PREPARATION AND BALANCING OF VITTILILD. CKINDING WULELS Contents introduction (o CUME About MURUGAPPA GROUP Introduction to abrasive Divion Plant Layout Process Flow Chart of Abrasives Raw materials Tests Conducted Study on out of Balance of Grinding Wheels Results and Conclusions SanetTiatinas sainemieatanianemeeee 7. ca: PREPARATION AND BALANCING OF VITRIFIED GRINDING WHEELS INRODUCTION Introduction to CUMI Carborundum Universal Limited (CUMI) a US$ 300 Million company was founded in 1954 as a tripartite collaboration between the Murugappa Group, Carborundum Inc, USA, and the Universal Grinding Wheel Co Ltd. UK, CUMI pioneered the manufacture of Coated and Bonded Abrasives in India, besides super -lectro mineral, Industrial Ceramics and Ceramic fibers. In syne with the global refectories. vision CUMI is expanding its produet Spread: the compa ceramics and refractory’s manufactured at 25 Locations ny makes over 20000 different varieties of abrasives, electro minerals, across India, Russia, South Africa, Australia, China. for All the manufacturing facilities of CUMI are ISO 9001:2000 and ISO 14000 Certi Quality standards and Environment - Friendly manufacturing practices. state-of-the - art facilities and strategic alliances with global partners have earned CUMI a reputation for quality and innovation. It is one of the few manufacturing of abrasives and ceramics in the world with fully integrated operations that include mining, cushioning. power generation and manufacturing, besides marketing and distribution. CUM is equipped with a State -of -the-art Research and development center which works aggressively on product development and efficiency enhancement It’s in house R&D and collaborative research with leading research institution have ensured market leadership in India and abroad. CUMI is known to be innovator and exports its products to 43 ‘countries spread across the globe. CUMI’S global expansion into AUSTRALIA, USA, Russia, Thailand and South Africa has enlarged its customer base.PREPARATION AND BALANCING OF VITRIFIED, GRINDING WHEELS The murugappa group. head quartered in Chennai. India, is a USS 3 billion conglomerate with interests in engineering, abrasives, finance. general insurance, fertilizers, farm inputs suger bioeproducts, nutraceuticals. cyeles and plantations. It has 29 limited companies under its globe. umbrella, with manufacturing facilities spread across th Iliance with leading international companies The group. which has forged strong joint venture a like DBS Bank, Mitsui Sumitomo, Cargill, china Engineering Exploration Bureau and Group ians, has Consolidated its status as one of the fastest growing diversified Chimique Tur business houses in India. LIGHTS: {BUSS 300 million company (aaCatering to 43 countries across the globe {B2}0ver 20,000 varieties of products. {25125 manufacturing locations across India, Russia, South Africa, Australia & China . Bastate - of - art facilities and strategic alliance with global partnersGRINDING WHEELS CUMLABRASIVES DIVISION. CUMI Abrasive’s division manufactures and exports a wide range of products used for in India diverse applications pioneered in the manufacture of bonded & coated Abrasiv Till 2006, CUM was primarily an Indian player. The Indian player. The establishment of the hina and the acquisitions of abrasive enterprises Inc. Canada along joint ventures VIZ. Jing on of Volzhskiy abrasive works Russia has given CUMI a strong with the major acquis manufacturing presence in the ‘RIC’ markels and also a sound base for increasing its global penetration In India CUMI is the market Leader. PRODUCTS: > BONDED ABRASIVES > COATED ABRASIVES > SUPER ABRASIVES > THIN WHEELS > NONWOVENS > METAL WORKING FLUIDS > POWER TOOLS VITRIFIED PRODUCTS > Module 1 150 to 250mm Module 2 300to 600mm + Module 3 6 to 150mm IGHT! > Over $0000 tons’ capacity in India, Russia& China, > Leader ship in Indian and Russian market. Products available in 42 countries,PREPARATION AND BALANCING OF VITRIFIED INDING WHEE R INDUSTRI AUTO AND AUTO OEW'S AUTO ANCILLARIES WOOD WORKING FABRICATION CONSTRUTION STEEL HANDTOOLS FLOORING CENTER LESS GRINDING WHEEL |CATE PRODUCTRAW MATERIAL WEIGHING MIXING MOULDING DRYING se FIRING FINISHING INSPECTION , LABELINGPRE VITRIFIED. ARATION AND BALANCING 0: GRINDING WHEELS RAW MATERIAL They are va Is such a internal grinding Tous types of products