Grinding, lapping, polishing, EDM,

laser cut, water jest, etc.

Grinding is an abrasive machining process that uses
a grinding wheel as the cutting tool.

Aluminum oxide, silicon carbide, diamond, and cubic boron

nitride (CBN) are four commonly used abrasive materials for the
surface of the grinding wheels.
A basic overview of Outside Diameter
Cylindrical Grinding. The Curved Arrows refer to
direction of rotation
A basic overview of Internal Diameter
Cylindrical Grinding. The Curved Arrows refer to
direction of rotation
Surface grinding is used to
produce a smooth finish on flat
surfaces. It is a widely
used abrasive machining process
in which a spinning wheel
covered in rough particles
(grinding wheel) cuts chips of
metallic or nonmetallic substance
from a workpiece, making a face
of it flat or smooth. The typical
precision of a surface grinder
depends on the type and usage,
however ±0.002 mm (±0.0001 in)
should be achievable on most
surface grinders.
The machine consists of a table that traverses both longitudinally
and across the face of the wheel. The longitudinal feed is usually
powered by hydraulics, as may the cross feed, however any
mixture of hand, electrical or hydraulic may be used depending
on the ultimate usage of the machine (i.e., production,
workshop, cost). The grinding wheel rotates in the spindle head
and is also adjustable for height, by any of the methods
described previously. Modern surface grinders are semi-
automated, depth of cut and spark-out may be preset as to the
number of passes and, once set up, the machining process
requires very little operator intervention.
Depending on the workpiece material, the work is generally held
by the use of a magnetic chuck. This may be either an
electromagnetic chuck, or a manually operated, permanent
magnet type chuck; both types are shown in the first image.
Types of surface grinders:
Horizontal-spindle (peripheral) surface grinders
The periphery (flat edge) of the wheel is in contact with the workpiece,
producing the flat surface. Peripheral grinding is used in high-precision
work on simple flat surfaces; tapers or angled surfaces; slots and
profiles.

Vertical-spindle (wheel-face) grinders

The face of a wheel (cup, cylinder, disc, or segmental wheel) is used on
the flat surface. Wheel-face grinding is often used for fast material
removal, but some machines can accomplish high-precision work. The
workpiece is held on a reciprocating table, which can be varied
according to the task, or a rotary-table machine, with continuous or
indexed rotation. Indexing allows loading or unloading one station
while grinding operations are being performed on another.
Outside Diameter Cylindrical Grinding
Internal Diameter Cylindrical Grinding
A schematic of the centerless grinding process.
Centerless grinding process
Honing or to "Hone"is an abrasive machining process that
produces a precision surface on a metal workpiece by
scrubbing an abrasive stone against it along a controlled path.
Honing is primarily used to improve the geometric form of a
surface, but may also improve the surface texture.
Typical applications are the finishing of cylinders for internal
combustion engines, air bearing spindle and gears. There are
many types of hones but all consist of one or more abrasive
stones that are held under pressure against the surface they
are working on.
In terms of sharpening knives,
a honing steel does not actually
hone knives, but simply realigns
the metal along the edge.
Superabrasives and hone head for cylinders.
Lapping is a machinng process, in which two surfaces are
rubbed together with an abrasive between them, by hand
movement or by way of a machine.

Polishing is the process of creating a smooth and shiny

surface by rubbing it or using a chemical action, leaving a
surface with a significant specular reflection.
Electrical discharge machining (EDM), sometimes colloquially also
referred to as spark machining, spark eroding, burning, die
sinking, wire burning or wire erosion, is a manufacturing process
whereby a desired shape is obtained using electrical discharges
(sparks). Material is removed from the workpiece by a series of
rapidly recurring current discharges between two electrodes,
separated by a dielectric liquide and subject to an electric voltage.
One of the electrodes is called the tool-electrode, or simply the
"tool" or "electrode", while the other is called the workpiece-
electrode, or "workpiece".
Wire-cut EDM
The wire-cut type of machine arose in the 1960s for the purpose
of making tools (dies) from hardened steel. The tool electrode in
wire EDM is simply a wire. To avoid the erosion of material from
the wire causing it to break, the wire is wound between two
spools so that the active part of the wire is constantly changing.
The earliest (NC) machines were conversions of punched-tape
vertical milling machines. The first commercially available NC
machine built as a wire-cut EDM machine was manufactured in
the USSR in 1967. Machines that could optically follow lines on a
master drawing were developed in the 1960s at Andrew
Engineering Company for milling and grinding machines. Master
drawings were later produced by (CNC) plotters for greater
accuracy. A wire-cut EDM machine using the CNC drawing plotter
and optical line follower techniques was produced in 1974.
Dulebohn later used the same plotter CNC program to directly
control the EDM machine, and the first CNC EDM machine was
produced in 1976[
A water jet cutter, also known as a water jet or waterjet, is an
industrial tool capable of cutting a wide variety of materials using
a very high-pressure jet of water, or a mixture of water and
an abrasive substance. The term abrasivejet refers specifically to
the use of a mixture of water and abrasive to cut hard materials
such as metal or granite, while the terms pure
waterjet and water-only cutting refer to waterjet cutting without
the use of added abrasives, often used for softer materials such
as wood or rubber
A diagram of a water jet cutter. #1:
high-pressure water inlet. #2: jewel
(ruby or diamond). #3: abrasive
(garnet). #4: mixing tube. #5:
guard. #6: cutting water jet. #7: cut
material
A 5-Axis Waterjet Cutting Head
Laser cutting is a technology that uses a laser to cut materials,
and is typically used for industrial manufacturing applications, but
is also starting to be used by schools, small businesses, and
hobbyists. Laser cutting works by directing the output of a high-
power laser most commonly through optics. The laser optics
and CNC (computer numerical control) are used to direct the
material or the laser beam generated. A typical commercial laser
for cutting materials would involve a motion control system to
follow a CNC or G-code of the pattern to be cut onto the material.
The focused laser beam directed at the material, which then
either melts, burns, vaporizes away, or is blown away by a jet of
gas, leaving an edge with a high-quality surface finish. Industrial
laser cutters are used to cut flat-sheet material as well as
structural and piping materials.
Diagram of a laser cutter
There are two main types of lasers used in laser cutting.
The CO2 laser is suited for cutting, boring, and
engraving. The neodymium (Nd) and neodymium
yttrium-aluminium-garnet (Nd-YAG lasers are identical
in style and differ only in application. Nd is used for
boring and where high energy but low repetition are
required. The Nd-YAG laser is used where very high
power is needed and for boring and engraving. Both
CO2 and Nd/ Nd-YAG lasers can be used for welding.
Plasma cutting is a process that is used to cut steel and
other metals of different thicknesses (or sometimes other
materials) using a plasma torch. In this process, a gas
(oxygen, air, inert and others dependant on material) is
blown at high speed out of a nozzle; at the same time an
electrical arc is formed through that gas from the nozzle to
the surface being cut, turning some of that gas to plasma.
The plasma is hot enough to melt the metal being cut and
moves fast enough to blow molten metal away from the cut.
Thank You for Your Attention