SUMMARY:

Abstract - Grinding is one of the most important manufacturing processes for high precision parts.
Grinding force has a direct influence on grinding wheel wear, grinding temperature, the surface quality
of the work piece and the design of machine tool component. Also, the cutting force is proportional to
the specific energy in grinding and this influences the performance and surface integrity of the
workpiece. Hence the measurement of forces in grinding process is very important. In surface grinding,
forces are measured using the dynamometer placed on the grinding table. But in cylindrical grinding
the force measurement is a difficult process compared to other machining and surface grinding process,
since the work piece and the wheel are in motion.

INTRODUCTION:
Production is being done using Hot Rolling here. This helps is changing the billet into desired shapes
and products. This may be a good process of making the product but due to some reasons we are not
able to get the product without the extra part i.e. fin. This is the only thing in this production giving us
the negative report.
As we are using cast iron for products, its very hard in removing. On other hand after getting cooled it
gets more harden which will not allow us to do any change in product. Using several operations, we
have not got the required result.
Keeping all this in mind, we are here to fabricate a grinding machine which grinds the fin easily without
disturbing any other part of the product and gives the best finishing.
Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used abrasive machining
process in which a spinning wheel covered in rough particles (grinding wheel) cuts chips of metallic or non-
metallic substance from a work piece, making a face of it flat or smooth. Surface grinding is the most common of
the grinding operations. It is a finishing process that uses a rotating abrasive wheel to smooth the flat surface of
metallic or non-metallic materials to give them a more refined look or to attain a desired surface for a functional
purpose. The surface grinder is composed of an abrasive wheel, a work holding device known as a chuck, and a
reciprocating or rotary table. The chuck holds the material in place while it is being worked on. It can do these
one of two ways: ferromagnetic pieces are held in place by a magnetic chuck, while non- ferromagnetic and non-
metallic pieces are held in place by vacuum or mechanical means. A machine vies (made from ferromagnetic steel
or cast iron) placed on the magnetic chuck can be used to hold non-ferromagnetic work pieces if only a magnetic
chuck is available. Factors to consider in surface grinding are the material of the grinding wheel and the material
of the piece being worked on. Typical work piece materials include cast iron and mild steel. These two materials
don't tend to clog the grinding wheel while being processed.

OBJECTIVES:
 Selection of Grinding wheel capacity.
Selecting the appropriate grinding wheel capacity for cast iron involves considering factors such as the
type of operation, material properties, machine specifications, and desired results. Here are some key
considerations:

1. Material Properties:
Hardness of Cast Iron: Cast iron is a relatively hard material. The abrasive material and hardness
of the grinding wheel should be chosen to effectively cut and remove material from the workpiece.
2. Type of Grinding Operation
Surface Grinding: For surface grinding operations on cast iron, a medium to coarse grit size with a
grinding wheel capable of handling larger material removal rates is generally suitable.
3. Cylindrical Grinding:
If you are performing cylindrical grinding, the wheel should have a shape suitable for the specific
operation.

4. Wheel Specifications:
Grit Size: Choose a grit size based on the surface finish requirements and the initial material
removal rate. Coarser grit sizes (lower numbers) are used for rough grinding.
Wheel Thickness: The thickness of the wheel should be selected based on the depth of cut and the
amount of material to be removed. Thicker wheels are suitable for higher material removal rates.
5. Machine Specifications:
Horsepower: Ensure that the grinding machine has sufficient horsepower to drive the selected
grinding wheel. Inadequate power can lead to inefficient grinding and overheating.
6. Spindle Speed:
Match the recommended operating speed of the grinding wheel with the spindle speed of the
machine. Exceeding the maximum speed can lead to wheel breakage.

7. Wheel Bond and Structure:

Vitrified Bond: Vitrified bonds are commonly used for grinding cast iron due to their ability to
withstand heat and provide good rigidity.
Open Structure: Consider a wheel with a more open structure to allow for better chip clearance and
reduced heat generation.
8. Coolant System:
Use an effective coolant system to control heat during grinding. This helps prevent thermal damage
to the workpiece and the grinding wheel.

