scholarly journals In-process monitoring and analysis of bearing outer race way grinding based on the power signal

2016 ◽  
Vol 231 (14) ◽  
pp. 2622-2635 ◽  
Author(s):  
Yulun Chi ◽  
Haolin Li ◽  
Xun Chen
Keyword(s):  
General Model ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Signal Model ◽  
Outer Race ◽  
Multi Stage ◽  
Grinding Power ◽  
Industrial Problem

In production engineering, monitoring of the grinding process is critical for acquiring information on material removal, wheel performance and workpiece quality. Here, a general model of the power signal and material removal rate is proposed to monitor the internal plunge grinding of a bearing outer race way product. Three continuous grinding cycles after dressing were used to analyse the roughing, semi-finishing, finishing and spark-out process under the same parameters. Based on the actual grinding process, a practical analysis method is applied to improve the general model to more accurately predict the power curve. Finally, estimations of grinding wheel performance and grind quality using the grinding power signal model coefficients are also presented. The experimental results showed that the improved power signal model is capable of solving the industrial problem of multi-stage infeed grinding cycles and improving grind quality.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Investigation on Material Removal Rate in Rotation Grinding for Large-Scale Silicon Wafer

2004 ◽  
Vol 471-472 ◽  
pp. 362-368 ◽  
Author(s):  
Y.B. Tian ◽  
Ren Ke Kang ◽  
Dong Ming Guo ◽  
Zhu Ji Jin ◽  
Jian Xiu Su
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Rotational Speed ◽  
Material Removal ◽  
Removal Rate ◽  
Geometric Dimension ◽  
Grit Size ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Cup Wheel

In this paper, the formula of material removal rate (MRR) in wafer rotation grinding process is deduced based on kinematics. The main effect on MRR of the grit size and the process parameters, including the rotational speed of the cup grinding wheel, the down feed rate of the grinding wheel spindle and the rotational speed of the chuck table, is both theoretically and experimentally investigated. The influence on MRR of the cup wheel grinding status, the geometric dimension of the cup-grinding wheel, the rigidity of the grinding machine and the coolant is also analyzed. The investigating results show that, the increase of the grit size and the down feed rate of the cup grinding wheel results in great increase of the MRR; the MRR increases as the rotational speed of the cup wheel increases whereas the MRR reduces and the ground surface becomes bad due to size effect if the rotational speed of the cup wheel is overlarge; in normal grinding, the MRR decreases as the rotational speed of the chuck table increases. The results provide a theoretical basis to improve grinding efficiency, reduce grinding cost and select the proper parameters of grinding process.

Influence of Dielectric Jet Flushing during Electro Discharge Diamond Surface Grinding Process

2013 ◽  
Vol 652-654 ◽  
pp. 2187-2190
Author(s):  
Gopal Agarwal ◽  
Manoj Modi
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Hybrid Machining Process

The influence of dielectric jet flushing during Electro Discharge Diamond Surface Grinding (EDDSG) on Ti-6A-4V has been reported in this paper. The metal bonded diamond grinding wheel is used as electrode in Electro Discharge Diamond Surface Grinding process. In this process mechanical grinding is coupled with electrical spark of electrical discharge machine to take up the advantages associated with hybrid machining process. The important input parameters in this investigation were “duty factor”, “wheel speed (rpm)”, “magnitude of current (ampere)” and its “duration (Ton, micro-second)”. The effects of these parameters on outcomes i.e. material removal rate (MRR) and surface roughness (Ra) are measured. The noticeable enhancements in material removal rate and surface finish have been seen during EDDSG of Ti-6Al-4V with effective jet flushing. The performance of EDDSG with jet flushing and without jet flushing has been compared.

