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

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.

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Producing Optimum Quality Grinding Spindle using Hardened AISI 4340 Steel through a Cylindrical Grinding Process

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.b6437.129219 ◽

2019 ◽

Vol 9 (2) ◽

pp. 447-454

Keyword(s):

Surface Roughness ◽

Grinding Process ◽

Rough Machining ◽

Aisi 4340 Steel ◽

Cylindrical Grinding ◽

4340 Steel ◽

Grinding Machine ◽

Experimental Runs ◽

The Ideal ◽

Aisi 4340

The intent of this study is to produce optimum quality grinding spindle using hardened AISI 4340 steel through the cylindrical grinding process. Primarily the AISI 4340 steel specimens are cut according to the product specification and subjected to rough machining. Then the steel specimens are subjected to a heat-treatment process to enhance the mechanical property hardness so that the specimen becomes wear-resistant. The experimental runs are planned depending on Taguchi’s L27(37) array and conducted in a cylindrical grinding machine (Toyoda G32 cylindrical grinding machine). The surface roughness of the machined specimens is measured using a calibrated surface roughness tester. A prediction model is created through regression analysis for the outcome. The significance of the selected grinding factors and their levels on surface roughness is found by analysis of variance (ANOVA) and F-test and finally. An affirmation test is directed to produce the ideal components.

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

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.496.7 ◽

2011 ◽

Vol 496 ◽

pp. 7-12 ◽

Cited By ~ 3

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.

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Study on the Grinding Process of Ceramic Zirconia Oxide Rod

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.575.121 ◽

2014 ◽

Vol 575 ◽

pp. 121-127

Author(s):

Shinn Liang Chang ◽

Dai Jia Juan ◽

Bean Yin Lee ◽

You Jhih Lin

Keyword(s):

Surface Roughness ◽

Grain Size ◽

Rotation Speed ◽

Grinding Wheel ◽

Grinding Process ◽

Hard Machining ◽

Grinding Machine ◽

Diamond Grain ◽

Zirconia Oxide

Grinding technology is used in this study to overcome the hard machining of ceramic with hard and brittle characteristics. The grinding machine with diamond grain size 25 and 5 , spindles speed 1720 rpm and 3450 rpm are applied. Combining the unintentional roll clamp and the grinding machine, ceramic rods can be ground to the desired size.In the research, surface profilometer is applied to measure the rod surface roughness of processing results under different conditions. The results show that the grinding wheel with finer particle, the roughness of the ground ceramic rod will be better. While the rotation speed of grinding wheel is increased, the surface roughness will have the same trend.

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Evaluation of machined surface of the hardened AISI 4340 steel through roughness and residual stress parameters in turning and grinding

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-05046-x ◽

2020 ◽

Vol 107 (1-2) ◽

pp. 791-803 ◽

Cited By ~ 4

Author(s):

Leonardo Roberto da Silva ◽

Diovani Antônio Couto ◽

Francisco Vieira dos Santo ◽

Fernando Júnio Duarte ◽

Rafael Siqueira Mazzaro ◽

...

Keyword(s):

Residual Stress ◽

Machined Surface ◽

Aisi 4340 Steel ◽

4340 Steel ◽

Stress Parameters ◽

Aisi 4340

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Evaluation of the oil flow using the MQL technique applied in the cylindrical plunge grinding of AISI 4340 steel with cbn grinding wheel

REM - International Engineering Journal ◽

10.1590/0370-44672017710139 ◽

2018 ◽

Vol 71 (3) ◽

pp. 397-402 ◽

Cited By ~ 2

Author(s):

Rafael Polato Francelin ◽

Wangner Barbosa da Costa ◽

José Claudio Lopes ◽

Alan Polato Francelin ◽

Hamilton Jose de Mello ◽

...

Keyword(s):

Grinding Wheel ◽

Plunge Grinding ◽

Aisi 4340 Steel ◽

4340 Steel ◽

Oil Flow ◽

Cbn Grinding Wheel ◽

Aisi 4340

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AISI 4340 STEEL GRINDING WITH GEOMETRY INTERRUPTED BY CONVENTIONAL GRINDING WHEEL

10.20906/cps/cob-2015-0133 ◽

2015 ◽

Author(s):

Marcel Yuzo Kondo ◽

MANOEL CLEBER DE SAMPAIO ALVES ◽

Eduardo Carlos Bianchi ◽

Cleverson Pinheiro ◽

HAMILTON JOSÉ DE MELLO ◽

...

