Wear Behavior of Grain Cutting Edge in Ultrasonic Assisted Grinding Using Mini-Size Wheel

2015 ◽  
Vol 9 (4) ◽  
pp. 365-372 ◽  
Author(s):  
Masakazu Fujimoto ◽  
◽  
Yongbo Wu ◽  
Mitsuyoshi Nomura ◽  
Hidenari Kanai ◽  
...  
Keyword(s):  
Wear Behavior ◽  
Diamond Wheel ◽  
Cutting Edge ◽  
Grinding Forces ◽  
Wheel Wear ◽  
Workpiece Surface ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted ◽  
Conventional Grinding ◽  
The Stability

This paper deals with the wear behavior of the mini-size diamond wheel used in Ultrasonic Assisted Grinding (UAG). The aim is to understand the wheel wear behavior. Sequential changes of the surface topography of the mini-size wheel, such as the number and shape of grains of the cutting edge, during the on-surface UAG process were observed and evaluated quantitatively using a Scanning Electron Microscope with four electron probes (3D-SEM). The obtained results show that a good wheel surface is maintained during the UAG process compared with the Conventional Grinding (CG) process. In particular, a number of sharp grain cutting edges are larger in the UAG process than those of the CG process. Additionally, these results are closely related to the stability of grinding forces and the reduction of the finished workpiece surface.

Surface Topography of Mini-Size Diamond Wheel in Ultrasonic Assisted Grinding (UAG)

2014 ◽  
Vol 8 (4) ◽  
pp. 569-575 ◽  
Author(s):  
Masakazu Fujimoto ◽  
◽  
Yongbo Wu ◽  
Mitsuyoshi Nomura ◽  
Hidenari Kanai ◽  
...  
Keyword(s):  
Surface Topography ◽  
Diamond Wheel ◽  
Grinding Wheel ◽  
3D Analysis ◽  
Grinding Forces ◽  
Wheel Surface ◽  
Workpiece Surface ◽  
Topographic Features ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted

The objectives of this paper are to describe a quantitative evaluation of mini-size diamond grinding wheel surface topography in Ultrasonic Assisted Grinding (UAG) process and demonstrate the effects of topography on grinding characteristics. In this study, threedimensional (3D) analysis of the wheel working surface was observed using a Scanning Electron Microscope (SEM) with four electron probes (hereafter described as 3D-SEM) in an on-surface UAG process. These results indicated that a good wheel surface maintained in the UAG process is related to the number and the area of cutting edges. Additionally, the resulting topographic features of the grinding wheel surface are closely related to low grinding forces and allow easy manufacturing of a mirror workpiece surface.

Elliptical Ultrasonic Assisted Grinding (EUAG) of Monocrystal Sapphire – Wear Behaviors of Resin Bond Diamond Wheel

2010 ◽  
Vol 126-128 ◽  
pp. 573-578 ◽  
Author(s):  
Yong Bo Wu ◽  
Zhi Qiang Liang ◽  
Xi Bin Wang ◽  
Wei Min Lin
Keyword(s):  
Diamond Wheel ◽  
Grinding Force ◽  
Grinding Forces ◽  
Wheel Wear ◽  
Wear Process ◽  
Work Surface ◽  
Ultrasonic Assisted Grinding ◽  
Abrasive Grains ◽  
Experimental Apparatus ◽  
Ultrasonic Assisted

This paper describes the wear behaviors of a resin bond diamond wheel in elliptical ultrasonic assisted grinding (EUAG) of monocrystal sapphire. The EUAG is a new grinding method proposed by the present authors in which an elliptical ultrasonic vibration is imposed on the workpiece by using an elliptical ultrasonic vibrator. In our previous work, an experimental apparatus mainly composed of the vibrator was produced and grinding experiments were conducted involving sapphire workpiece. In this paper, further investigations focusing on the wear behaviors of resin bond diamond wheel in EUAG of sapphire were carried out experimentally. The obtained results showed that: (1) the wheel wear process can be divided to three regions according to the variation trend of grinding forces, i.e., an initial region, a steady region, and a deteriorated region; (2) in the initial and steady regions, the grinding forces and the ratio of the normal grinding force to the tangential grinding force in EUAG are much smaller than that in conventional grinding (CG), but in deteriorated region, the grinding forces in EUAG are increased significantly up to be larger than that in CG whereas the grinding forces ratio has few difference between those in EUAG and CG; (3) in all the regions, the work-surface in EUAG is much smoother than that in CG whereas the wheel wear has little influence on the work-surface roughness; (4) the wheel wear in CG is mainly caused by the attrition wear and the macro-fracture and pullout of abrasive grains, while in EUAG by the micro-fracture and cleavage of abrasive grains.

