Experimental study on grinding wheel radial wear in surface grinding of steel CrV12 using a zonal centrifugal coolant provision system

2016 ◽  
Vol 230 (12) ◽  
pp. 1452-1461 ◽  
Author(s):  
Jarosław Sieniawski ◽  
Krzysztof Nadolny
Keyword(s):  
Experimental Studies ◽  
Careful Consideration ◽  
Surface Grinding ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Contact Conditions ◽  
Dry Grinding ◽  
Favorable Conditions ◽  
The Impact

The tribology of the grinding process can be considered in the context of a tribosystem, in which the main structural elements (grinding wheel, workpiece, grinding fluid, and environment) are interrelated and interdependent. One of the most important factors influencing the contact conditions of these listed elements of the grinding process tribosystem are the proper selection of grinding fluids and anti-adhesive substances, as well as careful consideration of how they are applied. This article describes a new zonal centrifugal coolant provision system as well as the results of experimental studies conducted into its use. The aim of these experiments was to determine the impact of the system of grinding fluids provision on grinding wheel radial wear in the surface grinding process of steel CrV12. Reference methods within the described studies consisted of dry grinding and grinding using the flood method, among others. The obtained results of the experiment revealed that the use of a zonal centrifugal coolant provision system enabled the acquisition of a similar radial wear rate of the grinding wheel at 90% reduction of grinding fluids flow rate, compared with flooding method. It was also demonstrated that in the most favorable conditions, it is even possible to significantly reduce the intensity of the radial wheel wear, compared with the conventional method.

scholarly journals Experimental Studies on the Centrifugal MQL-CCA Method of Applying Coolant during the Internal Cylindrical Grinding Process

Materials ◽  
2020 ◽  
Vol 13 (10) ◽  
pp. 2383 ◽  
Author(s):  
Krzysztof Nadolny ◽  
Seweryn Kieraś
Keyword(s):  
Hybrid Method ◽  
Experimental Studies ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Cylindrical Grinding ◽  
Minimum Quantity ◽  
Dry Grinding ◽  
Internal Cylindrical Grinding ◽  
Cooling And Lubrication

This paper presents the results of experimental research concerning the possibility of supporting the cooling function during internal cylindrical grinding using the minimum quantity lubrication (MQL) method by additional delivery of a compressed cooled air (CCL) stream. The article presents a description of a hybrid method of cooling and lubrication of the grinding zone integrating centrifugal (through a grinding wheel) lubrication with the minimum quantity of lubricant and cooling with a compressed cooled air stream generated by a cold air gun (CAG). The methodology and results of experimental studies are also presented in detail, with the aim of determining the influence of the application of the hybrid method of cooling and lubrication of the machining zone on the course and results of the internal cylindrical grinding process of 100Cr6 steel in comparison with other methods of cooling and lubrication, as well as compared with dry grinding. The research results obtained using the described hybrid method of cooling and lubrication of the grinding zone are related to the results obtained under the conditions of centrifugal MQL method, cooling with a stream of CCA, cooling and lubrication with a stream of oil-in-water emulsion delivered using the flood method, and dry grinding. The efficiency of the grinding process is evaluated (based on the average grinding power Pav, grinding wheel volumetric wear Vs, material removal Vw, and grinding ratio G), along with the thermal conditions of the process (based on the analysis of thermograms recorded by infrared thermal imaging method), the textures of machined surfaces (based on microtopography measured by contact profilometry), the state of residual stress in the surface layers of workpieces (determined by X-ray diffraction method), and the state of the grinding wheels’ active surfaces after grinding (based on microtopography measured by laser triangulation and images recorded with a digital measuring microscope). The obtained results of the analyses show that the application of the hybrid method allows for the longest wheel life among the five compared grinding methods, which is about 2.7 times the life of grinding wheels working under the flood cooling and centrifugal MQL methods, and as much as 8 times the life of grinding wheels working under the conditions of CCA only and dry grinding.

