scholarly journals The enhancement of cutting capacity of a grinding wheel when processing ductile steel blank parts by ultrasonic activation

2021 ◽  
pp. 55-62
Author(s):  
A. V. Khazov ◽  
◽  
A. N. Unyanin ◽  
Keyword(s):  
Numerical Simulation ◽  
Grinding Wheel ◽  
Ultrasonic Vibrations ◽  
Ultrasonic Activation ◽  
Workpiece Material ◽  
Steel Blank ◽  
Micro Cutting ◽  
Abrasive Grains ◽  
Junction Points ◽  
Cutting Capacity

The study aimed to identify the relations between the sticking intensity and ultrasonic vibrations (UV) used for processing and evaluate the wheels’ performance when grinding ductile materials blank parts. The authors carried out the numerical simulation of local temperatures and the 3H3M3F steel workpiece temperature when grinding by ultrasonic activation. The study determined that the application of ultrasonic vibrations with the amplitude of 3 µm causes the decrease in local temperatures by 13…40 %, and in blank part temperature – up to 20 %. The calculation identified that the activation of ultrasonic vibrations with the amplitude of 3 µm causes the decrease in the glazing coefficient by 33 % for cutting grain and by 7 % for deforming grain. When increasing the longitudinal feed rate or the grinding depth, the glazing coefficient increases to a lesser degree when using the ultrasonic vibration than in the case without ultrasonic activation. The authors carried out the numerical simulation of local temperatures when scratching the 3H3M3F steel specimens by single abrasive grains with ultrasonic activation. The sticking deformation and the stresses resulted from this deformation and affecting the junction points of sticking with grains with and without ultrasonic vibrations application are calculated. The experimental research included the micro-cutting of specimens with single abrasive grains. The experiments identified that the abrasive grains wear out and glaze to a lesser degree when micro-cutting a workpiece with ultrasonic vibrations activation. The lowering of the intensity of sticking of the workpiece material particles to the abrasive grains due to the adhesion causes the decrease in the glazing coefficient when using ultrasonic activation. The study considered the possibility to enhance the efficiency of flat grinding through the use of the energy of ultrasonic vibrations applied to a blank part in the direction with the grinding wheel axis. A workpiece fixed in the device between the vibration transducer and the support is one of the components of a vibration system. The authors performed the experiment when grinding 3H3M3F and 12H18N10T steel workpieces with the wheel face. When grinding with ultrasonic vibrations, the grinding coefficient increases up to 70 %, and the redress life increases twice or thrice.

Mathematical Model of the Grinding Force With Account for Blunting of Abrasive Grains of the Grinding Wheel

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Dmitrii V. Ardashev ◽  
Aleksandr A. Dyakonov
Keyword(s):  
Forecast Model ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Force Model ◽  
Cyclic Loads ◽  
Workpiece Material ◽  
Stochastic Nature ◽  
Abrasive Grains ◽  
Working Surface ◽  
Abrasive Grain

The paper offers a simulation model of the grinding force with account for the current condition of the grinding wheel's working surface—the value of the abrasive grain blunting area. The model of blunting area takes into account various wear mechanisms for abrasive grains: the mechanical wear is realized on the provisions of the kinetic theory of the strength of a solid subjected to cyclic loads, and the physicochemical wear is based on the intensity of interaction between the abrasive and the treated material at grinding temperatures. The offered model of the grinding force takes into account the unsteady stochastic nature of the interaction between abrasive grains of the grinding wheel and the working surface and the intensity of workpiece material deformation resistance. The model is multifactorial and complex and can be realized by supercomputer modeling. The numerical implementation of the model was performed with application of supercomputer devices engaging parallel calculations. The performed experiments on measurement of the grinding force during circular grinding have shown a 10% convergence with the calculated values. The developed grinding force model can be used as a forecast model to determine the operational functionality of grinding wheel when used in varying technological conditions.

MODELING OF THE GRINDING PROCESS BY MICRO-CUTTING SINGLE ABRASIVE GRAINS. PART 1. DETERMINATION OF THE STRENGTH OF ABRASIVE GRAINS

2020 ◽  
pp. 13-17
Author(s):  
Yu. M. Zubarev ◽  
A. V. Priemyshev
Keyword(s):  
Cutting Speed ◽  
Tool Material ◽  
Physical And Mechanical Properties ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Abrasive Grains ◽  
Maximum Cut ◽  
Wide Range ◽  
Cutting Speeds

Main performance indicators of grinding wheels are the strength and wear resistance of abrasive grains. The description of the installation for studying the process of micro-cutting of various materials with single abrasive grains, which allows you to approximate the working conditions of a single abrasive grain to the conditions of real grinding in a wide range of cutting speeds. The effect of the cutting speed on the maximum cut thickness maintained by the grain vertexes without their destruction is shown. The influence of physical and mechanical properties of the workpiece material and the abrasive tool material, together with technological factors, on the micro-cutting process is considered.

scholarly journals Influence of Shape and Orientation of Grinding Grains on Their Cutting Capacity

