A Grinding Power Model for Selection of Dressing and Grinding Conditions

1999 ◽  
Vol 121 (4) ◽  
pp. 632-637 ◽  
Author(s):  
Xun Chen ◽  
W. Brian Rowe ◽  
D. R. Allanson ◽  
B. Mills
Keyword(s):  
Chip Thickness ◽  
Grinding Force ◽  
Effective Density ◽  
Grinding Process ◽  
Wheel Surface ◽  
Grinding Conditions ◽  
Semi Empirical ◽  
Grinding Power ◽  
Potential Use ◽  
Selection Of

The grinding power is often used as a parameter for monitoring the grinding process. The power may also be used to monitor the effects of dressing. Empirical models are required to guide the selection of the dressing and grinding conditions. In this paper, the effects of dressing conditions and grinding conditions on grinding force and grinding power are reviewed. The effects of grinding conditions and dressing conditions on grinding force and grinding power are related to the shape of the idealized chip thickness. It is found that the grinding force and grinding power can be related to the dressing operation by considering the effective density of the cutting edges on the wheel surface. The semi-empirical model developed in this paper can be used to predict the variation of the grinding power during the wheel redress life cycle. Therefore the model can be used to guide the selection of dressing and grinding conditions. The potential use of the model for adaptive control of the grinding process is also described.

Intelligent optimization of grinding processes using fuzzy logic

1998 ◽  
Vol 212 (8) ◽  
pp. 647-660 ◽  
Author(s):  
P Vishnupad ◽  
Y C Shin
Keyword(s):  
Fuzzy Logic ◽  
Chip Thickness ◽  
Process Models ◽  
Grinding Process ◽  
Real Time Control ◽  
Plunge Grinding ◽  
Grinding Processes ◽  
Time Control ◽  
Grinding Conditions ◽  
Grinding Power

This paper presents a generalized intelligent grinding advisory system (GIGAS) for the optimization of the following three grinding processes: straight-cut surface grinding, internal and external cylindrical plunge grinding. The framework of GIGAS is based on model-based fuzzy logic. The main feature of GIGAS is that it can interactively accept several different process models pertaining to a specific grinding process, as well as heuristic rules. To this end, it uses generalized process models for the grinding force, the grinding power, the maximum chip thickness, the surface roughness, the grinding ratio, the effective dullness of the wheel and the grinding temperature. The scheme allows the user to change interactively the process models used by GIGAS for optimization and hence can accommodate a large number of grinding conditions. It is also demonstrated that accurate solutions can be obtained in the order of several seconds using fuzzy inferencing, thereby showing the possibility of real-time control. The performance of GIGAS is tested in comparison with a known conventional method of optimization of the internal cylindrical plunge grinding process.

Effects of Different Types of Grinding Fluids on Grinding Force with a Semi-Empirical Based Model

2015 ◽  
Vol 809-810 ◽  
pp. 3-8 ◽  
Author(s):  
Guo Xu Yin ◽  
Ioan D. Marinescu ◽  
Michael Weismiller
Keyword(s):  
Process Parameters ◽  
Sliding Friction ◽  
Tangential Force ◽  
Grinding Force ◽  
Force Model ◽  
Grinding Process ◽  
Grinding Conditions ◽  
Force Components ◽  
Semi Empirical ◽  
Sliding Force

In present paper, a semi-empirical grinding force model is developed combined with the achievements of previous researchers by composing effects of normal and tangential grinding forces in two main parts respectively: cutting force and sliding force. Final equations for the total normal and tangential force components is established. This model is used to predict the total normal and tangential force in the surface grinding. These force components were expressed in terms of the grinding process parameters. There are four unknown coefficients in each equation which can be determined by experiment results at specific conditions with the variations of grinding process parameters. An equation for sliding force is established with the effect of specific sliding energy in terms of the experimental parameters. The average contact pressure and friction coefficient are taken into account. Four different water-based grinding fluids were tested for different specific grinding conditions. Low viscosity grinding fluid can have better performance than the high viscosity one due to the higher useful flow in the grinding contact area. The calculated normal and tangential grinding results are compared with the experimental ones. The verifications show that deviations can be affected by the performance of the fluid at heavy grinding conditions due to the sliding friction inside of rolling friction. To have a better agreement with experiment data. Shallow grinding condition is chosen to obtain the modified model.