are available in vitrified wheel wheels, center sialties (bricks, blocks. els, center less grinding wheels, crank grinding wheel and specialties (brick stones) ete, TI ; + dimension of those Stones) ete, These wheel are named based on their usage or application. The dimension oft thickness range 3mm to Wheels are made of dj : heels are made of different from 10mm to 1200mm diame abrasives types ‘The grit size rang 100mm. These wheels are made of different grit size and from 24-120 and type abrasives includes Alumina and Silicon Carbide. >» — Brown aluminum oxide >» White aluminum oxide > Pink aluminum oxide Typical Characteristics include: Good Strength and stiffness Good hardn Good corrosion resistance ss and wear resistance Good thermal stability Typical app! ations include; > Electrical insulators > Grinding wheels > Wear components Silicon Carbide (SIC) is highly wear resistant and also having good mechanical properties, including high temperature, strength and thermal shock resistance, Sic as a technical ceramic, is produced in two main ways, Reaction bonded SiC is made by infiltrating compacts made of mixtures of SiC and Carbon with liquid silicon, The silicon reacts with the carbon forming, SiC.Conventional Ceramie forming process are used and the material is sintered in an inert atmosphere at temperature up to 2000°C or higher. In Sic used in abrasive wheels two types, + Green Silicon Carbide > Black Cilicon CarbidePREPARATION AND BALANCING OF VITRIFIED. GRINDING WHEELS MIXING: Mixing is an initial a process of vitrified wheel manufacturing We will take weighed raw material as per mix ticket To chan © the grains in to bowl and run it We will add liquid binder in to bowl at running condition Adding weighed bond in the pre wetted grains at running condition. End of the process mix is ready for moulding. Afier sieving the mix is ready for moulding. arameter: 1. Moisture content, 2. Grain& Bond Rati The above quality parameter are ok, the mix is ready for moulding.PREPARATION AND BALANCING OF VITRIFIED, GRINDING WHEELS TYPICAL CHARACTERISTICS INCLUDE density ® High strength >» No breakage > Excellent thermal shock resistance > High hardness and wear resistance > Excellent chemical resistance » Low thermal expansion and high thermal conductivity > Electrical conductivity Typical application includes: > Abrasive wheels > Killen furniture BOND: Bond is to bind the abrasive grains in the firing proces Wheel. It is a combination of clay, Minerals and frit to make the bond fuse at the firing temperature. FORMI: sand to give strength to the grindingPREPARATION AND BALANCING OF VITRIELEP 5 GRINDING WHEELS The manuti eae anufacture ¢ weighing. ™ Se dcture of grinding wheels includes the following processes Hike WS" “inte Sieving a pressing, The nd send to mixing area ad required raw materials are weighed ae vontains bow! and Pants ae mised with eeamie bonds in hunner mise the kupper contain é ee y the mix at sides 3 this can be rotated in both directions, There is a provision for serapine the mi coats the grain. After that the grain, The machine is to ensure better uniti re better uniformity of the mixture, First temporary binder cerami ¢ : A ie bond are added during running, the bond gets coated on the _ allowe, ‘ : ded a in Hlowed to run to get required consistency ofthe mix. Then the mix is unloaded and sieve whe sesure in the single the appropriate sieves. The mixture is pressed in a metal die by applying pressure" Cte Beret He irection (uniaxial pressing). It is a simple and inexpensive process. MOULDING PROCESS: Medium size grains filling in the cavity and also pressing is done. Then moulded wheel is handled & stored in racks, GREEN PROPERTIES: Green density The green wheels were taken diameter; thickness and weight were measured by using Vernier caliper, screw gauge and weighing balance respectively. The following formula is used. Mass: Density = ams/eubic inch Volume~~ = PREPARATION AND BALANCIN. GRINDING WHE aoe drying is to get th Only larger diameter wheels are dried in the drier. The main purpose © bate prevent th 1150 10 n stage and al abel isd i Ranta, inimum strength necessary for handling, at gr ine ned at 100°C 150°C i while lo: ading. The drying temperature is mainta Product dimensions After drying, the wheels are stacked in the kiln car. The wheels are kept over silicon carbide bats in about 7 