scholarly journals Modeling and simulation of the advanced structured surfaces machined by specially patterned grinding wheels via the structuring grinding process

2022 ◽  
Author(s):  
Amr Monier ◽  
Bing Guo ◽  
Qingliang Zhao ◽  
T. S. Mahmoud
Keyword(s):  
Modeling And Simulation ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Structured Surfaces

scholarly journals The Effects of Structured Grinding Wheel Designed Parameters On The Geometries of Ground Structured Surfaces

2021 ◽  
Author(s):  
Amr Monier ◽  
Bing Guo ◽  
Qingliang Zhao ◽  
Zhenfei Guo ◽  
Tamer S. Mahmoud ◽  
...  
Keyword(s):  
Modeling And Simulation ◽  
Geometrical Parameter ◽  
Simulation Models ◽  
Grinding Wheel ◽  
Geometrical Parameters ◽  
Grinding Process ◽  
Surface Geometry ◽  
Structured Surfaces ◽  
Simulation Results ◽  
Grinding Operations

Abstract This study investigates the effects of the structured wheels’ geometrical parameters on the geometries of structured surfaces machined by grinding operations. First, the geometrical parameters of the structured wheels were determined. The resultant geometrical parameters of structured surfaces were defined and related to the designed operating condition, including the structured wheel and grinding process by mathematical and simulation models. The results showed that each wheel’s geometrical parameter affects the structured surface geometry at different rates. Grinding experiments were then performed to explore experimentally how the geometrical parameters of the structured wheel affect the geometry of structured surfaces and verify the modeling and simulation results and explanations. The results showed a remarkable compatibility between the predicted and machined surfaces and reflected the accuracy of the presented method for machining the structured surfaces by grinding.

scholarly journals Modeling And Simulation of The Advanced Structured Surfaces Machined By Specially Patterned Grinding Wheels Via The Structuring Grinding Process

2021 ◽  
Author(s):  
Amr Monier ◽  
Bing Guo ◽  
Qingliang Zhao ◽  
T.S. Mahmoud
Keyword(s):  
Working Conditions ◽  
Simulation Method ◽  
Grinding Wheel ◽  
Operating Parameters ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Wheel Surface ◽  
Structured Surfaces ◽  
Structured Surface ◽  
Irregular Geometries

Abstract In this work, the ability to reshape the grinding wheels with special patterns to produce advanced structured surfaces with several geometries is studied. Firstly, a mathematical model is built for the process relating geometries of the grinding wheel, geometries of wheel patterns, the produced structured surface with the grinding operating parameters. Then, different regular and irregular geometries are designed to be patterned over the wheel surface. Afterward, a simulation method to express the patterned wheels and the structured surface at different working conditions is developed. The effects of the pattern geometries on the obtained structured surfaces are investigated.

scholarly journals THE EFFECT OF ABRASIVE GRAIN SHAPES ON QUALITY OF FERRITE MAGNETS GRINDING PROCESS

2020 ◽  
Vol 14 (2) ◽  
pp. 117-124
Author(s):  
Bayu Rahmat Saputro ◽  
Amin Suhadi
Keyword(s):  
Chemical Composition ◽  
Single Layer ◽  
Processing Parameters ◽  
Grinding Process ◽  
Model Design ◽  
Grinding Wheels ◽  
Abrasive Grains ◽  
Abrasive Grain ◽  
Shape And Size

Abstract A research was conducted on the grinding process of ferrite magnet with Strontium ferrite type (SrO.6 (Fe2O3)) using electroplated single layer grinding wheels. Many cracks have been found on work pieces during this work, which is coming from grinding processes. Research is conducted starting from chemical composition test and the effect of the shape and size of the abrasive grain of grinding wheels to the quality of grinding process results by measuring crack ratio of the work piece.  In this experiment, 3 (three) model design of grinding wheels with three different size and shape of abrasive grains are made. All of processing parameters are set at the same value as ordinary process.  The experimental results shown that 3rd model have the best results from the outputs number and also the lowest reject crack ratio compared to 1st and 2nd models. This is because the 3rd model has blocky shape which its distribution structure is denser and more uniform compared to the irregular shape, so that continuous grinding on hard and brittle work pieces is more stable and suitable

Five-Axis CNC Tool Grinding: Part I—Rake Face Grinding

2011 ◽  
Author(s):  
Mahmoud M. Rababah ◽  
Zezhong C. Chen
Keyword(s):  
Rake Angle ◽  
Grinding Process ◽  
Rake Face ◽  
End Mill ◽  
Grinding Wheels ◽  
Robust Algorithm ◽  
Geometric Representations ◽  
Five Axis ◽  
Face Grinding ◽  
Tool Grinding

