Grinding Wheel Surface Topography for Multiple Pass With Incremental Depth of Cut of Rotary Diamond Dresser

2015 ◽  
Author(s):  
M. A. K. Chowdhury
Keyword(s):  
Surface Topography ◽  
Removal Efficiency ◽  
Material Removal ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Simulation Tool ◽  
Wheel Surface ◽  
Working Surface ◽  
Multiple Pass

Grinding is often used material removal process in manufacturing. A grinding wheel has abrasive grains on its working surface and the material removal efficiency of a grinding wheel decreases with grinding operations. To restore the material removal efficiency of a grinding wheel, dressing is performed. There are several types of dressing methods and among these different methods, mechanical dressing is widely performed. In mechanical dressing, rotary diamond dresser is one of the effective dressers. The grinding wheel surface topography induced from dressing effect the performance of subsequent grinding operation. Therefore, grinding wheel preparation conditions, i.e., dressing conditions and consequently the grinding wheel surface topography have effect on grinding performance. The actual cutting points on diamond grits of a rotary diamond dresser are micro cutting tools which interact with the working surface of the grinding wheel. This interaction of the diamond grits of rotary diamond dresser restores the material removal efficiency of the grinding wheel. In precision engineering, multiple pass and incremental depth of cut of dresser is applied to increase the overall efficiency. This study deals with the surface topography of grinding wheel due to multiple pass and incremental depth of cut dressing operations by rotary diamond dresser. The objective of a dressing operation is to sharpen and protrude the abrasive grits embedded on the working surface of a grinding wheel. To achieve this, the rotary dresser should come in contact with all parts of the working surface of a grinding wheel without hitting the same location repeatedly. A simulation tool has been developed correlating the rotary diamond dresser parameters, grinding wheel parameters and dressing process parameters. In this research, a method is developed which enables one to determine the trajectories of dresser on the working surface of a grinding wheel (i.e., surface topography of grinding wheel) after performing dressing operations multiple times wherein the depth of cut is increased after each pass. A modified simulation is used to visualize surface topography of a grinding wheel for multiple pass with incremental depth of cut. The simulation tool also determines the dressing ratio (percent of working area of grinding wheel that has been dressed) and the areas which are dressed twice or more. Using the modified simulation tool, some strategies, i.e., single pass and multi pass dressing with incremental depth of cut is identified for determining optimal dressing conditions (the dressing conditions for which the dresser covers all circumferential surface of a grinding wheel without dressing the same area repeatedly).

scholarly journals Systematic Monitoring and Evaluating the Wear of Alumina Wheel When Grinding the Workpiece of Cr12

Complexity ◽  
2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
Fangyi You ◽  
Wang Zhou ◽  
Xuan Wang ◽  
Qiulian Dai
Keyword(s):  
Surface Topography ◽  
Image Recognition ◽  
Material Removal ◽  
Grinding Force ◽  
Projection Area ◽  
Grinding Wheel ◽  
Grinding Temperature ◽  
Machining Efficiency ◽  
Wheel Surface

The performance of the grinding wheel demonstrably affects the machining efficiency and the quality of the workpiece. Therefore, it is essential to evaluate the wear of the wheel and then operate the dressing or replacement in time. The wear procession of the wheel was monitored and evaluated systematically in this paper. A surface grinding experiment was performed by using an alumina wheel to grind the workpiece made of Cr12. The grinding force and the grinding temperature were monitored and measured while the wheel grinds the workpiece. The surface topography of the wheel was also being observed. The distribution of the gray value of pixels in the image of the wheel surface was analyzed by the method of the histogram. Processing of the binary image of the wheel was performed after determining the gray threshold of the gray value. Then, the blockading and the wearing area on the grinding wheel were calculated. Moreover, the relation of the projection area of a single abrasive derived from theory and derived by image recognition was studied. The results of the grinding experiment show that wheel performance degradation occurs when the material removal volume reaches 210 mm3/mm. At this time, the ratio of blockage area on the grinding wheel reaches 13.4%. The percentage of the wearing area is 9.5%. The method of image recognition combined with grinding temperature is workable to realize monitoring and evaluating the wear of wheels on site without unloading them.

Computer-Aided Simulation of Dressing Using Diamond Rotary Dresser and Visualization of Dressing Process

2014 ◽  
Vol 1017 ◽  
pp. 592-597 ◽  
Author(s):  
Akihiko Kubo ◽  
A.M.M. Sharif Ullah ◽  
Jun’ichi Tamaki
Keyword(s):  
Solid Body ◽  
Surface Profile ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Wheel Surface ◽  
Contour Map ◽  
Removal Process ◽  
Computer Aided ◽  
Actual Depth

The surface of a grinding wheel dressed by a diamond rotary dresser was generated by computer-aided simulation for the case of multipass dressing on the assumption that the grinding wheel is a homogeneous solid body and the dressing trajectories of the diamond grits are perfectly copied on the grinding wheel surface. The dressing process was visualized as a contour map of the dressed surface profile and the effects of the dressing strategy, i.e., down-cut dressing or up-cut dressing, on the grinding wheel removal process were investigated. It was found that the diamond grits remain the residual depth of cut on the surface of the grinding wheel, resulting in an actual depth of cut larger than that given by the rotary dresser.

