Volume of Material Removal in Cylindrical Grinding

Dear Sir, 22nd January,2010

I am P.Gangadharan, from Bangalore, India, a Mech.Engr. and a Consultant on Manufacturing having 40 years of Shop experience.I have specialised in Grinding but still am interested in Productivity and I shall be grateful if you please suggest a proper cylundrical grinding wheel for the details given below.

Details of the cylindrical grinding of a piston rod used in hydraulic cylinders of earth moving machines like excavators, bulldozers ctc.,

Piston rod: Rough Grinding vvv to 0.8 umRa with a circularity of 0.03 mm

Material--------------------------------------------------------45-C8 / IS 5517

Condition-Induction Hardened to HRC 52-60 with a case depth 1.5—3.00 mm

Straightness after Induction Hardening----------0.15 mm over 1045 mm long

Cylidrical grinding m/c---------------------------------HMT G22-Olivetti design(Italy)

Cast iron bed guideways-scraped-----------------Wheel Head Power---7.5 HP

Grinding wheel Dia,500x65x254 with a recess of dia.325x10 mm

Grinding wheel make-CUMI (Carburandum universal)

Grit & Grade---A 463 K5 V10------Surface speed used is 30 Meters per second

Wet grinding with Magnetic separator------Coolant used I Pol cut 60

Dressing diamond-----Multi point

Ground in between dead carbide centers without steady rest support

Diameter before grinding 70.80 mm and to be ground to dia. 69.98 mm x1045 mm long

Job RPM-N 110---with the following steps:

1- From diameter 70.80 mm up to diameter 70.02 mm

2- Depth infeed-0.05 mm on dia. per single traverse ie 0.05 mm from tailstock to work head.

Again 0.05 mm from work head to tailstock and this depth is given with a table traverse of 30 mm per

one revolution of the job.till dia.70.02 mm.

3-The floor to floor time is 20.5 minutes which includes 2 minutes of 3 wheel dressings and job checking

time of 1minute.So the actual grinding time comes to 17.5 minutes.

4-The material removal is 98 Cubic Centimeters in 17.5 minutes giving a material removal figure of

5.25 Cubic Centimeters per minute.

Our requirement:-

1- Achieve floor to floor time of 10 mts per piece through higher Material Rate of

9.00 CCM (approximately) per minute.

< To achieve this, Can You please suggest the suitable grit and grade of Vitrified Aluminium oxide wheel

2- Alternatively to achieve this MRR , can we use CBN Wheels and if so, what are the basics required please.

Thanking You,

With Regards,

Yours truly,

P.Gangadharan -----