Effects of Ultrasonic Assisted Grinding on CBN Grinding Wheels Performance

2009 ◽  
Author(s):  
Taghi Tawakoli ◽  
Bahman Azarhoushang
Keyword(s):  
Ultrasonic Vibration ◽  
Specific Energy ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Grinding Forces ◽  
Workpiece Surface ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted ◽  
Vitrified Cbn

The effects of ultrasonic assisted grinding on vitrified CBN grinding wheels performance have been investigated. The ultrasonic vibration has been superimposed to the workpiece in feed and cross feed directions and the kinematics of the process in both directions have been discussed. The obtained results show that applying ultrasonic vibration to the grinding process can improve the quality of the workpiece surface, the efficiency of the process and decrease the grinding forces and specific energy considerably.

An Experimental Investigation of Ultrasonic Assisted Grinding in DOE Approach

2012 ◽  
Vol 565 ◽  
pp. 129-134 ◽  
Author(s):  
Kyeong Tae Kim ◽  
Yun Hyuck Hong ◽  
Kyung Hee Park ◽  
Young Jae Choi ◽  
Seok Woo Lee ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotation Speed ◽  
Grinding Force ◽  
Machining Parameters ◽  
Grinding Forces ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted ◽  
Conventional Grinding

In this work, grinding test was performed in terms of machining parameters, such as grinding speed, feed rate, etc., in order to study effect of ultrasonic vibration in grinding. The design of experiment (DOE) approach was used for an optimal condition of ultrasonic assisted grinding, which can minimize the grinding forces. In DOE, ultrasonic amplitude power, feed rate, and rotation speed of spindle were chosen as the major machining factors. The grinding forces were measured and compared between the conventional grinding and ultrasonic assisted grinding. From the experiment, it was found that the grinding forces decreased as the ultrasonic vibration power and the rotation speed of spindle increased while the grinding force was reduced as the feed rate increased. In addition, regression model was formulated for obtaining optimal grinding condition.

Analytical and Numerical Simulation of Ultrasonic Assisted Grinding

2010 ◽  
Author(s):  
Ahmad Farhadi ◽  
Amir Abdullah ◽  
Javad Zarkoob ◽  
Abbas Pak
Keyword(s):  
Ultrasonic Vibration ◽  
Equations Of Motion ◽  
Motion Path ◽  
Grinding Forces ◽  
Wheel Wear ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted ◽  
Single Grain ◽  
Workpiece Interaction ◽  
Cutting Path

Ultrasonic assisted grinding of hard materials is a novel technique which is used in order to decrease grinding forces and energy. Grinding force is in direct connection with wheel wear, grinding accuracy, grinding temperature and surface integrity. In this paper the effects of ultrasonic vibration in creep feed grinding process which is superimposed to the workpiece in feed direction has been represented. The mechanism of grain-workpiece interaction in the presence of ultrasonic vibration has been investigated both analytically and numerically. The cutting path of a single grain in ultrasonic assisted grinding has been derived using equations of motion and has been compared to the grain cutting path in ordinary grinding. Using displacement equations of a single grain in ultrasonic assisted grinding and drawing the motion path, it has been shown that there exist a multiple-impact between grain and workpiece. By implementing a 2-D finite element modeling, the mechanism of chip formation in ultrasonic assisted grinding and ordinary grinding has been compared. Furthermore the effects of longitudinal workpiece vibration on the grinding forces have been investigated. FE analysis of grain-workpiece interaction in case of using ultrasonic vibration has shown a reduction of about 40% of grinding forces compared to ordinary grinding.

Effects of Vibration-Assisted Grinding on Wear Behavior of Vitrified Bond Al2O3 Wheel

2009 ◽  
Vol 76-78 ◽  
pp. 21-26 ◽  
Author(s):  
Taghi Tawakoli ◽  
Engelbert Westkämper ◽  
Bahman Azarhoushang
Keyword(s):  
Wear Behavior ◽  
Ground Surface ◽  
Cutting Fluid ◽  
Grinding Wheel ◽  
Grinding Forces ◽  
Wheel Wear ◽  
Dry Grinding ◽  
Conventional Grinding ◽  
Vitrified Bond ◽  
The Cost

The total removal of grinding wheel material includes two main parts. The larger of the two is the result of dressing and truing operation and the other relatively small part is due to the wheel wear which takes place during the actual grinding process. The frequency of dressing and truing operations depends on the cutting conditions, wheel characteristic, etc. However in dry grinding as there is no cutting fluid to transfer the heat from the contact zone, the wheel wear during grinding and the frequency of dressing is much higher due to the higher grinding forces and temperatures. Vibration grinding reduces wear of the grinding wheel during the process considerably and decreases the frequency of dressing operation significantly. Hence it increases the efficiency of the process and reduces the cost. The investigation carried out in the KSF institute shows the improvement on the surface roughness, reduction of the grinding forces, thermal damage of the ground surface and radial wear of the grinding wheel in case of using vibration grinding comparing to conventional grinding. The designed and developed ultrasonically vibrated workpiece holder and the experimental investigation show a decrease of up to 80% of radial wear of the grinding wheel.