scholarly journals Análise de Sinais de Emissao Acústica e Estatística Counts na Detecção da Alteração Microestrutural na Retificação de Aço 1045

2018 ◽  
Vol 3 (1) ◽  
pp. 414
Author(s):  
Felipe Aparecido Alexandre ◽  
Martin Antonio Aulestia Viera ◽  
Pedro Oliveira Conceição Junior ◽  
Leonardo Simões ◽  
Wenderson Nascimento Lopes ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Value Added ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Frequency Bands ◽  
Finishing Process ◽  
Grinding Conditions ◽  
Grinding Machine ◽  
1045 Steel ◽  
Selection Of

Grinding is a high-precision, high-value-added finishing process as it is usually the last stage of the manufacturing chain. However, unsatisfactory results may occur, mainly due to changes in the microstructure of the ground workpiece. Such changes are caused by the high temperatures involved in the process due to the grinding conditions in which the part was subjected. In this way, the main objective of this work is the monitoring of the grinding process in order to detect changes in the signal and to relate them with damage occurred in the ground workpiece. The tests were carried out on a surface grinding machine, aluminum oxide grinding wheel and ABNT 1045 steel parts. Metallography was performed on the parts for a more further analysis of their microstructure. The recording of signals was obtained at a sample rate of 2 MHz through an acoustic emission sensor (AE). A frequency study for the selection of the best frequency bands that characterize damage occurred in the ground workpiece. The event counts statistic was applied to the filtered signal in the chosen frequency bands. The results of this work show that the grinding conditions influence the signal and, therefore, its frequency spectrum.Keywords: Manufacturing process; automation, monitoring; grinding process; acoustic emission, damage detection

Kinematics Simulation of Grinding Process Based on Virtual Wheel Model and Micro-Cutting Analysis

2009 ◽  
Author(s):  
Xuekun Li ◽  
Yiming Kevin Rong
Keyword(s):  
Surface Condition ◽  
Machining Process ◽  
Iteration Step ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Surface ◽  
Grinding Processes ◽  
Kinematics Simulation ◽  
Wheel Model ◽  
Grinding Conditions

Grinding is a special machining process with large number of parameters influencing each other. Any grinding process involves six basic microscopic wheel-workpiece interaction modes in terms of grain cutting, plowing, and sliding, as well as bond-workpiece friction, chip-workpiece friction, and chipbond friction. And quantification of all the 6 modes immensely enhances understanding and managing of the grinding processes. In this paper, the kinematics simulation is presented to imitate the grinding wheel surface moving against the workpiece under specified grinding conditions. The grinding wheel surface is imported from the fabrication analysis based grinding wheel model of previous work. During each simulation iteration step, it provides the number of contacting grains, contact cross-section area for each grain, and resultant workpiece surface condition. Through retrieving the specific force value from the single grain cutting simulation, the cutting force and plowing force can be calculated. This model can also be potentially used in the time dependent behavior and thermal analysis of grinding processes.