2018 ◽  
Vol 41 ◽  
pp. 03003
Author(s):  
Dmitry Shatko ◽  
Vladimir Lyukshin ◽  
Pavel Strelnikov ◽  
Lyudmila Samorodova
Keyword(s):  
Shape Factor ◽  
Orientation Angle ◽  
Rotating Disk ◽  
Original Method ◽  
Capacity Assessment ◽  
Grinding Wheel ◽  
Abrasive Grains ◽  
Operational Characteristics ◽  
Cutting Capacity ◽  
Practical Recommendations

The issues of the influence of orientation and the shape of abrasive grains on one of their most important operational characteristics - cutting ability, and also on cutting properties of tools made of them, are considered in the article. Modern approaches to cutting capacity assessment, of both single grains, and loose abrasive mass are analyzed. The original method for the assessment of cutting capacity of a single grinding grain fixed in a rotating disk, implemented in surface grinding, is presented. The experimental data of the dependence of the cutting capacity on the shape and the orientation angle of the grinding grains are presented. In addition, the influence of the shape factor of the flap grinding wheel grains on its cutting capacity is shown. Practical recommendations on the application in practice of various varieties of grinding grains are proposed.

Numerical Simulation of Plunge Force During the Plunge Phase of Friction Stir Welding and Ultrasonic Assisted FSW

2008 ◽  
Author(s):  
Kwanghyun Park ◽  
Bongsuk Kim ◽  
Jun Ni
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
High Frequency ◽  
Hybrid Welding ◽  
Ultrasonic Vibrations ◽  
Welding Quality ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Welding Force ◽  
Welding Technique

Ultrasonic assisted friction stir welding (UaFSW) is an hybrid welding technique, where high frequency vibration is superimposed on the movement of a rotating tool. The benefit of using ultrasonic vibration in the FSW process refers to the reduction in the welding force and to the better welding quality. The UaFSW system is being developed and its mechanism needs to be understood using both the experiments and the numerical simulations. In this paper, FE simulations of FSW and UaFSW using ABAQUS/Explicit were carried out to examine plunge forces during the plunge phase of FSW and UaFSW, respectively. First, the simulations of the conventional FSW process were validated. Then, simulation of UaFSW process was performed by imposing sinusoidal horizontal ultrasonic vibrations on the tool.

Methodology for Evaluation of Treated Steels and Alloys in Abrasive Processing

2021 ◽  
Vol 410 ◽  
pp. 262-268
Author(s):  
Vyacheslav M. Shumyacher ◽  
Sergey A. Kryukov ◽  
Natal'ya V. Baidakova
Keyword(s):  
Physical And Mechanical Properties ◽  
Metals And Alloys ◽  
Grinding Wheel ◽  
Measuring Instruments ◽  
Abrasive Machining ◽  
Machining Performance ◽  
Abrasive Grains ◽  
Abrasive Tools ◽  
Composition Structure ◽  
Grinding Operations

One of the critical physical and mechanical properties of metals and alloys is the suitability for abrasive machining. Machining by abrasive tools is the final operation that sets the desired macro-geometry parameters of processed blanks and microgeometry parameters of processed surfaces such as roughness and length of a bearing surface. Abrasive machining determines the most important physical and mechanical parameters of a blank surface layer, i.e. stresses, phase composition, structure. Machinability by abrasive tools depends on the machining performance affected both by the blank material properties and various processing factors. In our previous studies, we proved that during abrasive machining the metal microvolume affected by abrasive grains accumulates energy. This energy is used for metal dispersion and is converted into heat. According to the theoretical studies described herein, one may note the absence of a reliable and scientifically valid method as well as measuring instruments to determine the machinability of metals and alloys by abrasive tools. For this reason, we suggested a method simulating the effect the multiple abrasive grains produce in a grinding wheel, and enabling us to identify machinability of metals and alloys, select the most efficient abrasive materials for machining of the same, and form the basis for development of effective grinding operations.

Theoretical Analysis and Experimental Verification of Validity Finished by Abrasive Jet with Grinding Wheel as Restraint

2008 ◽  
Vol 53-54 ◽  
pp. 39-44
Author(s):  
Chang He Li ◽  
Shi Chao Xiu ◽  
Yu Cheng Ding ◽  
Guang Qi Cai
Keyword(s):  
Ground Surface ◽  
Hydrodynamic Pressure ◽  
Machining Process ◽  
Grinding Wheel ◽  
Workpiece Material ◽  
Machined Surface ◽  
Mean Values ◽  
Work Surface ◽  
Geometry Parameter ◽  
Parameter Values

The integration manufacturing technology is a kind of compound precision finishing process that combined grinding with abrasive jet finishing, in which inject slurry of abrasive and liquid solvent into grinding zone between grinding wheel and work surface under no radial feed condition when workpiece grinding were accomplished. The abrasive particles are driven and energized by the rotating grinding wheel and liquid hydrodynamic pressure and increased slurry speed between grinding wheel and work surface to achieve micro removal finishing. In the paper, the machining process validity was verified by experimental investigation. Experiments were performed with plane grinder M7120 and workpiece material 40Cr steel which was ground with the surface roughness mean values of Ra=0.6μm. The machined surface morphology was studied using Scanning Electron Microscope (SEM) and metallography microscope and microcosmic geometry parameters were measured with TALYSURF5 instrument respectively. The experimental results show the novelty process method, not only can obviously diminish longitudinal geometry parameter values of ground surface, but also can attain isotropy surface and uniformity veins at parallel and perpendicular machining direction. Furthermore, the finished surface has little comparability compared to grinding machining surface and the process validity was verified.