decks. The bedding materials used here are flints, which can withstand at high temperature and also it prevents sticking of wheels with another,a a em me ee FIRING There are difficult cycles for firing based on the bond system . These cycles have same peak temperature, but different firing and cooling period, Firing and cooling period. Firing cycle for ceramic- bonded abrasive products. depending on the type of bond, wheel size and its composition used. ‘At the initial stage of heating of the wheel from room temperature up to 600° the rate of heating will be slow. But as the temperature rises, the heating rate also increases to about 50°e. The ware are at the soaking temperature for informing The wheels are then cooled and taken out. > Intermittent & contentious tunnel kiln used firing of wheels and temperature around 1300°e. > Kiln lining in wool and plates of car in silicon carbide. FINISHING & INSPECTION: The main operations carried out in finishing are Disking: Polishing the surfaces to the dimensions. Edging: To remove the non-uniformities in the edges,—— ee ee ee OF VITRIFIED PREPARATION AND BALANCING GRINDING WHE FIRED PREPARATION AND BALANCING OF VITRIFIED GRINDING WHEELS Painting: Arbor corrected by the paint to get required size FIRED PROPERTIES-FIRED DENSITY: After firing the dimensions and Weights of the samples were noted down. The fired density was calculated using the formula. gms /cubic inch Density Mass Volume ARBOR: Arbor Paint; synthetic paint > Lead bushing: lead melted in arbor for c > Plastic bushing: injection molding of plastic as bush. THICKNESS: Thickness finishing to required size is done in Discing. Steel grit used for finishing the thickness on metal bed in diseing operation. Two types Discing Machine > Auto finishing > Manual disking DIAMETER: > Edging finishing of outer diameter of wheel. PACKING: > Quality checked wheel are sent for packing TYPICAL CHARACTERISTICS INCLUDE: > Good Strength > Good hardness and wear resistance > Good corrosion resistance > Good thermal stability TYPICAL APPLICATIONS INCLUDE: + Finishing of Bearing > Finishing/grinding operation in Automobile Industry ee TT LEE ET TE ETPREPARATION AND BALANCING OF VITRIE GRINDING WHEEL Hardness, manufacturers indicate wheel grade with letters ranging from “A" for very soft to “Z" for very hard ins of a more open wheel structure goes from closed Structure indicating less gt plant located at Hosur, UTK, Ahmadabad, , Chennai, China The grinding wheel manufaeturin, Japan and Russia, Plant at Hosur consists of wheel of Hundred clines. As the cost of ‘manufacturing the grinding wheel products, inside the factory is high when compared to other extemal venders, the thrust is upon reducing cost, improving quality, productivity and shorten the delivery time in order to remain competi Grinding wheel Manufacturing process Conventional m Auto Mould Route route cagee, & ——— —s “2 MR Han el Ream PREPARATION AND AL ANCING OF VETULILD GALNDING WHEELS Suu) On OU OT balinee of grinding wheels Hor satiatietory Work, the grinding Wheel and i sleeve oF mount must be in a reasonably good stale of balanee, Except for extremely high preetslon work, the wheel assembly does not noe t0 be 1, oF corrected to, preelie balanee, The reawonn for this li that the well-designed wrinading machine fe a0 rigid hat vibrations due to normal wheel imbalance within the eto yer design and construction will alse ingpection limits are of practically no eonxequence, Pr Juve eliminated any possibility of the wheel apindle operating at, near the resonant frequeney of any nutchine component While grinding wheels today are held (0 very close limits with respect (o structural uniformly and grade duplication, some manufacturing tolerance, however small, must be observed for grinding wheels, as for any manufactured product, and therefore some imbalance may be present, Besides, even if a wheel conceivably, were imperfect balance when made, some imbalance is inevitable when the wheel is mounted, for the simple reason that if that if the Standard Safety Code is to be observed, the wheel must not fit tightly on the spindle, Clearance must be provided so that any possible expansion of the spindle or sleeve due to grinding heat or bearing or bearing heat cannot exert outward pressure or stress at the hole This is very important as it has been cleatly established that the