Problem NO: 6

A surface grinding operation is being performed on a 6150 steel workpart (annealed, approximately 200 BHN). The designation on the grinding wheel is C

A surface grinding operation is being performed on a 6150 steel workpart (annealed, approximately 200 BHN). The designation on the grinding wheel is C-24-D-5-V. The wheel diameter = 7.0 in and its width = 1.00 in. Rotational speed = 3000 rev/min. The depth (infeed) = 0.002 in per pass, and the crossfeed = 0.5 in. Workspeed = 20 ft/min. This operation has been a source of trouble right from the beginning. The surface finish is not as good as the 16 µ-in specified on the part print, and there are signs of metallurgical damage on the surface. In addition, the wheel seems to become clogged almost as soon as the operation begins. In short, nearly everything that can go wrong with the job has gone wrong. (a) Determine the rate of metal removal when the wheel is engaged in the work. (b) If the number of active grits per square inch = 200, determine the average chip length and the number of chips formed per time. (c) What changes would you recommend in the grinding wheel to help solve the problems encountered? Explain why you made each recommendation.

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