Abrasive Definitions
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Manufacturing Processesprocesses
MANUFACTURINGMANUFACTURING PROCESSESPROCESSES - AMEM 201 – Lecture 10 : Machining Processes Grinding and other Abrasive Machining Processes DR. SOTIRIS L. OMIROU Abrasive Machining Abrasive machining uses tools that are made of tiny, hard particles of crystalline materials. Abrasive particles have irregular shape and sharp edges. The workpiece surface is machined by removing very tiny amounts of material at random points where a particle contacts it. By using a large number of particles, the effect is averaged over the entire surface, resulting in very good surface finish and excellent dimension control , even for hard, brittle workpieces. Abrasive machining is also used to machine brittle materials . Such materials cannot be machined easily by conventional cutting processes since they would fracture and crack in random fashion. 2 1 The main uses of grinding and abrasive machining 1. To improve the surface finish of a part manufactured by other processes. Examples: (a)A steel injection molding die is machined by milling. The surface finish must be improved for better plastic flow, either by manual grinding using shaped grinding tools, or by electro-grinding. (b) The internal surface of the cylinders of a car engine are turned on a lathe. The surface is then made smooth by grinding, followed by honing and lapping to get an extremely good, mirror-like finish. (c) Sand-paper is used to smooth a rough cut piece of wood. 3 The main uses of grinding and abrasive machining 2. To improve the dimensional tolerance of a part manufactured by other processes Examples: (a)ball-bearings are formed into initial round shape by a forging process; this is followed by a grinding process in a specially formed grinding die to get extremely good diameter control (≤ 15µm). -
Hand Saws Hand Saws Have Evolved to fill Many Niches and Cutting Styles
Source: https://www.garagetooladvisor.com/hand-tools/different-types-of-saws-and-their-uses/ Hand Saws Hand saws have evolved to fill many niches and cutting styles. Some saws are general purpose tools, such as the traditional hand saw, while others were designed for specific applications, such as the keyhole saw. No tool collection is complete without at least one of each of these, while practical craftsmen may only purchase the tools which fit their individual usage patterns, such as framing or trim. Back Saw A back saw is a relatively short saw with a narrow blade that is reinforced along the upper edge, giving it the name. Back saws are commonly used with miter boxes and in other applications which require a consistently fine, straight cut. Back saws may also be called miter saws or tenon saws, depending on saw design, intended use, and region. Bow Saw Another type of crosscut saw, the bow saw is more at home outdoors than inside. It uses a relatively long blade with numerous crosscut teeth designed to remove material while pushing and pulling. Bow saws are used for trimming trees, pruning, and cutting logs, but may be used for other rough cuts as well. Coping Saw With a thin, narrow blade, the coping saw is ideal for trim work, scrolling, and any other cutting which requires precision and intricate cuts. Coping saws can be used to cut a wide variety of materials, and can be found in the toolkits of everyone from carpenters and plumbers to toy and furniture makers. Crosscut Saw Designed specifically for rough cutting wood, a crosscut saw has a comparatively thick blade, with large, beveled teeth. -
GRINDING Abrasive Machining
GRINDING Abrasive machining: •The oldest machining process - “abrasive shaping” at the beginning of “Stone Era”. •Free sand was applied between two moving parts to remove material and shape the stone parts. Grinding: • Removing of metal by a rotating abrasive wheel. (Very high speed, Shallow cuts) • the wheel action similar to a milling cutter with very large number of cutting points. •Grinding was first used for making tools and arms. SURFACE GRINDING: Depth of Cut: 2-5 thou, 50-125 microns Work Table reciprocates beneath the wheel, Longitudinal feed Wheel crossfeed (Transverse feed) and infeed What makes the grinding different? Large number of cutting edges that are very small and made of abrasive grits. The cutting edges cut simultaneously. Very fine and shallow cut are only possible good surface finish (<Ra=0.8) and dimensional accuracy Finishing and important Operation Abrasive grits are extremely hard very hard material can be machined. e.g. hardened steel, glass, carbides, ceramics etc. Features with strict tolerance and surface finish are machined by grinding. e.g. Turbine Blade Fir-tree, Bearing seat diameters, tool making, tool repair, etc. Mesh sizes: 4 240 for grinding 240 600 for honing & lapping The shape of the grain affects accuracy of the grain screening GRINDING WHEELS Abrasive bonded together in a disk (wheel) three main factors influence the performance of the grinding wheel: a) Abrasive material b) Bonding material c) Structure Abrasives different for: Grinding (Bonded wheel) Honing (Bonded, very fine) Snagging (Bonded, belted) Lapping ( Free abrasives) Abrasive grains are bonded together to form tools (wheels) Abrasive NATURAL & MANUFACTURED A. -
