diamond is

7. Adjust the table laterally so that the diamond is

Positioning of the diamond under the high point of the wheel.

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