Abrasive machining is a

machining Machining is a process in which a material (often metal) is cut to a desired final shape and size by a controlled material-removal process. The processes that have this common theme are collectively called subtractive manufacturing, which utilizes ...

process where material is removed from a workpiece using a multitude of small

abrasive An abrasive is a material, often a mineral, that is used to shape or finish a workpiece through rubbing which leads to part of the workpiece being worn away by friction. While finishing a material often means polishing it to gain a smooth, reflec ...

particles. Common examples include grinding, honing, and polishing. Abrasive processes are usually expensive, but capable of tighter tolerances and better surface finish than other machining processes

Mechanics of abrasive machining

Abrasive machining works by forcing the abrasive particles, or grains, into the surface of the workpiece so that each particle cuts away a small bit of material. Abrasive machining is similar to conventional machining, such as milling or turning, because each of the abrasive particles acts like a miniature cutting tool. However, unlike conventional machining the grains are much smaller than a cutting tool, and the geometry and orientation of individual grains are not well defined. As a result, abrasive machining is less power efficient and generates more heat. The grain size may be different based on the machining. For rough grinding, coarse abrasives are used. For fine grinding, fine grains (abrasives) are used.

Abrasive machining processes

Abrasive machining processes can be divided into two categories based on how the grains are applied to the workpiece. In bonded abrasive processes, the particles are held together within a matrix, and their combined shape determines the geometry of the finished workpiece. For example, in grinding the particles are bonded together in a wheel. As the grinding wheel is fed into the part, its shape is transferred onto the workpiece. In loose abrasive processes, there is no structure connecting the grains. They may be applied without lubrication as dry powder, or they may be mixed with a lubricant to form a slurry. Since the grains can move independently, they must be forced into the workpiece with another object like a polishing cloth or a lapping plate. Common abrasive processes are listed below.

Fixed (bonded) abrasive processes

* Grinding * Honing, superfinishing *Tape finishing, abrasive belt machining *Abrasive sawing, Diamond wire cutting,

Wire saw A wire saw is a saw that uses a metal wire or cable for mechanical cutting of bulk solid material such as stone, wood, glass, ferrites, concrete, metals, crystals etc.. Industrial wire saws are usually powered. There are also hand-powered surv ...

Sanding upright=1.35, Sheets of sandpaper with different grit sizes (40 (coarse), 80, 150, 240, 600 (fine)). Sandpaper and glasspaper are names used for a type of coated abrasive that consists of sheets of paper or cloth with abrasive material glued to ...

Loose abrasive processes

Polishing Polishing is the process of creating a smooth and shiny surface by rubbing it or by applying a chemical treatment, leaving a clean surface with a significant specular reflection (still limited by the index of refraction of the material accordin ...

Lapping Lapping is a machining process in which two surfaces are rubbed together with an abrasive between them, by hand movement or using a machine. Lapping often follows other subtractive processes with more aggressive material removal as a first ste ...

* Abrasive flow machining (AFM) *

Hydro-erosive grinding Hydro-erosive grinding (HEG) is a process for radiusing orifice edges and hole intersections by flowing an abrasive fluid through. This process can calibrate the holes to flow a certain static flow rate. See also * Abrasive flow machining Abrasiv ...

* Water-jet cutting *

Abrasive blasting Sandblasting, sometimes known as abrasive blasting, is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface or remove su ...

* Mass finishing, tumbling **Open barrel tumbling **Vibratory bowl tumbling **Centrifugal disc tumbling **Centrifugal barrel tumbling

Abrasives

The most important property of an abrasive is its hardness. For abrasive grains to effectively cut, they must be significantly harder than the workpiece material. They can be grouped based on their hardness into two categories: conventional abrasives and superabrasives. Conventional abrasive materials have been used since the advent of machining. They are made of materials that exist naturally on Earth, and they are abundant and cheap. Conventional abrasives can suitably machine most materials. Superabrasives are much harder than conventional abrasives. Since they are much more expensive, they are used when conventional abrasives will not suffice. Common abrasives are listed below.

Conventional

* Aluminium oxide (

Corundum Corundum is a crystalline form of aluminium oxide () typically containing traces of iron, titanium, vanadium and chromium. It is a rock-forming mineral. It is a naturally transparent material, but can have different colors depending on the pr ...

) *

Silicon carbide Silicon carbide (SiC), also known as carborundum (), is a hard chemical compound containing silicon and carbon. A semiconductor, it occurs in nature as the extremely rare mineral moissanite, but has been mass-produced as a powder and crystal s ...

* Emery *

Pumice Pumice (), called pumicite in its powdered or dust form, is a volcanic rock that consists of highly vesicular rough-textured volcanic glass, which may or may not contain crystals. It is typically light-colored. Scoria is another vesicular v ...

Sand Sand is a granular material composed of finely divided mineral particles. Sand has various compositions but is defined by its grain size. Sand grains are smaller than gravel and coarser than silt. Sand can also refer to a textural class ...

Steel abrasive Steel abrasives are steel particles that are used as abrasive or peening media. They are usually available in two different shapes (shot and grit) that address different industrial applications. Steel shot refers to spherical grains made of molt ...

Superabrasives

Diamond Diamond is a solid form of the element carbon with its atoms arranged in a crystal structure called diamond cubic. Another solid form of carbon known as graphite is the chemically stable form of carbon at room temperature and pressure, b ...

Cubic Boron Nitride Boron nitride is a thermally and chemically resistant refractory compound of boron and nitrogen with the chemical formula BN. It exists in various crystalline forms that are isoelectronic to a similarly structured carbon lattice. The hexagonal ...

(CBN),

Borazon Borazon is a brand name of a cubic form of boron nitride (cBN). Its color ranges from black to brown and gold, depending on the chemical bond. It is one of the hardest known materials, along with various forms of diamond and kinds of boron nitride ...

References

* {{DEFAULTSORT:Abrasive Machining Machining