Keyword(s):

Grinding Wheel ◽

Aisi 4340 Steel ◽

4340 Steel ◽

Conventional Grinding ◽

Aisi 4340

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Effect of Hardness on the Surface Integrity of AISI 4340 Steel

Journal of Engineering for Industry ◽

10.1115/1.3187060 ◽

1986 ◽

Vol 108 (3) ◽

pp. 169-175 ◽

Cited By ~ 96

Author(s):

Y. Matsumoto ◽

M. M. Barash ◽

C. R. Liu

Keyword(s):

Residual Stress ◽

White Layer ◽

Electron Diffraction Study ◽

Optical Microscope ◽

Machined Surface ◽

Aisi 4340 Steel ◽

4340 Steel ◽

Scanning Transmission ◽

Reflection Electron Diffraction ◽

Aisi 4340

The effect of hardness on the residual stress in the machined surface of AISI 4340 steel was studied. Chips produced during the machining also were examined and the surface structure was investigated using optical microscope and scanning transmission microscope. Reflection electron diffraction study revealed the existence of austenite in the white layer of the machined surface together with untempered martensite. The residual stress near the machined surface or hardened steel is a compressive stress, and it changes to tensile stress as the hardness decreases. Chip segmentation was observed when steel with hardness of over Rc 50 was machined.

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Surface Integrity Characterization of Hardened AISI 4340 Steel in Grinding Process with Biodegradable Formulations of Cutting Fluids

Materials Research ◽

10.1590/1980-5373-mr-2016-0658 ◽

2017 ◽

Vol 20 (2) ◽

pp. 496-501 ◽

Cited By ~ 4

Author(s):

Cintia Braga ◽

Leonardo Roberto da Silva ◽

Evanilton José Alves Barbosa ◽

Elaine Carballo Siqueira Corrêa

Keyword(s):

Surface Integrity ◽

Grinding Process ◽

Cutting Fluids ◽

Aisi 4340 Steel ◽

4340 Steel ◽

Aisi 4340

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RPM-Synchronous Grinding: Control Concepts to Improve Surface Qualities for a Highly Efficient Non-Circular Grinding Approach

Volume 2: Advanced Manufacturing ◽

10.1115/imece2017-71256 ◽

2017 ◽

Cited By ~ 1

Author(s):

Matthias Steffan ◽

Franz Haas ◽

Thomas Spenger

Keyword(s):

Grain Size ◽

Fixed Ratio ◽

Basic Research ◽

Force Sensor ◽

Grinding Wheel ◽

Grinding Process ◽

Wheel Wear ◽

Process Step ◽

Fine Grain ◽

Grinding Machine

The RPM-Synchronous Grinding process offers new possibilities to generate defined macro- and micro-geometries on workpieces. With present technology, various macroscopic non-circular geometries must be grinded subsequently in an oscillating process where the X-axis is coupled with the rotary workpiece-spindle axis. Such workpieces can be machined in an ordinary plunge grinding process by implementing the approach of RPM-Synchronous Non-Circular Grinding. Therefore, the workpiece and the grinding wheel rotational rates are in a fixed ratio. A non-circular grinding wheel is used to transfer its geometry onto the workpiece. The authors use a unique machine tool for basic research and control concept development for RPM-Synchronous Grinding (RSG). The machine was especially designed for this RSG technology. Highest revolution rates on the workpiece spindle are mandatory for its success. The grinding approach is performed in a two-step process. For roughing, a highly porous vitrified bonded grinding wheel with medium grain size is used. It ensures high specific material removal rates for producing the non-circular geometry on the workpiece efficiently. A control algorithm adapts this process step, which uses acquired data from a piezoelectric three-component force sensor fixed at the tailstock-side of the grinding machine. For finishing, a grinding wheel with fine grain size is suited. This process step is tuned by a digital process adaption strategy. Roughing and finishing are performed consecutively among the same clamping of the workpiece with two locally separated grinding spindles. With the presented control and adaption concepts for RPM-Synchronous Grinding, a significant increase in surface quality on the workpiece is attained. The minimization of grinding wheel wear results concurrently. Especially the automotive industry shows big interest in RPM-Synchronous Non-Circular Grinding. This emerging trend in finishing machining opens up various fields of application.

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