Abrasive Wheel Grinder Abrasive Wheels and Grinding Machines Come in Many Styles, Sizes, and Designs
Abrasive wheel grinder Abrasive wheels and grinding machines come in many styles, sizes, and designs. Both bench-style and pedestal (stand) grinders are commonly found in many industries. These grinders often have either two abrasive wheels, or one abrasive wheel and one special-purpose wheel such as a wire brush, buffing wheel, or sandstone wheel. These types of grinders normally come with the manufacturer’s safety guard covering most of the wheel, including the spindle end, nut, and flange DEWALT Industrial Tool Co. projection. These guards must be strong enough to withstand the effects of a bursting wheel. In addi- tion, a tool/work rest and transparent shields are often provided. Hazard Bench-style and pedestal grinders create special safety problems due to the potential of the abrasive wheel shattering; exposed rotating wheel, flange, and spindle end; and a naturally occurring nip point that is created by the tool/work rest. This is in addition to such concerns as flying fragments, sparks, air contaminants, etc. Cutting, polishing, and wire buffing wheels can create many of the same hazards. Grinding machines are powerful and are designed Exposed spindle end, flange, and nut. No tool/workrest. to operate at very high speeds. If a grinding wheel shatters while in use, the fragments can travel at more than 300 miles per hour. In addition, the wheels found on these machines (abrasive, polishing, wire, etc.) often rotate at several thousand rpms. The potential for serious injury from shooting fragments and the rotating wheel assemblies (including the flange, spindle end, and nut) is great. To ensure that grinding wheels are safely used in your work- place, know the hazards and how to control them. -
5.1 GRINDING Definitions
UNIT-V GRINDING AND BROACHING 5.1 Grinding Definitions Cutting conditions in grinding Wheel wear Surface finish and effects of cutting temperature Grinding wheel Grinding operations Finishing Processes Introduction Finishing processes 5.1 GRINDING Definitions Abrasive machining is a material removal process that involves the use of abrasive cutting tools. There are three principle types of abrasive cutting tools according to the degree to which abrasive grains are constrained, bonded abrasive tools: abrasive grains are closely packed into different shapes, the most common is the abrasive wheel. Grains are held together by bonding material. Abrasive machining process that use bonded abrasives include grinding, honing, superfinishing; coated abrasive tools: abrasive grains are glued onto a flexible cloth, paper or resin backing. Coated abrasives are available in sheets, rolls, endless belts. Processes include abrasive belt grinding, abrasive wire cutting; free abrasives: abrasive grains are not bonded or glued. Instead, they are introduced either in oil-based fluids (lapping, ultrasonic machining), or in water (abrasive water jet cutting) or air (abrasive jet machining), or contained in a semisoft binder (buffing). Regardless the form of the abrasive tool and machining operation considered, all abrasive operations can be considered as material removal processes with geometrically undefined cutting edges, a concept illustrated in the figure: The concept of undefined cutting edge in abrasive machining. Grinding Abrasive machining can be likened to the other machining operations with multipoint cutting tools. Each abrasive grain acts like a small single cutting tool with undefined geometry but usually with high negative rake angle. Abrasive machining involves a number of operations, used to achieve ultimate dimensional precision and surface finish. -
CBN & Diamond Grinding Wheels
1 CBN & Diamond Grinding Wheels 2 3 Contents 4 6 24 About the CBN and Diamond For company Grinding Wheels users NAXOS-DISKUS Diamond and Application form Schleifmittelwerke GmbH Cubic Boron Nitride Technical information The DVS TECHNOLOGY GROUP Application-specific development at NAXOS-DISKUS Grinding wheel construction The key component: AUMENTO bonding Technical specification 4 5 About the company NAXOS-DISKUS NAXOS-DISKUS Schleifmittelwerke the extensive experience of the The The DVS TECHNOLOGY GROUP is With a unique combination of GmbH was founded as NAXOS- DVS mechanical engineering and made up of Germany-based compa- machining technologies, tooling Schleifmittelwerke UNION in Frankfurt in 1871, and production companies, a fact which DVS TECHNOLOGY nies focusing on the turning, gear innovation and production experi- cutting, grinding and gear honing ence for the machining of vehicle manufactures precision grinding GmbH is clearly refl ected in the quality GROUP technologies. Besides engineering powertrain components DVS is one tools for greatly differing applica- and design of the grinding wheels. and manufacturing machine tools as of the leading system suppliers in tions. The product range covers Special products such as mill well as grinding and honing tools, the industry. abrasive wheels for double face wheels, leather polishing rollers, DVS operates two production sites where automotive parts are The DVS TECHNOLOGY GROUP grinding, outer diameter grinding, nurit rollers and bulk abrasives machined in series production has more than 1,000 employees centerless grinding as well as gear supplement the extensive range of exclusively on DVS machines. This worldwide. On key markets like grinding and gear honing, from products. -