Research on Material Removal Mechanism of Single Grit Cutting Based on FEM Simulation

2014 ◽  
Vol 1017 ◽  
pp. 82-87
Author(s):  
Lan Yan ◽  
Feng Jiang ◽  
Cong Fu Fang
Keyword(s):  
Finite Element ◽  
Material Removal ◽  
Removal Rate ◽  
Fem Simulation ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Aisi D2 ◽  
Cutting Processes ◽  
Workpiece Interaction

Grinding process can be considered as micro-cutting processes with irregular abrasive grits on the surface of grinding wheel. The study of grit-workpiece interaction through single grit cutting was an important contribution to describe material removal process in the grinding process. This paper presented a finite element simulation model for the analysis of AISI D2 cutting process using alumina abrasive grit. Finite element simulations of AISI D2 single grit cutting processes were performed using AdvantedgeTM software. Results of material deformation, forces, the critical depth of cut, temperature and material removal rate were discussed.

Development of a New Plate Polishing Technique with an Instantaneous Tiny-Grinding Wheel Cluster Based on Magnetorheological Effect

2008 ◽  
Vol 53-54 ◽  
pp. 155-160 ◽  
Author(s):  
Qiu Sheng Yan ◽  
Ai Jun Tang ◽  
Jia Bin Lu ◽  
Wei Qiang Gao
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Abrasive Particles ◽  
Magnetorheological Effect ◽  
Material Removal Model ◽  
Mr Effect ◽  
Removal Model

A new plate polishing technique with an instantaneous tiny-grinding wheel cluster based on the magnetorheological (MR) effect is presented in this paper, and some experiments were conducted to prove its effectiveness and applicability. Under certain experimental condition, the material removal rate was improved by a factor of 20.84% as compared with the conventional polishing methods with dissociative abrasive particles, while the surface roughness of the workpiece was not obviously increased. Furthermore, the composite of the MR fluid was optimized to obtain the best polishing performance. On the basis of the experimental results, the material removal model of the new plate polishing technique was presented.

Parametric Study of Micro Machining Three Dimensional Microstructure with the Tiny-Grinding Wheel Based on the EMR Effect

2010 ◽  
Vol 447-448 ◽  
pp. 193-197
Author(s):  
Wei Qiang Gao ◽  
Qiu Sheng Yan ◽  
Yi Liu ◽  
Jia Bin Lu ◽  
Ling Ye Kong
Keyword(s):  
Magnetic Field ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Rotation Speed ◽  
Optical Glass ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Machining Time ◽  
Fluctuation Phenomenon

Electro-magneto-rheological (EMR) fluids, which exhibit Newtonian behavior in the absence of a magnetic field, are abruptly transformed within milliseconds into a Bingham plastic under an applied magnetic field, called the EMR effect. Based on this effect, the particle-dispersed EMR fluid is used as a special instantaneous bond to cohere abrasive particles and magnetic particles together so as to form a dynamical, flexible tiny-grinding wheel to machine micro-groove on the surface of optical glass. Experiments were conducted to reveal the effects of process parameters, such as the feed rate of the horizontal worktable, feeding of the Z axis, machining time and machining gap, on material removal rate of glass. The results indicate that the feed rate of the worktable at horizontal direction has less effect on material removal rate, which shows a fluctuation phenomenon within a certain range. The feed rate of the Z axis directly influences the machining gap and leads to a remarkable change on material removal rate. Larger material removal rate can be obtained when the feeding frequency of Z direction is one time per processing. With the increase of rotation speed of the tool, material removal rate increases firstly and decreases afterwards, and it gets the maximum value with the rotation speed of 4800 rev/min. The machining time is directly proportional to material removal amount, but inversely proportional to material removal rate. Furthermore, material removal rate decreases with the increase of the machining gap between the tool and the workpiece. On the basis of above, the machining mode with the tiny-grinding wheel based on the EMR effect is presented.

