Detailed Analysis and Description of Grinding Wheel Topographies

2017 ◽  
Vol 139 (5) ◽  
Author(s):  
Markus Weiß ◽  
Fritz Klocke ◽  
Sebastian Barth ◽  
Matthias Rasim ◽  
Patrick Mattfeld
Keyword(s):  
Detailed Analysis ◽  
Functional Properties ◽  
Quantitative Description ◽  
Cutting Edge ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
New Approach ◽  
Wheel Topography ◽  
The Impact

In this paper, an innovative approach for the description of the functional properties of a grinding wheel surface is discussed. First, the state of the art in the description of grinding wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of grinding wheel topographies are provided. In order to analyze the functional properties of a grinding wheel's topography depending on its specification, grinding experiments were carried out. For the experimental investigations vitrified, synthetic resin bonded and electroplated grinding wheels with varied compositions were analyzed. During the experiments, the topographies of the investigated grinding wheels have been analyzed by means of the topotool in detail. The developed software tool allows a detailed description of the kinematic cutting edges depending on the grinding process parameters and the grinding wheel specification. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge, a differentiation of the cutting edge areas in normal and tangential areas of the grinding wheel's circumferential direction is implemented. Furthermore, the topotool enables to analyze the kinematic cutting edges shape by calculating the angles of the grain in different directions. This enables a detailed analysis and a quantitative comparison of grinding wheel topographies related to different grinding wheel specifications. In addition, the influence of the dressing process and wear conditions to the grinding wheel topography can be evaluated. The new approach allows a better characterization of the contact conditions between grinding wheel and workpiece. Hence, the impact of a specific topography on the grinding process behavior, the generated grinding energy distribution, and the grinding result can be revealed.

Detailed Analysis and Description of Grinding Wheel Topographies

2015 ◽  
Author(s):  
Markus Weiß ◽  
Fritz Klocke ◽  
Sebastian Barth ◽  
Matthias Rasim ◽  
Patrick Mattfeld
Keyword(s):  
Detailed Analysis ◽  
Functional Properties ◽  
Quantitative Description ◽  
Software Tool ◽  
Cutting Edge ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Grinding Process ◽  
New Approach ◽  
The Impact

In this paper, an innovative approach for the description of the functional properties of a grinding wheel surface is discussed. First, the state of the art in the description of grinding wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of grinding wheel topographies are provided. In order to analyze the functional properties of a grinding wheel’s topography depending on its specification, grinding experiments were carried out. For the experimental investigations both vitrified and synthetic resin bonded grinding wheels with varied compositions were analyzed. During the experiments, the topographies of the investigated grinding wheel surfaces have been analyzed in detail. The developed software tool allows for a detailed description of the kinematic cutting edges depending on the grinding process parameters and the grinding wheel. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge a differentiation of the cutting edge areas in normal and tangential areas of the grinding wheel’s circumferential direction is implemented. This enables a detailed analysis and a quantitative comparison of grinding wheel topographies related to different grinding wheel specifications. In addition, the influence of the dressing process and wear conditions can be evaluated. The new approach allows a better characterization of the contact conditions between grinding wheel and workpiece. Hence, the impact of a specific topography on the grinding process behavior and the grinding result can be revealed.

Quantitative Beschreibung der Schleifscheibentopographie*/Quantitative description of the grinding wheel topography. Application-oriented characterization of the grinding wheel topography based on quantitative parameters

2018 ◽  
Vol 108 (06) ◽  
pp. 441-447
Author(s):  
S. Barth ◽  
J. Röttger ◽  
D. Trauth ◽  
P. Mattfeld ◽  
T. Bergs ◽  
...  
Keyword(s):  
Mechanical Load ◽  
Quantitative Description ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Surface Zone ◽  
Quantitative Parameters ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Lack Of Knowledge

In der Schleiftechnik besteht ein erhebliches Wissensdefizit über den Einfluss der Schleifscheibentopographie auf das Schleifprozessverhalten und die Ausbildung der Bauteilrandzoneneigenschaften. Ziel der Untersuchungen war daher die Identifikation und Analyse quantitativer Kenngrößen zur Beschreibung der geometrischen Schleifscheibentopographieeigenschaften. Diese Kenngrößen ermöglichten fortführend die Modellierung des thermo-mechanischen Belastungskollektivs im Schleifprozess in Abhängigkeit von der Schleifscheibentopographie.   In grinding technology, there is a considerable lack of knowledge about the influence of the grinding wheel topography on the process behaviour and the formation of the component surface zone properties. Therefore, the aim of the investigations was to investigate quantitative parameters for the description of the geometrical topography properties. These parameters enable to model the thermo-mechanical load collective in the grinding process as a function of the grinding wheel topography.