Grinding the helical surfaces in end-mill cutters using two-axis CNC machines is well investigated in literature. However, the grinding wheels do not have explicit geometric representations and the produced helical angles differ from the designed values. Moreover, to the best knowledge of the authors, no reliable and robust algorithm exists to grind generic shape cutters with constant normal rake angles. Thus, the first part of this work introduces a five-axis grinding process that keeps the normal rake angle constant along the rake face. The parameters that affect the shape of the tool flutes are also analyzed and studied in this part. These parameters are then optimized in the second part to obtain optimum wheel shapes grinding the tool flutes along optimum paths. Overall, the grinding process proposed grinds the tool flutes with close matching to the designed ones and replaces the complex wheel shapes commonly used by simple prismatic ones.

The temperature of the holes of the bearing rings when grinding with a precast textured wheel

2022 ◽  
Vol 2022 (1) ◽  
pp. 29-36
Author(s):  
Vladimir Gusev
Keyword(s):  
Thermal Stress ◽  
Experimental Models ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Average Temperature ◽  
Bearing Rings ◽  
Grinding Time

The problem of reducing the thermal stress of the grinding process of bearing rings has been viewed. The possibility of reducing the temperature of the treated surface based on the use of precast textured grinding wheels has been presented. Experimental models of pulse, contact, average temperature, velocities and rates of their change in the function of grinding time are found.

scholarly journals Internal Cylindrical Grinding Process of INCONEL® Alloy 600 Using Grinding Wheels with Sol–Gel Alumina and a Synthetic Organosilicon Polymer-Based Impregnate

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 115 ◽  
Author(s):  
Wojciech Kapłonek ◽  
Krzysztof Nadolny ◽  
Krzysztof Rokosz ◽  
Jocelyne Marciano ◽  
Mozammel Mia ◽  
...  
Keyword(s):  
Sol Gel ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Alloy 600 ◽  
Abrasive Tool ◽  
Grinding Wheels ◽  
Impregnation Process ◽  
Organosilicon Polymer ◽  
Internal Cylindrical Grinding ◽  
Abrasive Tools

The development of modern jet engines would not be possible without dynamically developed nickel–chromium-based superalloys, such as INCONEL® The effective abrasive machining of above materials brings with it many problems and challenges, such as intensive clogging of the grinding wheel active surface (GWAS). This extremely unfavorable effect causes a reduction in the cutting ability of the abrasive tool as well as increase to grinding forces and friction in the whole process. The authors of this work demonstrate that introduction of a synthetic organosilicon polymer-based impregnating substance to the GWAS can significantly improve the effects of carrying out the abrasive process of hard-to-cut materials. Experimental studies were carried out on a set of a silicon-treated small-sized sol–gel alumina 1-35×10×10-SG/F46G10VTO grinding wheels. The set contained abrasive tools after the internal cylindrical grinding process of INCONEL® alloy 600 rings and reference abrasive tools. The condition of the GWAS after the impregnation process was studied, including imaging and measurements of its microgeometry using confocal laser scanning microscopy (CLSM), microanalysis of its elemental distribution using energy dispersive X-ray fluorescence (EDXRF), and the influence of impregnation process on the grinding temperature using infrared thermography (IRT). The obtained results confirmed the correctness of introduction of the impregnating substance into the grinding wheel structure, and it was possible to obtain an abrasive tool with a recommended characteristic. The main favorable features of treated grinding wheel concerning the reduction of adhesion between the GWAS and grinding process products (limitation of the clogging phenomenon) as well as reduction of friction in the grinding process, which has a positive effect on the thermal conditions in the grinding zone.

scholarly journals Modeling and Simulation of Process-Machine Interaction in Grinding of Cemented Carbide Indexable Inserts

2015 ◽  
Vol 2015 ◽  
pp. 1-8 ◽  
Author(s):  
Wei Feng ◽  
Bin Yao ◽  
BinQiang Chen ◽  
DongSheng Zhang ◽  
XiangLei Zhang ◽  
...  
Keyword(s):  
Modeling And Simulation ◽  
Dynamic Instability ◽  
Process Models ◽  
Cemented Carbide ◽  
Machining Process ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Machine Model ◽  
Machine Interaction ◽  
Process Machine Interaction

Interaction of process and machine in grinding of hard and brittle materials such as cemented carbide may cause dynamic instability of the machining process resulting in machining errors and a decrease in productivity. Commonly, the process and machine tools were dealt with separately, which does not take into consideration the mutual interaction between the two subsystems and thus cannot represent the real cutting operations. This paper proposes a method of modeling and simulation to understand well the process-machine interaction in grinding process of cemented carbide indexable inserts. First, a virtual grinding wheel model is built by considering the random nature of abrasive grains and a kinematic-geometrical simulation is adopted to describe the grinding process. Then, a wheel-spindle model is simulated by means of the finite element method to represent the machine structure. The characteristic equation of the closed-loop dynamic grinding system is derived to provide a mathematic description of the process-machine interaction. Furthermore, a coupling simulation of grinding wheel-spindle deformations and grinding process force by combining both the process and machine model is developed to investigate the interaction between process and machine. This paper provides an integrated grinding model combining the machine and process models, which can be used to predict process-machine interactions in grinding process.