Experimental Studies on Grinding of Titanium Alloy with SG Wheels

2007 ◽  
Vol 329 ◽  
pp. 75-80 ◽  
Author(s):  
H.X. Zhang ◽  
Wu Yi Chen ◽  
Z.T. Chen
Keyword(s):  
Titanium Alloy ◽  
Experimental Studies ◽  
Dimensional Accuracy ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Conventional Grinding ◽  
Abrasive Tools

The grinding process has been investigated in the machining of titanium alloy with conventional grinding wheel and SG grinding wheel respectively. The machinability discussed here includes grinding force, surface roughness, dimensional accuracy, grinding ratio, grinding-wheel wear and grinding-wheel life. The SG grinding wheel is found to possess particularly good grinding properties and is more suitable for grinding titanium alloy when compared with conventional abrasive tools.

scholarly journals Optimization of Replaced Grinding Wheel Diameter for Surface Grinding Based on a Cost Analysis

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 448 ◽  
Author(s):  
Thi-Hong Tran ◽  
Anh-Tung Luu ◽  
Quoc-Tuan Nguyen ◽  
Hong-Ky Le ◽  
Anh-Tuan Nguyen ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Cost Analysis ◽  
Surface Grinding ◽  
Grinding Wheel ◽  
Wheel Wear ◽  
Steel Material ◽  
The Difference ◽  
Set Up ◽  
The Cost ◽  
The Impact

Based on a cost analysis, a method of identifying and predicting optimum replaced grinding wheel diameter (De.op) in a surface grinding operation for 9CrSi steel material was developed in this study. The De.op value was determined by minimizing the cost function. An experimental design was set up, and a computational program was developed to perform the experiment in order to calculate the De.op value. Furthermore, the impact of the grinding process parameters such as the initial grinding wheel diameter, the grinding wheel width, the total dressing depth, the Rockwell hardness of the workpiece, the radial grinding wheel wear per dress, and the wheel life on the De.op value were investigated. Moreover, the impacts of the cost components such as the machine tool hourly rate and the grinding wheel cost on the De.op value were given. Based on that, a mathematical model was proposed to determine the De.op value. The predicted De.op value was also verified by an experiment. The obtained result shows that the difference between the experimental De.op value and the predicted De.op value is within 1.7%, indicating that the mathematical model proposed in the study is reliable.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

scholarly journals Grinding of AISI 4340 steel with interrupted cutting by aluminum oxide grinding wheel

2015 ◽  
Vol 68 (2) ◽  
pp. 229-238
Author(s):  
Hamilton Jose de Mello ◽  
Diego Rafael de Mello ◽  
Eduardo Carlos Bianchi ◽  
Paulo Roberto de Aguiar ◽  
Doriana M. D'Addona
Keyword(s):  
Aluminum Oxide ◽  
Rotation Speed ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Machined Surface ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Grinding Machine ◽  
Aisi 4340

AbstractThere has been a great advance in the grinding process by the development of dressing, lubri-refrigeration and other methods. Nevertheless, all of these advances were gained only for continuous cutting; in other words, the ground workpiece profile remains unchanged. Hence, it becomes necessary to study grinding process using intermittent cutting (grooved workpiece – discontinuous cutting), as little or no knowledge and studies have been developed for this purpose, since there is nothing found in formal literature, except for grooved grinding wheels. During the grinding process, heat generated in the cutting zone is extremely high. Therefore, plenty of cutting fluids are essential to cool not only the workpiece but also the grinding wheel, improving the grinding process. In this paper, grinding trials were performed using a conventional aluminum oxide grinding wheel, testing samples made of AISI 4340 steel quenched and tempered with 2, 6, and 12 grooves. The cylindrical plunge grinding was performed by rotating the workpiece on the grinding wheel. This plunge movement was made at three different speeds. From the obtained results, it can be observed that roughness tended to increase for testing sample with the same number of grooves, as rotation speed increased. Roundness error also tended to increase as the speed rotation process got higher for testing the sample with the same number of grooves. Grinding wheel wear enhanced as rotation speed and number of grooves increased. Power consumed by the grinding machine was inversely proportional to the number of grooves. Subsuperficial microhardness had no significant change. Micrographs reveal an optimal machining operation as there was no significant damage on the machined surface.

scholarly journals Modeling of Vibration Condition in Flat Surface Grinding Process

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Process Model ◽  
Flat Surface ◽  
Normal Component ◽  
Cutting Speed ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Forces ◽  
Vibration Condition

This article presents a new model of the flat surface grinding process vibration conditions. The study establishes a particular analysis and comparison between the influence of the normal and tangential components of grinding forces on the vibration conditions of the process. The bifurcation diagrams are used to examine the process vibration conditions for the depth of cut and the cutting speed as the bifurcation parameters. The workpiece is considered to be rigid and the grinding wheel is modeled as a nonlinear two-degrees-of-freedom mass-spring-damper oscillator. To verify the model, experiments are carried out to analyze in the frequency domain the normal and tangential dynamic grinding forces. The results of the process model simulation show that the vibration condition is more affected by the normal component than the tangential component of the grinding forces. The results of the tested experimental conditions indicate that the cutting speed of 30 m/s can permit grinding at the depth of cut up to 0.02 mm without sacrificing the process of vibration behavior.