 Fabrication and design of semi automated

The parts and working process of semi-automated grinding machines can vary based on the specific
design and functionality of the machine. However, here is a general overview of the common
components and the typical working process:
a) Parts of a Semi-Automated Grinding Machine:
1. Bed:
The bed forms the base of the machine and provides support for various components.
2. Table:

The table holds the workpiece and can move in different directions (longitudinal, transverse,
and vertical) to position the workpiece for grinding.
3. Grinding Wheel:
The grinding wheel is a rotating abrasive tool used to remove material from the workpiece. It
can have different shapes, sizes, and abrasive materials depending on the application.
4. Spindle:
The spindle is responsible for rotating the grinding wheel. It is a critical component for
achieving the desired surface finish and material removal rate.
5. Work holding Devices:
Jigs, fixtures, or other work holding devices secure the workpiece in place during the grinding
process.
6. Coolant System:
A coolant system helps to dissipate heat generated during grinding and removes grinding swarf
(chips and particles) from the work area.

SKETCH

b) Working Process of a Semi-Automated Grinding Machine:

1. Workpiece Setup:
The operator or an automated system loads the workpiece onto the table and secures it using
work holding devices.
2. Machine Initialization:
The operator or automation system initializes the machine by setting parameters such as feed
rate, depth of cut, and other relevant parameters.

3. Grinding Operation:
The grinding wheel is brought into contact with the rotating workpiece, and material removal
begins. The table may move in different directions to achieve the desired shape and surface
finish.

4. Automation Assistance:
In a semi-automated system, automation components may assist in tasks such as workpiece
positioning, tool changes, or in-process measurements.

5. Coolant Application:
The coolant system is activated to cool the grinding wheel, prevent overheating, and flush away
grinding swarf.

6. Monitoring and Adjustment:

Operators or automated systems monitor the grinding process and make adjustments as needed
to maintain quality and efficiency.

7. Workpiece Unloading:
After grinding is complete, the workpiece is unloaded from the machine.

8. Quality Inspection:
A quality check may be performed on the ground workpiece to ensure it meets specifications.

NEED ANALYSIS:

For a semi-automated surfacing grinding machine used for cast iron with the dimensions mentioned
earlier, the selection of spindle speed, horsepower (HP), grit size, thickness, and depth of cut (DOC)
depends on several factors, including the specific application, material removal requirements, and the
characteristics of the cast iron. Here are general recommendations:

i. Spindle Speed:
Spindle speed for grinding cast iron can typically range from 1500 to 3000 RPM. The actual speed
may depend on the diameter of the grinding wheel and the material removal requirements.
ii. Horsepower (HP):
The horsepower of the grinding machine can vary based on factors such as the size of the machine
and the material removal rate. For a machine with the dimensions mentioned, a motor in the range
of 5 to 15 HP may be suitable. The specific horsepower requirement depends on the machine's
efficiency and the aggressiveness of the grinding process.
iii. Grit Size:
For initial material removal on cast iron, a coarse grit size in the range of 24 to 36 is common. This
grit size provides effective cutting and material removal. Subsequent passes with finer grits may be
used for finishing.
iv. Thickness of Grinding Wheel:
The thickness of the grinding wheel can vary depending on the specific application and machine
specifications. For a medium-sized machine, a wheel thickness in the range of 15mm to 25mm is
common. Thicker wheels may be used for heavy-duty applications.
v. Depth of Cut (DOC):
The depth of cut per pass can vary based on factors such as material removal requirements, machine
rigidity, and the desired surface finish. A starting point for the depth of cut could be in the range of
0.1mm to 0.5mm per pass. Adjustments can be made based on the results of test runs.