maximum stresses ina rotating body are tangential at the edge of the hole and any additional stress might lead to breakage. This mandatory hole-to-spindle clearance thus means that at any grinding wheel of necessity will be produce a certain amount of Imbalane If refinement of balance is vital to the successes of work regularly ground, then an automatic wheel balance should be considered for use on cylindrical grinders, Conventional balancing procedures can be time- consuming, In contrast, since the automatic wheel is built into the Wheel head, this allows balancing in place this allows balancing in place on the machine in on the machine and the machine and the operator merely2 a 3 ' y si 5 , 4 , ——— VITRIFIED seconds. Thus, ated after about 5 secon Pushes al grinding, with y termi @ button. The balancing eyele is automatically ter y act s, expect during a Precise wheel balancing can be accomplished at any time, eXf No special operator skill required \ detailed study on the subject of wheel balance must include: ~ e amount of ermine and isolate th 1. The development of mathematical formula € to determine ar Imbalance due to physical dimensions along rement aad an lance requirement an * The employing of electronic equipment to determine realistic balance req Various types of grind machines; vai equipment and 3. The development a 1 rl facturing and installation of the most advanced wheel manufac! Methods to ensur cation. The results of this the utmost in wheel structural uniformly and duplication. Th Will enable us to affect us to signifi CHECK WHEEL SLEEV (OR BALANCE f the study of wheel balance into practic following procedure should be improvements in wheel balance. benefits to the user, the adopted by the wheel user. All wheel sleeves and flanges should be checked for balance with standard balance equipment for grinding wheels; if found to be marked, so that it can be subsequently allowed. Wheel Sleeves for CUMI Grinding Machines, in the course of manufacture, are checked for balance (dynamically)PREPARATION AND BALANCING OF VITRIFIED GRINDING WHEELS With the uniform structure and balance built into CUMI precision grinding wheels toda scfund wheel belanelng 16 seldont required In the general run of production grin Nevertheless, almost any wheel when wuspended on arbor and allowed to turn will in variabl show a light side... Wheel for precision grinding, which are oven 14 in diameter are at tim marked with an arrow (-) shovwing the light side, together with the instruction, Mount up see fig. This means that ifthe wheel to be mounted is hung on a fixed spindle, as would normally be the case, the wheel should be positioned so that the arrow points upwards, then the excess material would be trued off the light side Wheels are stenciled with an arrow for Mounting purposes as shown in fig. p, the heavier side of the wheel will be at the greatest distance By mounting the light side uy wn, This means that when the outer diameter is turned to from the finial center of rotatio concentricity, the excess material will be removed from the heavier side of the wheel, which of course is desirable. As there must always b sleeve or spindle, the cavity thus caused, though e of imbalance, which we call residual imbalance. By mou ve some clearance between the hole diameter and ver so slight, will result in a certain amount inting the wheel with its light side up, this residual imbalance will always be diametrically opposite to the heavier side, thereby acting as a corrective factor. If, on the other hand, the wheel was to be mounted up, with heavy side upwards, then the excess material would be trued off the light side, thus aggravating the amount of imbalance, As In the case of a wheel 500 mm*200mm*304.8mm (20*8*12) for example, with a normal hole-to-spindle clearance of 0.54mm (010) it has been observed that by simply.PREPARATION AND BALANCING OF VITRIFIED GRINDING WHEELS Yo move the ‘wo balance Wwelphts away from the light spot by equal amounts, until a satisfactory state of operative balance is obtained PS INBALACING A WHEEL Standan! equipment for balance grinding wheels consists of a balance stand and balancing 3 to fit various sizes to fit v walancing a wheel is as follows: sarious sizes of wheel sleeves, The procedure to follow in bi 1, Mount the wheel on it rrow should point upwards). Tighten the flange bolts evenly and enough to hold the wheel firmly Allow the wheel to turn until it has come to rest with the heavy side down ‘achalk mark on the side of the wheel at the exact top (directly opposite the heavy sleeve, (In case of wheels with 3. Draw side). 