Material Removal Model and Experimental Verification for Abrasive Jet Precision Finishing with Wheel as Restraint

2006 ◽  
Vol 304-305 ◽  
pp. 555-559 ◽  
Author(s):  
Chang He Li ◽  
Guang Qi Cai ◽  
Shi Chao Xiu ◽  
Q. Li
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Experimental Results ◽  
Grinding Wheel ◽  
Rate Model ◽  
Material Removal Model ◽  
Material Removal Rate Model ◽  
Three Body ◽  
Precision Finishing

The material removal rate (MRR) model was investigated in abrasive jet precision finishing (AJPF) with wheel as restraint. When abrasive wore and workpiece surface micro-protrusion removed, the size ratio for characteristic particle size to minimum film thickness gradually diminishing, the abrasive machining from two-body lapping to three-body polishing transition in AJPF with grinding wheel as restraint. In the study, the material removal rate model was established according to machining mechanisms and machining modes from two-body to three-body process transition condition, and active number of particles in grinding zone were calculated and simulated. Experiments were performed in the plane grinder for material removal mechanism and academic models verification. It can be observed from experimental results that the surface morphology change dramatically to a grooved or micro-machined surface with all the grooves aligned in the sliding direction in two-body lapping mode. On the other hand, the surface is very different, consists of a random machining pits with very little sign of any directionality to the deformation in the three-body machining mode. Furthermore, the material removal rate model was found to give a good description of the experimental results.

Study on Effect of Grinding Fluid Supply Parameters on Surface Integrity in Quick-Point Grinding for Green Manufacturing

2008 ◽  
Vol 53-54 ◽  
pp. 209-214 ◽  
Author(s):  
Shi Chao Xiu ◽  
Ya Dong Gong ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
High Speed ◽  
Point Contact ◽  
Green Manufacturing ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Fluid ◽  
Fluid Supply ◽  
High Speed Grinding ◽  
Grinding Power

In high and super-high speed grinding process, there is an airflow layer with high speed around the circle edge of the grinding wheel that hinders the grinding fluid into contact layer, namely, the air barrier effect. The speed of airflow layer is directly proportional to the square of the wheel speed. Quick-point grinding is a new type of high and super-high speed grinding process with a point contact zone and less grinding power. The edge effect of the air barrier is weakened because the thin CBN wheel is applied in the process. By the analysis of dynamic pressure and velocity distributions in the airflow layer around the wheel edge, the mathematic models of the flow and jet pressure of grinding fluid for effective supply in the process were established and the process of optimization calculation of the jet nozzle diameter for green manufacturing was also analyzed based on the thermodynamics and the technical character of quick-point grinding process. The quick-point grinding experiment for surface integrity influenced by grinding fluid supply parameters was performed.

Grinding of Chromium Carbide Coatings Using Electroplated Diamond Wheels

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Zhongde Shi ◽  
Amr Elfizy ◽  
Helmi Attia ◽  
Gilbert Ouellet
Keyword(s):  
Surface Roughness ◽  
Chromium Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Process Conditions ◽  
Carbide Coatings ◽  
Grinding Power ◽  
Chromium Carbide Coatings

This paper reports an experimental study on grinding of chromium carbide coatings using electroplated diamond wheels. The work was motivated by machining carbide coatings in gas turbine engine applications. The objective is to explore the process conditions and parameters satisfying the ground surface quality requirements. Surface grinding experiments were conducted with water-based grinding fluid on chromium carbide coated on flat surfaces of aluminum blocks for rough grinding at a fixed wheel speed vs = 30 m/s, and finish grinding at vs = 30, 60 m/s. The effects of depth of cut and workspeed on grinding power, forces, and surface roughness were investigated for each of the wheel speeds. Material removal rate Q = 20 mm3/s for rough grinding at a grinding width b = 101.6 mm was achieved. It was found that the maximum material removal rate achievable in rough grinding was restricted by chatters, which was mainly due to the large grinding width. The specific energy ranged from 27 to 59 J/mm3 under the tested conditions. Surface roughness Ra = 3.5–3.8 μm were obtained for rough grinding, while Ra = 0.6–1.5 μm were achieved for finish grinding. Surface roughness was not sensitive to grinding parameters under the tested conditions, but was strongly dependent on the diamond grain sizes. Imposing axial wheel oscillations to the grinding motions reduced surface roughness by about 60% under the tested condition. It was proved that it is feasible to grind the chromium carbide coating with electroplated diamond wheels.

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