Characteristics of the Wheel Surface Topography in Ultra-precision Grinding of Silicon Wafers

2008 ◽  
Vol 389-390 ◽  
pp. 36-41
Author(s):  
Feng Wei Huo ◽  
Dong Ming Guo ◽  
Ren Ke Kang ◽  
Zhu Ji Jin
Keyword(s):  
Surface Topography ◽  
Sampling Interval ◽  
Grinding Wheel ◽  
Height Distribution ◽  
Wheel Surface ◽  
Diamond Grinding Wheel ◽  
Diamond Grinding ◽  
Cutting Surface ◽  
Ultra Precision ◽  
Cutting Direction

A 3D profiler based on scanning white light interferometry with a lateral sampling interval of 0.11μm was introduced to measure the surface topography of a #3000 diamond grinding wheel, and a large sampling area could be achieved by its stitching capability without compromising its lateral or vertical resolution. The protrusion height distribution of diamond grains and the static effective grain density of the grinding wheel were derived, and the wheel chatter and the deformation of the wheel were analyzed as well. The study shows that the grain protrusion height obeys an approximate normal distribution, the static effective grain density is much lower than the theoretical density, and only a small number of diamond grains are effective in the grinding process with fine diamond grinding wheel. There exists waviness on the grinding wheel surface parallel with the wheel cutting direction. The cutting surface of the grinding wheel is not flat but umbilicate, which indicates that the elastic deformation at the wheel edges is much larger than in the center region.

Influence of Cup Wheel Grinding and Etching Pretreatment on Residual Stress and Surface Topography for Coated Cemented Carbide Tools

2012 ◽  
Vol 497 ◽  
pp. 10-14
Author(s):  
Tie Jun Song ◽  
Zhi Xiong Zhou ◽  
Wei Li ◽  
Ai Min Tang
Keyword(s):  
Residual Stress ◽  
Surface Topography ◽  
Cutting Tools ◽  
Wheel Speed ◽  
Cemented Carbide ◽  
Machining Process ◽  
Grinding Wheel ◽  
Near Surface ◽  
Cup Wheel ◽  
Coated Cemented Carbide

Cup wheel grinding and etching pretreatment are widely used in complex coated cemented carbide cutting tools machining process. The two processes determine different surface properties due to various mechanical and thermal loads in grinding and complex chemical reaction in etching pretreatment. In this paper, the effect of the grinding wheel speed, the grinding feed rate and the etching time with the Murakami and acid solution on the residual stress and surface topography of coated cemented carbide cutting tools are investigated. After each process, the samples are characterized by scanning electron microscopy and X-ray diffraction. It is found that the grinding wheel speed has a significant influence on residual stress measured in the WC phase. Etching by Murakami generated smooth surface, which partly removed the near-surface residual stress quickly but cannot eliminate.

Feasibility Study on Grinding of Titanium Alloys with Electroplated CBN Wheels

2013 ◽  
Vol 797 ◽  
pp. 73-78 ◽  
Author(s):  
Zhong De Shi ◽  
Helmi Attia
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Material Removal ◽  
High Pressures ◽  
Surface Cleaning ◽  
Depth Of Cut ◽  
Wheel Surface ◽  
Removal Rates ◽  
Grinding Fluid ◽  
Creep Feed

An experimental investigation is reported on the grinding of a titanium alloy using electroplated CBN wheels with water-based grinding fluid and wheel surface cleaning fluid applied at high pressures. This work was motivated by applying grinding fluid and wheel surface cleaning fluid both at high pressures for avoiding wheel loading, which is commonly seen in titanium alloy grinding. The objective is to explore the feasibility to grind titanium alloys with electroplated CBN wheels and high pressure wheel surface cleaning fluid for enhancing material removal rates. Straight surface grinding experiments were conducted on titanium alloy blocks in both shallow depth of cut and creep-feed modes. Grinding power, forces, and surface roughness were measured. Specific material removal rates of 8 mm2/s in shallow cut mode and 3 mm2/s at a depth of cut as high as 3 mm in creep-feed mode were achieved without burning and smearing of ground surfaces. It was showed that it is feasible to grind titanium alloys with electroplated CBN wheels at enhanced removal rates by applying grinding and wheel cleaning fluid at high pressures.