Development and Research on the Dynamics Simulation System for Surface Grinding Process with Diamond Wheel

2013 ◽  
Vol 589-590 ◽  
pp. 658-664 ◽  
Author(s):  
Yong Chen ◽  
Guo Qin Huang
Keyword(s):  
Process Parameters ◽  
Dynamic Characteristics ◽  
Chip Thickness ◽  
Diamond Wheel ◽  
Grinding Force ◽  
Simulation System ◽  
Surface Grinding ◽  
Dynamics Simulation ◽  
Grinding Process ◽  
Regenerative Chatter

Vibration during high-speed surface grinding process is one of important factors to influence surface precision of machined workpieces and lead to low efficiency of grinding machine. Process parameters are usually obtained from empirical data or reference manuals for the avoidance of serious vibration even chatter and its effect. As a result, it generally leads to low rated power of machine tool and long processing cycle. To solve the problem, designing and development on a dynamics simulation system for surface grinding with high accuracy ,which will be capable to predict a series of dynamic characteristics in time and frequency domains, such as grinding force-vibration, as well as phase/frequency characteristics, relative power spectral analysis etc is necessary and shows good application prospect. Meanwhile, the system will be used to indicate the process parameters optimization and investigate distribution characteristics of grain chip thickness and surface topography precision. In the paper, surface grinding process with diamond wheel is chosen as the study object and its dynamic characteristics are investigated. Based on studies on the comprehensive influence mechanism of regenerative chatter theory and wheel run-out rotational model on instantaneous grinding chip thickness of grain unit, analytical models of grinding force are improved. Differential equations of damper grinding vibration system with two-degree-of-freedom and a close-loop control system model with regenerative chatter feedback circle on the basis of interaction behaviors of force and vibration are built. Several relevant numerical methods are introduced to develop the simulation system of grinding dynamics. By comparative analysis on solution accuracy, steadiness and convergence of the correlative algorithms, explicit Runge-Kutta formula is identified as the best solution to simulation system modeling. On the basis of the above work, main subsystems and functional modules in the system are presented. The whole designs of framework and prototype systems are finished.

Grinding Characteristic Research of High Efficiency Deep Grinding for Viscous Material

2010 ◽  
Vol 126-128 ◽  
pp. 88-95
Author(s):  
Xiao Min Sheng ◽  
Li Guo ◽  
Kun Tang ◽  
Hai Qing Mi ◽  
Jian Wu Yu ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Material Removal ◽  
High Efficiency ◽  
Chip Thickness ◽  
Grinding Force ◽  
Tc4 Titanium Alloy ◽  
Force Ratio ◽  
Systemic Process ◽  
Material Removal Mode ◽  
Grinding Power

Focusing on the characteristic of hard-to-grinding for viscous materials, such as titanium alloy, systemic process experiments were done about grinding viscous materials, such as TC4 titanium alloy, under the high efficiency deep grinding (HEDG). Based on the analysis to the changing and characteristic of unit area grinding force F' with maximum undeformed chip thickness hmax and equivlent cutting thickness aeq , this paper discussed the changing of its material removal mode and analyzed the changing and characteristic of grinding force ratio N, specific grinding energy es with corresponding parameters further. Then, it was analyzed about the consumption of grinding power on the process of HEDG for TC4 titanium alloy. The experiment results reveal that application of HEDG can improve machining efficiency of grinding viscous materials.

Selection of optimal conditions in the surface grinding process using a differential evolution approach

2007 ◽  
Vol 221 (7) ◽  
pp. 1185-1192 ◽  
Author(s):  
A Gopala Krishna
Keyword(s):  
Differential Evolution ◽  
Production Rate ◽  
Optimization Technique ◽  
Surface Grinding ◽  
Machining Process ◽  
Grinding Process ◽  
Machining Parameters ◽  
Wheel Wear ◽  
Grinding Conditions ◽  
Selection Of

The selection of machining parameters in any machining process significantly affects the production rate, quality, and cost of a component. The present work involves the application of a recently developed global optimization technique called differential evolution to optimize the machining parameters of a surface grinding process. The wheel speed, workpiece speed, depth of dressing, lead of dressing, cross-feed rate, wheel diameter, wheel width, grinding ratio, wheel bond percentage, and grain size are considered as the process variables. The production cost, production rate, and surface finish are evaluated for the optimal grinding conditions, subject to the constraints of thermal damage, wheel wear parameter, and machine tool stiffness. An example is taken from the literature to compare the results obtained by the proposed approach with other approaches.