Place the Gouge in the Third Station of the Sharpening Guide and Lay the Side of the Gouge Against the Left Wall of the Station (Figure 24-12)
Figure 24-14.Position the roundnose chisel, Figure 24-13.Set the parting tool’s side in bevel up in the fourth station. Tighten the the first station. knob. Place the gouge in the third station of the sharpening guide and lay the side of the gouge against the left wall of the station (Figure 24-12). Rotate the gouge until its center touches the abrasive. With the machine "OFF" practice rotating the gouge, first clockwise from the center to the edge, and then counterclockwise from the center of the gouge to the edge. You should notice while rotating the gouge that in order to keep the bevel in contact with the abrasive, you must slide the gouge forward on the station as the bevel is ground from the center to each edge. After you get the feel of this grinding motion, be sure the gouge is not touching the abrasive and the speed dial is set to "Slow" (if you are using the Mark V), then turn on the machine. Gently slide the gouge against the wall of the station and into the moving abrasive. Start rotating the gouge, like you practiced. Repeat this several times. Grind away only enough metal to remove any damage to the cut-ting edge and create a slight burr. If the gouge is being ground for scraping, it is ready to use (the burr is sharp and scrapes very well). If the gouge is being ground for shearing or cutting, it will need to be honed to a razor sharp edge. Grinding the Parting Tool— The parting tool has a bevel ground on both the top and bottom edges. -
Ct 250 Nd Soluble Oil for Machining/Grinding Applications on All Metals - Chlorinated
METAL WORKING FLUID | TECHNICAL DATA SHEET CT 250 ND SOLUBLE OIL FOR MACHINING/GRINDING APPLICATIONS ON ALL METALS - CHLORINATED PRODUCT DESCRIPTION APPLICATION CT 250 ND is a water emulsifiable, soluble oil cutting and grinding fluid. CT 250 ND exhibits a balanced lubrication regime of both boundary lubricant additives and chlorine for extreme pressure requirements. CT 250 ND forms a clean and stable emulsion in all water types and is formulated with a non- formaldehyde biocide to extend the serviceable sump life of the emulsion. CT 250 ND combines tenacious film strength with improved cooling capacity found only in water reducible products. It is particularly well suited for a variety of cutting and grinding operations such as broaching, tapping, gear shaping, deep drilling, boring, screw machining, end milling, and reaming of hard steels and nickel alloys. CT 250 ND is applicable for use on both ferrous and non-ferrous metals. COMPATIBLE METALS Cast Iron Carbon Steel FEATURED BENEFITS Tool Steel • Unusually tight emulsion for a soluble oil. Improves wetting and cooling Stainless Steel for superior tool life. Aluminum • Reduced Consumption: A stable tight emulsion reduces usage from carry Titanium Inconel out when compared with other soluble oils. Bronze • Additive Independent: No need for tank side pH buffers, emulsifiers, or Copper costly and hazardous biocides Brass • Cost effective regardless of whether you have individual sumps or large central systems MACHINING CAPABILITIES • Applicable for both ferrous and non-ferrous metal applications -
Tuning Metal Bench Planes for the Rest of Us by Chris Black
Tuning Metal Bench Planes for the Rest of Us By Chris Black It’s an unfortunate reality that most metal bench planes don’t work to their full potential right out of the box, and that a certain amount of tuning needs to be done by the end user. With apologies to all engineer/machinist woodworkers, I will endeavor to explain how to tune a metal bench plane without involving a machine shop or taking up vast amounts of your valuable woodworking time or money. I’ll leave out the small stuff like after market blades and accessories. This is by no means the final word on this subject, but maybe you can pick up a thing or two from my many years of making a living with these wonderful tools. If you find my methods rudimentary or crude, let me paraphrase Jim Krenov who said at some point the engineer and artisan must part ways. SHARPEN THE IRON If there’s a given principle in woodworking, it must be sharp tools. If your steel isn’t keen, not much happens. Learn to sharpen and everything else in woodworking will begin to fall into place. 80% of all plane problems can be fixed by getting your irons as sharp as possible. There’s a ton of information about sharpening out there, but stick with the basics and worry about other stuff like cambered edges and different bevel angles later. I recommend Thomas Lie-Nielsen’s book Complete Illustrated Guide to Sharpening (202299), Leonard Lee’s Complete Guide to Sharpening (200831), or Jim Kingshott’s video Sharpening the Professional Way (221508). -