Design and Fabrication of the Superabrasive Grinding Wheel with Phyllotactic Pattern

2012 ◽  
Vol 472-475 ◽  
pp. 2354-2360 ◽  
Author(s):  
Yu Shan Lu ◽  
Cheng Yi Zhao ◽  
Jun Wang ◽  
Yan He ◽  
Zhi Hui Kou
Keyword(s):  
Experimental Results ◽  
Grinding Wheel ◽  
Wheel Surface ◽  
Work Surface ◽  
Phyllotactic Pattern ◽  
Uv Lithography ◽  
Working Surface ◽  
Abrasive Grain ◽  
Grinding Performance ◽  
Cluster Pattern

In order to achieve the controllability of the abrasive arrangement on the working surface of grinding wheel,a new kind of the superabrasive grinding wheel, which has defined abrasive grain cluster pattern, has been designed based on the phyllotaxis theory of biology, and fabricated with UV lithography method and electroplating technology. The analytical results indicate that the phyllotactic parameters influence on the abrasive arrangement configuration on the work surface of the superabrasive grinding wheel, so as to improve grinding performance of the grinding wheel, increasing the diameter of phyllotactic abrasive grain cluster and decreasing phyllotactic coefficient can increases the abrasive grain density of the surperabrasive grinding wheel surface. Electroplating experimental results show that the reasonable electroplating processes can reduce the faults of defined abrasive arrangement on the superabrasive grinding wheel surface.

Research on On-Machine 3D Measuring System of Grinding Wheel Surface Topography by Binocular Stereopsis

2016 ◽  
Vol 2016.11 (0) ◽  
pp. D02
Author(s):  
Hirotaka OJIMA ◽  
Kazuki KOMATSUZAKI ◽  
Libo ZHOU ◽  
Jun SHIMIZU ◽  
Teppei ONUKI
Keyword(s):  
Surface Topography ◽  
Measuring System ◽  
Grinding Wheel ◽  
Wheel Surface

Visualization of Grinding Wheel Surface Topography for Multiple Passes of Rotary Diamond Dresser

2012 ◽  
Vol 565 ◽  
pp. 222-227 ◽  
Author(s):  
M.A.K. Chowdhury ◽  
Jun’ichi Tamaki ◽  
Akihiko Kubo ◽  
A.M.M. Sharif Ullah
Keyword(s):  
Surface Topography ◽  
Grinding Wheel ◽  
Visualization Tool ◽  
Visualization Method ◽  
Wheel Surface ◽  
Design Variables

The grinding wheel surface topography after dressing is an indicator of the effectiveness of dressing operation and, thereby, the effectiveness of grinding as a whole. During dressing, the dresser travels the grinding wheel surface several times so that the dresser grits could hit all most all points on the circumference of the grinding wheel. But the same point should not be hit several times by the dressing grits. This study describes a method and tool for visualizing the grinding wheel surface topography for multiple passes of rotary diamond dresser. Using the proposed visualization method and tool, one can determine the effectiveness of certain dressing conditions beforehand. In addition, the visualization tool can be used for optimizing the design variables of a rotary diamond dresser.

Analysis of Effective Cutting-Edge Distribution of Grinding Wheel Based on Topography of Working and Ground Surfaces

2011 ◽  
Vol 325 ◽  
pp. 60-65
Author(s):  
Haruhisa Sakamoto ◽  
Kyoko Nakamura ◽  
Yoshinori Sasaki ◽  
Shinji Shimizu
Keyword(s):  
Surface Topography ◽  
Grain Shape ◽  
Pure Copper ◽  
Surface Profile ◽  
Ground Surface ◽  
Cutting Edge ◽  
Grinding Wheel ◽  
Noise Component ◽  
Working Surface ◽  
Ground Surface Roughness

In this study, the determination method of the number of the effective cutting-edges had been proposed based on the measurements of working surface topography and the grinding force. Furthermore, its validity is made clear based on the topographical analysis of the ground surface roughness of pure copper, which is excellent in transcribing the working surface. From the results, the following are found out: The ground surface topography contains the periodical component, which is originated in the grinding and dressing conditions, on the fractal noise component. The cutting traces by each cutting-edge can be countable from the ground surface profile, and then, the number of the effective cutting-edges is identified at one line within the working surface. On the other hand, the number of the effective cutting-edges also can be identified based on the working surface, but, this method requires the determination of the typical grain shape. From the experiment, it is confirmed that the grain shape should be almost spherical for making the numbers of the effective cutting-edge identified from the working and ground surfaces equal.

scholarly journals Improve the Material Removal Rate of Electrochemical Grinding on Monel 400 Using RSM

2019 ◽  
Vol 8 (2) ◽  
pp. 3219-3222
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Mechanical Grinding ◽  
Monel 400 ◽  
Electrochemical Grinding

Electrochemical grinding is combination of electrochemical machining and mechanical grinding process.in this process 90%-98% percentage of material are removed by electrochemical machining, only 3%-5% of materials can only remove by mechanical grinding process. Faradays law of electrolysis (or) reverse electroplating act as a basic principle for this ECG process. This ECG has various advantages than other machining process for high strength materials .low induvial stress, large depth of cut .here Monel 400 alloy take base material ,its Ni-Cu alloy so it’s have very high level corrosion resistance, so it’s used in marine engineering ,heat exchanger. Here silicon carbide abrasive insulated brass grinding wheel used instead of copper bonded diamond wheel. Voltage, electrolyte concentration, electrolyte flowrate take are the parameters of this process. Three factors and two levels of RSM methodology takes for optimization. The Analysis of variance (ANOVA) has been delivers the variation between the parameters performed to develop mathematical model. The parameters high voltage and concentration of electrolyte to produce maximum material removal rate.

Sign in / Sign up

Export Citation Format

Share Document