Design of Ultrasonic Horn for Grinding Using Finite Element Method

2012 ◽  
Vol 565 ◽  
pp. 135-141 ◽  
Author(s):  
Young Jae Choi ◽  
Kyung Hee Park ◽  
Yun Hyuck Hong ◽  
Kyeong Tae Kim ◽  
Seok Woo Lee ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Grinding Force ◽  
Machining Performance ◽  
Grinding Forces ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Grinding ◽  
Ultrasonic Assisted ◽  
Conventional Grinding ◽  
Element Method

In this paper, a ultrasonic horn, which can vibrate longitudinally with a frequency of 20㎑, was designed using finite element method (FEM). And the ultrasonic horn was fabricated for ultrasonic assisted grinding. To evaluate machining performance of the fabricated ultrasonic horn, grinding test was conducted on alumina ceramic (Al2O3). In the grinding test, grinding forces was measured and compared between the conventional grinding and the ultrasonic assisted grinding. The results showed that the grinding force in the ultrasonic grinding was lowered than the conventional grindign by 3~20%.

Experimental Research on Surface Roughness of Ultrasonic Assisted Grinding on 7075 Aluminum Alloy

2021 ◽  
Vol 1047 ◽  
pp. 62-67
Author(s):  
Shen Wang ◽  
Le Tong ◽  
Guang Jun Chen ◽  
Mao Xun Wang ◽  
Bin Dai ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Processing Parameters ◽  
7075 Aluminum Alloy ◽  
Machined Surface ◽  
Ultrasonic Assisted Grinding ◽  
Great Performance ◽  
Ultrasonic Assisted ◽  
Conventional Grinding ◽  
Micro Morphology

7075 aluminum alloy is widely used due to its great performance, especially in aerospace area. In this paper, ultrasonic-assisted grinding technology is used to process 7075 aluminum alloy. The data is obtained through experiments, and the surface roughness and morphology of ultrasonic assisted grinding and conventional grinding under different spindle speeds, feed rates, and amplitudes are analyzed. Research has found that the increase in spindle speed and amplitude will improve the quality of the machined surface and reduce the surface roughness by 82.1% and 36%. However, with the increase of feed rate, the surface quality decreased significantly, and the surface roughness increased by 55.6%. The surface micro-morphology of the machined workpiece is observed, and the effects of different processing parameters on the surface micro-morphology are obtained.

Experimental Study on the Mechanism of Axial Ultrasonic-Assisted Grinding

2012 ◽  
Vol 490-495 ◽  
pp. 2449-2453
Author(s):  
S.X. Yuan ◽  
M. Xiao
Keyword(s):  
Experimental Study ◽  
Grinding Force ◽  
Paper Analysis ◽  
Kinematics Model ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted ◽  
Conventional Grinding

This paper analysis the mechanism of axial ultrasonic-assisted grinding(AUAG), by establishing the kinematics model of a single grit; The reason why AUAG forces are more lower than conventional grinding(CG) forces is presented, and the experiments of the grinding force in AUAG comparison with CG were carried out. The results indicate that the grinding force of the superalloy in AUAG is about 40% to 50% less than that in CG.

An improved semi-analytical approach for modeling of process damping in orthogonal cutting considering cutting edge radius

2019 ◽  
Vol 234 (3) ◽  
pp. 641-653 ◽  
Author(s):  
Chang Cao ◽  
Xiao-Ming Zhang ◽  
Tao Huang ◽  
Han Ding
Keyword(s):  
Computational Efficiency ◽  
Orthogonal Cutting ◽  
Finite Amplitude ◽  
Cutting Edge ◽  
Workpiece Surface ◽  
Process Damping ◽  
Flank Face ◽  
The Stability ◽  
The Time Domain ◽  
Stability Limits

Process damping generated between the tool flank face and the wavy finish workpiece surface has a non-negligible effect on cutting dynamics and chatter stability, especially at low cutting speeds, resulting in higher stability limits. In modeling of process damping, the calculation of extruded volume is one of the most critical challenges, especially in machining with honed tools due to the complex and time-variable contact condition between the arc cutting edge and the finite amplitude wave surface. In this study, a semi-analytical method with high computational efficiency is proposed to calculate the extruded volume in cutting with honed tools. Based on this method, we construct the stability lobes under the condition of finite vibration amplitude accurately and efficiently, which overcomes the limitation of analytical methods based on the assumption of small amplitude vibrations and the low computational efficiency of numerical method. The predicted cutting stability is verified against both the experimental results and the time-domain simulation results.

Sign in / Sign up

Export Citation Format

Share Document