ANALYSIS OF WHEEL WEAR USING FORCE DATA IN SURFACE GRINDING

2003 ◽  
Vol 27 (3) ◽  
pp. 193-204 ◽  
Author(s):  
Andrew Warkentin ◽  
Robert Bauer
Keyword(s):  
Mild Steel ◽  
Surface Grinding ◽  
Grinding Process ◽  
Time Varying ◽  
Grinding Forces ◽  
Wheel Wear ◽  
Excessive Heat ◽  
Abrasive Grains ◽  
Different Depths ◽  
Force Data

Grinding involves many randomly shaped and distributed abrasive grains removing material from a workpiece. Wheel wear results when these grains dull, fracture or break away. As a result, grinding forces are time-varying. In order to automate and optimize the grinding process an understanding of how forces are generated and change during grinding is critical to avoid workpiece damage, surface finish deterioration, cracking, excessive heat generation, and excessive residue stresses. This paper builds upon the existing grinding literature by studying the relationships between wheel wear and grinding forces for different depths of cut when surface grinding mild steel with an aluminum oxide wheel.

Analysis of the Tribological Conditions in Grinding of Polycrystalline Diamond Based on Single Grain Friction Tests Using the Pin-Disk Principle

2018 ◽  
Vol 767 ◽  
pp. 259-267 ◽  
Author(s):  
Frederik Vits ◽  
Daniel Trauth ◽  
Patrick Mattfeld ◽  
Rudolf Vits ◽  
Fritz Klocke
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Polycrystalline Diamond ◽  
Grinding Wheel ◽  
Grinding Process ◽  
State Variables ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Single Grain ◽  
Zone Temperature

Cutting tools made of polycrystalline diamond (PCD) are used for machining of aluminum alloys, fiber-reinforced plastic composites and wood. Compared to cemented carbide tools with geometrically defined cutting edges, PCD tools offer significant advantages with respect to tool life. High demands regarding the cutting edge roughness and the quality of the rake and the flank face usually require a grinding process with diamond grinding wheels. The PCD grinding process, however, is characterized by low material removal rates and high grinding wheel wear. The material removal rate and the grinding wheel wear, in turn, highly depend on the process state variables process force and process temperature. However, the relationship between these process state variables and the process input variables is largely unknown. This work provides a contribution to the closure of this knowledge gap by means of an adapted friction law. A single grain friction test stand using the pin-disk principle was developed, which enables a measurement of the friction force and the contact zone temperature for normal forces and relative speeds that are common in PCD grinding. During the experiments, the specification of the PCD disc, the cross-sectional area of the friction sample made of monocrystalline diamond as well as the process parameters normal force and relative speed were varied. In addition, the tests were carried out without lubrication as well as with a minimum lubrication. A high correlation between the contact force and the coefficient of friction was determined. This relationship was mathematically formulated in a friction law. In addition, a direct influence of the contact force and the relative velocity on the contact zone temperature was identified. The knowledge gained leads to an improved understanding of the PCD grinding process and thus enables a more efficient grinding process design.

Improvement for Bearing Ring Grinding Process Based on Six Sigma Methods

2013 ◽  
Vol 423-426 ◽  
pp. 898-903
Author(s):  
Ming Yue Guo ◽  
Hong Liang Lou
Keyword(s):  
Tilt Angle ◽  
Six Sigma ◽  
Orthogonal Experiment ◽  
Outer Ring ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Roundness Error ◽  
Assessment Index ◽  
Bearing Ring ◽  
The Impact

In this paper, six sigma methods were used in bearing ring grinding process improvement. In the improvement, bearing outer ring roundness error was selected as the assessment index, and exsiting problems in grinding process were defined, roundness error of bearing outer ring was measured.One-way analysis of variance was applied to analyze the test results, it indicates that workpiece center height, guide wheel tilt angle and grinding wheel balance are the three main factors that affecting roundness error.According to this analysis, orthogonal experiment was designed. The results show that grinding wheel balance, guide wheel tilt angle and workpiece center height on the impact of roundness error are in descending order. On this basis, a series of measures were carried out to control these three parameters. Uitimately, the grinding process capability index is increased from 0.88 to 1.43, and the target of improvement are achieved.

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.

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