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.

Mirror Grinding Process Parameter Selection and Design

2014 ◽  
Vol 670-671 ◽  
pp. 526-528
Author(s):  
Li Hua ◽  
Xiang Jun Wang ◽  
Rui Zhou
Keyword(s):  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Experimental Conditions ◽  
Dressing Tool ◽  
Resin Binder ◽  
Tool Cutting ◽  
The Impact ◽  
Mirror Grinding ◽  
Work Table

Mirror grinding mainly depends on the precision of the machine tool, cutting and grinding amount and wheel selection and dressing. This paper mainly studies the MG1432 high-precision universal cylindrical grinder, exploring the impact on the workpiece roughness through selection and design of various process parameters in grinding, such as changing work table speed in dressing the grinding wheel and grinding, workpiece linear velocity and excessive feeding. The experimental conditions were: Using resin binder white corundum graphite grinding wheels, workpiece: GCr15 (HRC60); dressing tool: sharp single particle diamond correction pen, and ultimately achieving mirror grinding process results.

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

2017 ◽  
Author(s):  
Fritz Klocke ◽  
Sebastian Barth ◽  
Michael Rom ◽  
Christian Wrobel
Keyword(s):  
Spatial Arrangement ◽  
Distribution Functions ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Mathematical Methods ◽  
Edge Zone ◽  
Application Behavior ◽  
Wheel Topography ◽  
Grinding Wheel Topography

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 a great challenge for todays manufacturers and users of grinding tools. This is mainly caused by inadequate predictability of the forces and temperatures acting in the process, which depend on the topography of the grinding wheel coming into contact with the workpiece during the grinding process. The topography of a grinding wheel depends, beside the dressing process, on the structure of the grinding wheel, which is determined by its recipe-dependent volumetric composition. The structure of a grinding tool therefore determines its application behavior strongly. As a result, the knowledge-based prediction of the grinding wheel topography and its influence on the machining behavior is only possible if the recipe-dependent grinding wheel structure is known. In this paper, an innovative approach for modeling the grinding wheel structure and the resultant grinding wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical-generic grinding wheel 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. With this model it is possible to determine the resulting grinding wheel structure and the grinding wheel topography of vitrified and synthetic resin-bonded CBN grinding wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of grinding wheels, taking into account the entire grinding wheel structure and build up the topography based on it. Using original mathematical methods, the components of grinding wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the grinding wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of grinding processes.

scholarly journals The methodology of the grinding wheel active surface evaluation in the aspect of their machining potential

Mechanik ◽  
2018 ◽  
Vol 91 (8-9) ◽  
pp. 690-697 ◽  
Author(s):  
Wojciech Kacalak ◽  
Dariusz Lipiński ◽  
Filip Szafraniec ◽  
Katarzyna Tandecka
Keyword(s):  
Active Surface ◽  
Complex Problem ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Abrasive Grains ◽  
Conditioning Process ◽  
Wheel Topography

Estimation of the machining capacity of grinding wheels after the conditioning process, during their operation and after the grinding process is an important and complex problem. The article presents a methodology for the evaluation of wheel topography using a new height indicator and sharpness of abrasive grains, which enables determination of the machining potential of the wheel to be tested. Analysis of the developed parameter was carried for three different grinding wheels and for two different state after the conditioning process and after 30 minutes of grinding.