SPECIFICATIONS:

1. Machine Bed:
Length: Approximately 1500 mm to 2500 mm
Width: Approximately 600 mm to 1000 mm
2. Table Size:
Length: 1000 mm to 2000 mm
Width: 400 mm to 800 mm
3. Grinding Wheel Diameter:
250 mm to 400 mm (depends on the application and machine size)
4. Maximum Workpiece Height:

300 mm to 500 mm (vertical distance between the table surface and the spindle center)
5. Spindle Motor Power:
3 kW to 10 kW (depending on the size of the machine and material removal requirements)
6. Control System:
Depending on the level of automation, the control system may include features such as automatic
feed control, depth adjustment, and programmable logic control (PLC) for semi-automated
operation.
7. Overall Machine Height:
Considering the height of the machine components, such as the grinding wheel, spindle, and the
table, the overall height may vary but typically falls within the range of 1500 mm to 2000 mm.
8. Weight:
The weight of the machine can vary widely based on its size and construction. It may range from
1000 kg to 5000 kg or more.
GRINDING WHEEL MATERIAL:

The choice between the materials depends on factors such as the specific application, the type of cast
iron being ground, and the desired surface finish. Here are some considerations:
Aluminium Oxide: Suitable for general-purpose grinding of cast iron. It is cost-effective and widely
used for various applications.
Silicon Carbide: Effective for grinding cast iron, especially when a more aggressive cutting action is
needed. It is commonly used for rough grinding.
CBN: Ideal for high-speed grinding of cast iron, providing excellent heat resistance and wear resistance.
CBN wheels are suitable for both ferrous and non-ferrous materials.
Diamond: Offers superior hardness and is effective for achieving high precision and fine finishes.
Diamond wheels are used for applications where a high-quality surface finish is critical.
Among these we prefer to use Silicon Carbide as material for Grinding Wheel.

MATERILA HANDLING:

Automated Material Loading/Unloading Systems:

Dedicated systems that automatically load and unload workpieces onto and from the grinding machine.
Conveyors:
Automated conveyor systems transport workpieces between different stages of the grinding process.

Manual Handling:
Operators manually load and unload workpieces onto and from the grinding machine.
Automated Material Loading/Unloading Systems:
Dedicated systems that automatically load and unload workpieces onto and from the grinding machine.
Load Sensors and Feed Systems:
Systems that use sensors to detect the presence of workpieces and adjust the feed rate accordingly.

Here we are using jigs and fixtures as material handling. This jigs and fixtures help us to hpld easily
without any inconvenience. Jigs and fixtures play a crucial role in material handling within grinding
machines. They are specialized tools that are designed to hold and guide workpieces during machining
processes. In the context of grinding machines, jigs and fixtures are used for various purposes related
to material handling. Here are some ways in which jigs and fixtures are utilized:
Workpiece Positioning:
Jigs and fixtures are designed to precisely position and hold workpieces in a specific orientation. This
is critical in grinding operations where the accuracy of the final product depends on the precise
positioning of the workpiece.
Clamping and Fixturing:
Jigs and fixtures provide a means to securely clamp and fixture the workpiece during the grinding
process. This ensures stability and accuracy in the grinding operation.
Multiple Workpiece Handling:
Jigs and fixtures can be designed to hold multiple workpieces simultaneously. This is especially useful
in high-volume production where multiple parts need to be ground in a single setup.
Repeatability and Consistency:
Jigs and fixtures offer repeatability, ensuring that each workpiece is held in the same position for every
grinding cycle. This consistency is crucial for maintaining tight tolerances and achieving uniform
results.
Reduced Setup Time:
Well-designed jigs and fixtures help reduce setup time by providing a standardized and efficient means
of securing workpieces. This is beneficial in environments where frequent changeovers are required.
Automated Loading and Unloading:
Jigs and fixtures can be integrated into automated loading and unloading systems, allowing for seamless
material handling. Robots or other automated systems can manipulate jigs and fixtures to load and
unload workpieces from the grinding machine.
In-Process Gauging:
Jigs and fixtures can incorporate in-process gauging systems to measure and monitor the dimensions of
the workpiece during the grinding operation. This allows for real-time feedback and adjustments to
ensure quality.
Safety and Operator Ergonomics:
Properly designed jigs and fixtures contribute to the safety of the operation by securely holding
workpieces. They also facilitate ergonomic considerations for the operator by minimizing manual
handling and reducing the risk of injuries.
Customization for Specific Applications:
Jigs and fixtures can be customized to suit the specific requirements of different grinding applications.
This adaptability allows manufacturers to optimize material handling for various workpieces and
processes.