Grinding Force and Specific Energy in Plunge Grinding of 20CrMnTi with Monolayer Brazed CBN Wheel

2013 ◽  
Vol 770 ◽  
pp. 34-38 ◽  
Author(s):  
Shen Shen Gu ◽  
Chang Yong Yang ◽  
Yu Can Fu ◽  
Wen Feng Ding ◽  
Da Shun Huang
Keyword(s):  
Specific Energy ◽  
Cubic Boron Nitride ◽  
Chip Thickness ◽  
Grinding Force ◽  
Depth Of Cut ◽  
Grinding Forces ◽  
Wheel Surface ◽  
Plunge Grinding ◽  
Cbn Wheel ◽  
White Fused Alumina

In this paper, plunge grinding experiment was conducted on 20CrMnTi with monolayer brazed cubic boron nitride (CBN) wheel. Surface integrity was evaluated through morphology observing and roughness testing. It is found that surface roughness Ra is lower than 0.8μm. Grinding forces were measured and the effects of process parameters (i.e. workpiece speed and depth of cut) on grinding forces were studied. The changing regulation of specific grinding energy with the increase of equivalent chip thickness was revealed. The result shows that both grinding force and specific energy are lower comparing with white fused alumina (WA) wheels. In general, monolayer brazed CBN wheels perform better in grinding of 20CrMnTi than WA wheels.

Effect of Cutting Oil on Grinding Cemented Carbide

2012 ◽  
Vol 472-475 ◽  
pp. 949-953
Author(s):  
Xiao Fan Yang ◽  
Chao Li ◽  
Teng Hui Zeng ◽  
Ling Xiang Li ◽  
Zhi Long Xu ◽  
...  
Keyword(s):  
Total Synthesis ◽  
Surface Quality ◽  
Chip Thickness ◽  
Grinding Force ◽  
Grinding Wheels ◽  
Low Viscosity ◽  
Grinding Conditions ◽  
Depth Increase ◽  
Cut Depth

Based on the experiment of grinding cemented carbides end mill blade flute with diamond wheels, the effect of the viscosity of total-synthesis cutting oil on grinding process is studied under different feeding speeds and different cut depths. The results of the experiment have shown that grinding with the total-synthesis cutting oil of low viscosity can reduce the grinding force, improve the surface quality of workpiece, and reduce the wear of grinding wheels under the same grinding conditions. As the feeding speed and cut depth increase, maximum undeformed chip thickness of grinding is increased and grinding force gets higher, that leads to the worse surface quality of workpiece and the increased wear of grinding wheels.

Experimental Research of Grinding Force and Specific Grinding Energy of TC4 Titanium Alloy in High Speed Deep Grinding

2009 ◽  
Vol 76-78 ◽  
pp. 55-60 ◽  
Author(s):  
Xiao Min Sheng ◽  
Kun Tang ◽  
Jian Wu Yu ◽  
Hai Qing Mi
Keyword(s):  
Titanium Alloy ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Chip Thickness ◽  
Grinding Force ◽  
Specific Grinding Energy ◽  
Undeformed Chip Thickness ◽  
Tc4 Titanium Alloy ◽  
Grinding Power

Focusing on the characteristic of hard-to-grind for titanium alloy, experiments were conducted about grinding TC4 titanium alloy under high speed deep grinding (HSDG) condition. The changing of grinding force per unit area with maximum undeformed chip thickness hmax and equivalent cutting thickness aeq are analyzed in this paper. The effect of maximum undeformed chip thickness hmax and specific material removal rate Zw' on specific grinding energy es, material removal mechanism and consumption of grinding power in HSDG process are also discussed. The experiment results reveal that application of HSDG can improve machining efficiency of grinding TC4.

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