Einfluss der Abrichtgrößen beim Schleifen*/Influence of dressing parameters on the grinding process - Systematic research of dressing parameters on workpiece roughness and surface integrity

2016 ◽  
Vol 106 (01-02) ◽  
pp. 44-50
Author(s):  
T. Lierse ◽  
B. Karpuschewski ◽  
T. R. Kaul
Keyword(s):  
Aluminum Oxide ◽  
Surface Integrity ◽  
Cvd Diamond ◽  
Grinding Wheel ◽  
Systematic Research ◽  
Grinding Process ◽  
Wheel Topography ◽  
Grinding Wheel Topography

Dieser Beitrag zeigt, dass die durch die Abrichtparameter erzeugte Schleifscheibentopographie nicht nur die Oberflächengüte des Werkstücks, sondern auch dessen Eigenspannungszustand in der Werkstückrandzone in weiten Grenzen verändert. Die Untersuchungen zum Abrichten von Korundschleifscheiben mit einer CVD-Diamantformrolle stellen den Zusammenhang zwischen dem Abrichten unterschiedlicher Schleifscheiben zur Bauteilqualität in Form der Oberflächenrautiefe und randzonennahen Eigenspannungen her.   The quality of the workpiece rim is changed by every grinding process. The grinding wheel topography created by the dressing process has not only influence on the workpiece roughness but also on the surface integrity. The pointed research using aluminum oxide abrasive wheels dressed by CVD diamond dressing discs shows a correlation between the dressing parameters, the workpiece roughness and the surface integrity.

COMPARISON OF EXPERIMENTALLY MEASURED AND SIMULATED WORKPIECE AND GRINDING WHEEL TOPOGRAPHY USING A NEW DRESSING MODEL

2016 ◽  
Vol 40 (1) ◽  
pp. 1-17 ◽  
Author(s):  
Abdalslam Darafon ◽  
Andrew Warkentin ◽  
Robert Bauer
Keyword(s):  
Surface Finish ◽  
Metal Removal ◽  
Ground Surface ◽  
Cutting Edge ◽  
Edge Density ◽  
Grinding Wheel ◽  
Workpiece Surface ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Conditions

This paper presents a new empirical model of the dressing process in grinding which is then incorporated into a 3D metal removal computer simulator to numerically predict the ground surface of a workpiece as well as the dressed surface of the grinding wheel. The proposed model superimposes a ductile cutting dressing model with a grain fracture model to numerically generate the resulting grinding wheel topography and workpiece surface. Grinding experiments were carried out using “fine”, “medium” and “coarse” dressing conditions to validate both the predicted wheel topography as well as the workpiece surface finish. For the grinding conditions used in this research, it was observed that the proposed dressing model is able to accurately predict the resulting workpiece surface finish for all dressing conditions tested. Furthermore, similar trends were observed between the predicted and experimentally-measured grinding wheel topographies when plotting the cutting edge density, average cutting edge width and average cutting edge spacing as a function of depth for all dressing conditions tested.

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 Effects of the Grinding Wheel Eccentricity and Waviness on the Dynamics of Tool Grinding

2017 ◽  
Vol 869 ◽  
pp. 128-138
Author(s):  
Kristin M. de Payrebrune ◽  
Matthias Kröger
Keyword(s):  
System Dynamics ◽  
Complex Dynamics ◽  
Grinding Wheel ◽  
Process Conditions ◽  
Grinding Process ◽  
Integrated Simulation ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Excitation Frequencies ◽  
Tool Grinding

The complex dynamics of grinding repeatedly cause critical or unstable process conditions. For a better understanding and prediction of such occurrences, the dominant excitation phenomena need to be identified and their interrelation with the system dynamics have to be analyzed.Based on measurements of the excited frequencies in several operation modes of the grinding machine, the grinding wheel rotation is identified as a major excitation source. Further analysis of the grinding wheel surface displays three main components that define the excitation frequencies of the system; these are the eccentricity, waviness and roughness (also named wheel topography). Moreover, the wheel topography and thus the excitation frequencies can change over time due to excessive wear.Following the experimental results, a grinding wheel topography and wear model are developed and included in an integrated simulation of tool grinding. The analysis of the calculated cutting forces in the frequency domain confirm the excitation due to the grinding wheel topography.Firstly, this work has extracted the grinding wheel as a prominent excitation mechanism and reproduced it with the developed grinding model. Secondly, we have evidence that a complete description of the complex grinding process is only possible when considering the interdependence between system dynamics, wheel kinematics and the grinding process.

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