Potential for improving efficiency of the internal cylindrical grinding process by modification of the grinding wheel structure—Part II: Grinding wheels made of superabrasive grains

2016 ◽  
Vol 231 (4) ◽  
pp. 813-823 ◽  
Author(s):  
Krzysztof Nadolny ◽  
Witold Habrat
Keyword(s):  
Cubic Boron Nitride ◽  
Positive Influence ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Structural Modifications ◽  
Synthetic Diamonds ◽  
Wide Range ◽  
Internal Cylindrical Grinding ◽  
Different Diameters

This article offers an overview of 11 grinding wheel construction modifications used in the peripheral grinding of flat, shaped, internal, and external cylindrical surfaces, when grinding wheels made of superabrasive grains are used (natural and synthetic diamonds, as well as mono- and microcrystalline cubic boron nitride). The text contains characteristics of grinding wheels with: bubble corundum grains, glass-crystalline bond, conic chamfer, zones of different diameters, a centrifugal provision of the coolant into the grinding zone, aggregate grains, zone-diversified structure, as well as impregnated (self-lubricating), multiporous, segment and “intelligent” grinding wheels. Each of the presented structural modifications were described by giving construction scheme, used abrasive grains, range of applications, advantages as well as disadvantages. Modifications of the grinding wheel construction allow for effective improvement of both the conditions and the results of the grinding process. A wide range of the known modifications allow for their proper selection depending on the required criteria of effective evaluation and taking into account the specific characteristics of superabrasive grains. As a result, it is possible to obtain positive influence on a number of technological factors of the grinding process. The described modifications of the grinding wheel structure can be also an inspiration and the basis for creating new solutions in this field.

Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Sebastian Barth ◽  
Michael Rom ◽  
Christian Wrobel ◽  
Fritz Klocke
Keyword(s):  
Research Work ◽  
Distribution Functions ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Edge Zone ◽  
Application Behavior ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool

The prediction of the grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used grinding wheel is still a great challenge for today's manufacturers and users of grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the grinding wheel, which comes into contact with the workpiece during the grinding process. The topography of a grinding wheel mainly depends on the structure of the grinding wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the grinding wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent grinding wheel structure is known. This paper presents an innovative approach for modeling the grinding wheel structure and the resultant grinding wheel topography. The overall objective of the underlying research work was to create a mathematical-generic grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a grinding wheel. This model enables the user to determine the resulting grinding wheel structure and the grinding wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) grinding wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of grinding tools, which takes into account the entire grinding wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of grinding wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the grinding wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of grinding processes.

Optimization and Application of Laser-Dressed cBN Grinding Wheels

2016 ◽  
Vol 1136 ◽  
pp. 90-96 ◽  
Author(s):  
Ali Zahedi ◽  
Bahman Azarhoushang ◽  
Javad Akbari
Keyword(s):  
Environmental Concerns ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Average Roughness ◽  
Cylindrical Grinding ◽  
Laser Dressing ◽  
Dressing Tool ◽  
Cbn Grinding Wheel ◽  
Spindle Power

Laser-dressing has been shown to be a promising method for overcoming some shortcomings of the conventional methods such as high wear of the dressing tool and its environmental concerns, high induced damage to the grinding wheel, low form flexibility and low speed. In this study, a resin bonded cBN grinding wheel has been dressed with a picosecond Yb:YAG laser. The efficiency of the laser-dressed grinding wheels has been compared with the conventionally dressed and sharpened grinding wheels through execution of cylindrical grinding tests on a steel workpiece (100Cr6). The conventional dressing and sharpening processes have been performed by using a vitrified SiC wheel and vitrified alumina blocks, respectively. By recording the spindle power values along with the surface topography measurements of the ground workpieces and the extraction of two roughness parameters (the average roughness Ra and the average roughness depth Rz), it is possible to provide an assessment of the cylindrical grinding process with different dressing conditions i.e. laser-dressing and conventional dressing. Accordingly, a strategy will be proposed to optimize the cylindrical grinding process with laser-dressed wheels regarding the forces and roughness values.

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