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.

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.

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.

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.

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.

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.

scholarly journals Optimizing the Sharpening Process of Hybrid-Bonded Diamond Grinding Wheels by Means of a Process Model

Machines ◽  
2021 ◽  
Vol 10 (1) ◽  
pp. 8
Author(s):  
Eckart Uhlmann ◽  
Arunan Muthulingam
Keyword(s):  
Economic Efficiency ◽  
Process Model ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Wheel Topography ◽  
Process Reliability ◽  
Grinding Wheel Topography ◽  
Conventional Grinding ◽  
Block Width

The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure of the grinding wheel. Due to the lack of scientific knowledge, the sharpening process is mostly performed manually in industrial practice. A CNC-controlled sharpening process can not only improve the reproducibility of grinding processes but also decrease the secondary processing time and thereby increase the economic efficiency significantly. To optimize the sharpening process, experimental investigations were carried out to identify the significant sharpening parameters influencing the grinding wheel topography. The sharpening block width lSb, the grain size of the sharpening block dkSb and the area-related material removal in sharpening V’’Sb were identified as the most significant parameters. Additional experiments were performed to further quantify the influence of the significant sharpening parameters. Based on that, a process model was developed to predict the required sharpening parameters for certain target topographies. By using the process model, constant work results and improved process reliability can be obtained.

Kornbruchverhalten beim Abrichten von CBN/Fracture behavior of CBN during dressing – Analysis of the single grain dressing process of CBN

2021 ◽  
Vol 111 (06) ◽  
pp. 408-413
Author(s):  
Marius Ohlert ◽  
Sebastian Prinz ◽  
Sebastian Barth ◽  
Thomas Bergs
Keyword(s):  
Fracture Behavior ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Single Grain

Die Schleifscheibentopographie, welche durch den Abrichtprozess erzeugt wird, ist ein wesentlicher Einflussfaktor für das Prozessergebnis beim Schleifen. Das Bruchverhalten der Kornwerkstoffe beim Abrichten hängt nicht nur von den Abrichtparametern, sondern auch von dem Korntyp der Schleifscheibe ab. Daher wurden Abrichtversuche an einzelnen CBN-Körnern durchgeführt, um den Einfluss der Abrichtparameter und des Korntyps auf das Prozessergebnis zu ermitteln.   The grinding wheel topography generated by the dressing process is a factor of major impact on the result of the grinding process. The fracture behavior of the grains of the grinding wheel during dressing not only depends on the dressing parameters but also on the grain type of the grinding wheel. Therefore, dressing tests of single CBN grains were conducted to determine how the dressing parameters and the grain type influence the process result.

Hochharte Schleifscheiben als 4-Stoffsystem*/Superabrasive grinding wheels as quaternary system - Influence of secondary grains in vitrified-bonded cBN grinding wheels

2016 ◽  
Vol 106 (06) ◽  
pp. 407-411
Author(s):  
E. Prof. Uhlmann ◽  
J. Thalau
Keyword(s):  
State Of The Art ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grain Sizes ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool ◽  
Process Behavior ◽  
External Cylindrical Grinding ◽  
Stand Der Technik

Der Schleifbelag hochharter CBN (kubisches Bornitrid)-Schleifscheiben in keramischer Bindung enthält neben der Primärkörnung in der Regel eine Sekundärkörnung, die aus einem konventionellen Schleifmittel besteht. Im 3-Stoffsystem, das dem Stand der Technik entspricht, wird die Sekundärkörnung als Bindungsbestandteil betrachtet, der vorrangig die Härte des Belages beeinflusst. Computertomografische Analysen und Untersuchungen von Schleifscheibentopografien zeigen jedoch, dass die Sekundärkörnung sowohl einen Einfluss auf das Gefüge als auch auf die Gestalt des Schneidenraums der Schleifscheibe hat. Technologische Untersuchungen zum Quer-Umfangs-Außen-Rundschleifen mit Schleifwerkzeugen, die sich in der Sekundärkorngröße unterscheiden, bestätigen diese Beobachtungen und zeigen einen Einfluss der Sekundärkörnung sowohl auf die Prozesskennwerte als auch auf das Arbeitsergebnis.   The grinding layer of vitrified-bonded superabrasive grinding wheels contains, in addition to its primary cBN-grains, in many cases secondary conventional abrasive grains. The ternary system considers secondary grains according to the state of the art as part of the bonding, which primarily affect the bond hardness. However, computer tomographic measurements and the analysis of grinding wheel topographies indicate that the secondary grains affect both the inner structure of the grinding wheel as well as the characteristic of the grinding wheel topography which directly influences the interaction of grinding tool and workpiece. Technological investigations on external cylindrical grinding across the circumference using grinding wheels with different secondary grain sizes confirm those observations and show a direct influence of the secondary grains on the grinding process behavior as well as on the grinding results.

T-Dress, A Novel Approach in Dressing and Structuring of Grinding Wheels

2012 ◽  
Vol 565 ◽  
pp. 217-221 ◽  
Author(s):  
Taghi Tawakoli ◽  
Amir Daneshi
Keyword(s):  
Ground Surface ◽  
Decisive Role ◽  
Bearing Steel ◽  
Formation Condition ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grinding Forces ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Ground Surface Roughness

Since the grinding wheel topography directly influences the grinding forces and material removal mechanism, the dressing of grinding wheels has a decisive role in the desired product quality achievement. A new dressing concept is introduced in this paper in order to reach the optimum chip formation condition. The novel dresser, T-Dress, creates a new structure on the grinding wheel owing to which remarkable reduction in grinding forces occur. These lead to the lower heat generation in the wheel-workpiece contact zone and consequently lower thermal damages. The experiments prove about 40% lower grinding forces in grinding of bearing steel materials, 100Cr6, when dressing with T-Dress compared to the case of dressing with conventional profile rollers with almost no difference in the ground surface roughness values.

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.

Sign in / Sign up

Export Citation Format

Share Document