Forming Mechanism of Composite Abrasive Grains in Oxide Film on ELID Wheel and its Microstructure

2016 ◽  
Vol 709 ◽  
pp. 77-81 ◽  
Author(s):  
Ji Cai Kuai ◽  
Cheng Ran Jiang ◽  
Jiang Wei Wang
Keyword(s):  
Oxide Film ◽  
Grinding Wheel ◽  
Compound Structure ◽  
Wheel Surface ◽  
Forming Mechanism ◽  
Elid Grinding ◽  
Abrasive Grains ◽  
Shaped Crack

In this paper we analyze the forming mechanism of composite abrasive grains in oxide film on ELID grinding wheel surface, By using composition information and by taking advantage of microscale structure, we have investigated that abrasive grains surface is covered by a layer of oxide film and the fresh oxide film is loose and porous like turtle shaped crack when crushed and dried. The elements of oxide film consist of α-Fe2O3 with sphere grain of 5-50nm. This phenomena is demonstrated that the composite abrasive grains in oxide film is a compound structure which is centered by abrasive grains, with α-Fe2O3,Fe (OH)3 surrounded.

Wear Monitoring on Microcrystalline Aluminum Oxide Grinding Wheels on Profile Grinding with the Aid of Acoustic Emission

2014 ◽  
Vol 894 ◽  
pp. 95-103 ◽  
Author(s):  
Lucas Benini ◽  
Walter Lindolfo Weingaertner ◽  
Lucas da Silva Maciel
Keyword(s):  
Acoustic Emission ◽  
Wear Behavior ◽  
Grinding Wheel ◽  
Wheel Wear ◽  
Profile Grinding ◽  
Grinding Wheel Wear ◽  
Abrasive Grains ◽  
Profile Deviation ◽  
Synthetic Materials ◽  
External Cylindrical Grinding

The localized wear on grinding wheel edges is a common phenomenon on profile grinding since the abrasive grains are less attached to the bond. The grinding wheel wear depends heavily on the process parameters, workpiece and wheel composition, causing changes on the process and profile deviation behaviors. In order to cope with these uncertainties, many natural and synthetic materials have been used in different grinding processes. However, the influence of mixed compositions of different types of abrasive grains on external cylindrical grinding is not well known. In order to assess this relation, a methodology procedure was developed providing an overview of the cinematic edges behavior on a progressive wheel wear. The methodology procedure is based on the acoustic emission technology, using a transducer with a 50 μm radius diamond tip. The tip, when in contact with a rotating grinding wheel, enables the evaluation of the cinematic cutting edges. The abrasive grain density was evaluated for different grinding wheel compositions and specific wear removal values. Furthermore, these results were compared to the profile deviation observed on the same tool, allowing the assessment of the influence of different microcrystalline corundum grains on the overall grinding wheel wear behavior.

scholarly journals Microstructure-Based 3D FE Modeling for Micro Cutting Ferritic-Pearlitic Carbon Steels

2014 ◽  
Author(s):  
M. Abouridouane ◽  
F. Klocke ◽  
D. Lung
Keyword(s):  
Size Effects ◽  
Chip Thickness ◽  
Rake Angle ◽  
Carbon Steels ◽  
Micro Milling ◽  
Fe Model ◽  
Two Phase ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Feed Force

The mechanics of the cutting process on the microscopic level differ fundamentally from the conventional macro cutting. For example, the tool edge radius influences the cutting mechanism in micro machining significantly with regard to the effective rake angle, the minimum chip thickness, the dominance of ploughing, and the related elasto-plastic deformation of the workpiece material. These phenomena, known as size effects, have a profound impact on the cutting force, process stability, and resulting surface finish in micro cutting. Therefore, microstructural effects in microscale cutting require quite different assumptions to be made concerning underlying material behaviour during micro cutting and have led to the need for new modeling approaches to account for such effects. This paper presents a three-dimensional finite element approach to incorporate microstructure into micro cutting simulation based on the concept of a representative volume element (RVE) and constitutive material modeling as well as using the Lagrangian formulation proposed in the implicit FE code Deform 3D™. Micro drilling and micro milling tests using solid carbide tools with different diameters (d = 50 μm − 1 mm) were performed on ferrite-pearlite two-phase steel AISI 1045 for the verification of the developed 3D multiphase FE computation model regarding chip formation, feed force, and torque. The developed 3D multiphase FE model was successfully used to predict size effects in micro cutting.

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