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Wheels used for grinding operations can range widely in their shape, size and configuration The successful application of grinding wheels will depend both on a thorough understanding of the grinding process and the wheel configurations Figure 45 shows some of the available shapes for conventional (left side) and superabrasive (right side) wheels It is clearly seen that conventional wheels are often entirely made of abrasives, whereas only small sections of the superabrasive wheel contain abrasives As superabrasive wheels are very expensive compared to conventional abrasive grain wheels, it is not economical to make the entire wheel with abrasives, as is common for conventional wheels Hence, superabrasive wheels are often designed with a core section that does not have any abrasives The abrasive only forms a layer of a few millimetre thickness on the outer section of the core, and their shape is partly regarded as the standard wheel configuration During grinding operations for different wheel configurations, extra care should be taken when selecting the grinding face; if the wrong side is engaged to the workpiece, it may damage/break the wheel and can thus subject the operator to unsafe conditions Apart from the wheel shape and configurations, the user must also take account of the outside diameter, height, width of the abrasive, bore size and other dimensions as necessary A standardized system of letters and numbers is used to mark bonded abrasives, indicating the type of the abrasive, grain size, grade, structure, concentration, bond type and the thickness of the abrasive layer Table 42 shows one type of marking method in a block diagram that is generally used in wheel marking systems



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Fig 45: On the left are shown some common types of solid grinding wheels made using conventional abrasives

17-2

[7], whereas on the right are shown typical shapes of standard metallic rim configurations for superabrasive wheels [17]

where b is one half of the dead band. Z is set to 1 (the heater is turned on) when X (the temperature) is less than Y (the desired temperature) minus b (half of the dead band). Likewise, if the temperature goes above the dead band s top, turn o the heater.





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This coding system simplifies all technical specifications of the bonded abrasive required for the wheel, and it is normally designed slightly differently for conventional and superabrasive wheels as indicated in Figure 46 and Figure 47 In the superabrasive wheel coding system, the diamond/ CBN concentrations replace the structure and the thickness of the abrasive layer added at the end Usually, wheel coding systems use acronyms A, C, B and D to represent abrasive types for aluminium Table 42

Standard method for marking wheels [1]

There is a reason we jump around, illustrating concepts using di erent notations. The symbols used to communicate an idea are not as important as the idea itself. There are many di erent ways to say any given thing. The more of these ways you can recognize, the better. While it may be confusing at times, it builds character.

X Grain size X Grade X Structure X Bond type X Manufacturer s no (optional)

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oxide, silicon carbide, cubic boron nitride and diamond, respectively However, manufacturers also often use their own acronyms to distinguish the variety of specific abrasive types available within the same group Table 43 lists out some examples Table 43 Some examples of specific abrasive types and their acronyms used in the standard wheel marking system

Note that when the heater is turned off, the environment continues to get hotter for a while. Also, the temperature falls a bit after the heater has turned on. Physical systems have momentum, a tendency to continue in their current direction. The amount that the measured value goes above the target value, in this case the top of the dead band, is called overshoot. Likewise, falling under the mark is undershoot.

Abrasive Type Brown fused alumina White fused alumina Rose fused alumina Black silicon carbide Green silicon carbide Cubic boron nitride metal coated Cubic boron nitride microcrystalline Natural diamond Synthetic diamond Synthetic diamond metal coated Acronym A WA GA C GC CBC CBM D SD SDC

Everything has a position in both space and time. There isn t a unit of measurement for position; however, many of the other units relate to the forces needed to change something s position.

Boothroyd [22] has suggested that the following general guidelines be used for the selection of a grinding wheel: 1 Aluminium oxide for steels and silicon carbide for carbides and non-ferrous metals 2 A hard-grade wheel for soft materials and a soft-grade wheel for hard materials 3 A large grit for soft and ductile materials and a small grit for hard and brittle materials 4 A small grit for a good finish and a large grit for getting the maximum metal removal rate 5 A resinoid, rubber or shellac bond for getting a good finish and a vitrified bond for obtaining the maximum metal removal rate 6 Avoid choosing a vitrified bond for surface speeds greater than 32 m/s

Mounted points sometimes known as mounted wheels or grinding pins are commonly used as grinding tools for internal grinding operations Besides the above applications, these wheels can be used as deburring tools to remove recess material after the machining processes, smoothing out casting risers, fins and repair welds They come in various types and shapes to suit different applications (Figure 48 (a c)) Materials such as tungsten carbide and abrasives can be used for the tool Mounted tools made from tungsten carbide (Figure 48 (b)) are commonly used for smoothing die cavities, chamfering

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