Dedtru® Centerless Grinding Product Line
Price List PL UNISON CORPORATION DedTru® Centerless Grinding Product Line Model C Model PGF DedTru Grinding Fixture Plunge Grind Fixture Model C6 Model IGF DedTru Grinding Fixture Internal Grind Fixture 1601 Wanda Avenue Ferndale, MI 48220 Phone: 248-544-9500 Fax: 248-544-7646 Website: www.unisoncorp.com Email: [email protected] 1 DedTru ® Centerless Grinding Product Line The description of Unison Corporation’s DedTru Centerless Grinding product line is presented in the following information. Please contact any member of our Marketing Department to request a detailed quotation for each machine. DedTru ® Systems, 6x18 Grinder DedTru Centerless Grinding Systems (388-0000) includes the DedTru Basic 6 x 18 Grinder with a hole through the column for longer parts; Model C DedTru Unit, dual sine base assembly, 3 hp spindle, coolant system with FilTru Tank Assembly and FilTru Coolant Settling Tank, 1/4” carbide blades for throughfeed (with guides), plunge and infeed work from 1/4” to 1-1/4” diameter, one part stop, one pressure roll assembly, work light and wheel guarding for up to 2” wide wheel. Arranged for 230 or 460 volt (when ordering specify voltage), 3 phase, 60 Hz power supply. For manual operation; maximum part diameter with optional accessories 4”. (For diameters to 5” add increased height for grinder, page 9, and 078-0000 (page 6), for diameters from .031” to 1/4” (tooling accessories, page 5). Shipping Weight and Dimensions: 1345 lbs/46” x 56” x 82” high DedTru Centerless Grinding System with Model PGF Unit ( 399-0000) is the same as a Model 388-0000 except it is equipped with a Model PGF DedTru Unit with quick change 5” x 2” regulating roll. -
How Scroll Saw Blades Are Made There Are Three Ways We Manufacture Scroll Saw Blades
lson has been a leading manufacturer of scroll saw blades for more than 80 years, offering a full Oline of superior quality blades to satisfy almost every scrolling application. Olson blades are for use with scroll/jig saw machines sold by Delta, DeWalt, Dremel, Skil, Rockwell, Pro-Tech, Powermatic, RB Industries, Hegner, Sakura, Shopsmith, Excalibur, Rexon, Ryobi, Sears Craftsman, and Makita. (virtually all domestic and imported scroll saws). They can also be used in hand held fret and jewelers saw frames. The Olson Saw Co. has introduced many innovative blades, including: PGT® (Precision Ground Tooth) Scroll Saw Blades in skip and new double tooth styles with reverse teeth are simply the finest scroll saw blades there are! Considered among experts as “the best blade available”, PGT® blades are made with an exclusive grinding process that forms teeth in hardened steel. The blades are double ground to ensure that every edge of the tooth (face, tip, and gullet) is as sharp as possible. Crown Tooth™ Blades are a recent edition to the line. They have a unique tooth design that cuts on both the up and down stroke. Because of this two-way cutting action, Crown Tooth blades allow for cutting with more control while leaving a smooth, splinter-free finish. Also, they can be turned over for cutting with a fresh set of teeth. They are also excellent for cutting many kinds of plastics. Reverse Skip Tooth Blades with special reverse teeth on the lower end of the blade for a smooth, splinter-free finish on the bottom surface. Olson is continually improving and expanding its blade selection. -
Abrasive Cut Off Saw Tulane University Safety Instructions and Job Hazard Analysis: Abrasive Cut Off Saw
Maker Space Job Hazard Analysis: Abrasive Cut Off Saw Tulane University Safety Instructions and Job Hazard Analysis: Abrasive Cut Off Saw 1 Maker Space Job Hazard Analysis: Abrasive Cut Off Saw Tulane University Job/Task Step Hazard Hazard Control Method/PPE Inspect Equipment/PPE Check/Buddy System N/A Don all required PPE for use of the Abrasive Cut Off Saw. Approved Safety Glasses with side shields, Long Pants, and Closed Toe Shoes Consider the use of Ear Plugs to reduce noise. All combustible and flammable materials must be a minimum of 10 feet away from this machine while it is being operated. Tuck in shirt, no loose fitting clothing or jewelry. Long hair must be pulled back or tucked into a hat. Work with the supervisor of the space to review operation and ensure all risks have been addressed. Ensure the Saw is placed on a Level Surface/Secure Muscle Strains, Pinch Points If the saw’s placement needs to be the Saw adjusted for leveling purposes, use proper lifting technique or ask for help due to the weight and awkwardness of the saw. Be aware of hand and body placement. Ensure Material being cut is Secure and Level Muscle Strains, Pinch Points, This saw is ONLY for steel. The blade will Abrasions/Lacerations, be ruined if it’s used to cut brass, aluminum, wood or anything that isn’t magnetic. Use proper lifting technique when placing material to be cut on the saw’s platform. Use clamps to secure the material once it’s leveled. Be aware of pinch points while handling material.