4. Replace the two balancing weights in the flange groove with their adjacent ends meeting Under the chalk mark, tighten the weight just enough to hold them in position temporarily. Give the wheel a quarter turn the wheel may not remain at rest in this position; move the weights gradually& equally from the chalk mark until the balance is established. Give the wheel a half tum, Test for balance and then keep turning the wheel in the trinding the wheel for a complete revolution, stopping and checking for balance at about eight of a revolution. 7. Carefully rest the wheel on the floor, remove the balancing arbor and mount the wheel in the grinding machine. Finally, are true the wheel preparatory to grinding, The sketches in, show the balancing weights, the chalk mark and where the heavy spot are first sketches in, crosshatched areas on the weightsPREPARATION AND BALANCING OF VITRIFIED, GRINDING W CONCULATION 1, Proper Racking & Leveling 2. Mixing and sieving Impact on OOB in green stage 3. Moisture level impact on the OOB 4. Particle size distribution Access the wheel 5. Uniform distribution of green mix in the mouldVITRIFIED. EWIS -A Text book of modern grinding practice by KENETH BT and WILLIAM P SCHICHIER «1976 Reference books’ perlodieulssKAUFMAN J JETAL, 1994 Byaluating Br ‘American Value ® The Grinding whee ain Storming ideas, the making of the VE Work Shop Annual proceedings society of Engineers. >» Time to markets Reducing the protect lead Time- Cyril C ‘harney > Hand book of productivity improvement “William Christoper, Karl G Thor > Perry's chemical Engineers ‘Hand BOOK, Eighth edition, Don Gr en(Author), Robert Perry (Author), MANUAL > Cumi Manufacturing standards, Web Sites: > www. Wikipedia.org > www, Cumi.com hup://onlinelibrary. wilev.com/ ¥v.< ——— LEE 4 xa et SIMU Oeeeererte SCE « PREPARATION AND BALANCING OF SITIUEILD: GHINDING WHEELS Plan of Works Sh | | 1 | Data collection | | Studyae validation of Existing Process 3 | Bench Marking 4 | Development of New Process 5 | Lab o TrialsdResults 6 | Line-trialsa& Validation | 7 | Implementation& | StandardizationEPARATION AND BALANCING OF VITRIFIED GRINDING WH CONCLL “To manufacture balanced wheel the follow steps are to be monitored nufacturing performances. The In this dissertation, an effort was made to improve the three imperative like lead time, productivity and cost on which process conversion should perform has been addressed and way to improve them have been shown, With this we conclude that by implementing the planned actions, we can minimize the losses during mixing moulding and loading. The other most important aspect of these plans is standard time of mixer. And by using soft cloth tong, we can reduce the handling of the combination stone. Moreover, various forms of procedures can be placed on the worker’s requirement. To summarize the following benefits achieved through grinding wheel projects. OOB checking skill in final stage Leveling skill_in moulding Leveling unit not positioned Carriage Movement In Moulding Turn table rotation QOB stand calibration OOB flange calibration 0B checking after powder application! Sieving method after mixing Levelling method Moisture content of mix not uniform Lumps in Mix No uniform Mixing > Grinding wheel Manufacturing Lead time reduced Introduced raking method for even levelling at the stage of molding process. + Correct weight as been molded as per the mix ticket > Weighing scale calibration done in daily,OF VITRIFIED, GRINDING WHEELS -REFERENCES: > The Grinding wheel-A Text book of modern grinding practice by KENETH B, LEWIS and WILLIAM F SCHICHIER «1976 » Reference books periodicals-KAUFMAN J JETAL, 1994 Evaluating Brain Storming Nas, the making of the VE Work Shop Annual proceedings society of American Value Engineers, > Time to market: Reducing the protect lead Time- Cyril Charney > Hand book of productivity improvement - iam Christoper, Karl G Thor * Perry's chemical Engineers ‘Hand BOOK, Eighth edition, Don Green(Author), Robert Perry (Author), MANUALS > Cumi Manufacturing standards, Web Sites: > www. Wikipedia oz > www. Cumi.com > bap:/onlinelibrary.wilev.com/