Wheel Working Surface Topography and Grinding Force Distributions in Creep Feed Grinding

2018 ◽  
Vol 12 (2) ◽  
pp. 223-229 ◽  
Author(s):  
Masakazu Fujimoto ◽  
Susumu Ohishi ◽  
Ryosuke Hinaga ◽  
Yuki Kubo ◽  
◽  
...  
Keyword(s):  
Wear Behavior ◽  
Grinding Force ◽  
Cutting Edge ◽  
Grinding Forces ◽  
Topographic Features ◽  
Distribution Form ◽  
Working Surface ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Edge Wear

This paper discusses the topographic features of wheel working surfaces and the grinding force distributions in wheel-work contact zones of creep feed grinding. Grain cutting edge wear is observed by a Scanning Electron Microscope (SEM) and quantitatively evaluated in terms of attritious wear flat percentage, which is able to characterize the wear behavior. By measuring the normal and tangential grinding force distribution in the grinding zone, the distribution form of grinding forces can be approximated to be triangular and the grinding forces increased rapidly due to workpiece burn. It is shown that the variation of the grinding force and the distribution are closely related to cutting edge wear characteristics.

Finite Element Simulation of Axial Creep-Feed Grinding Engineering Ceramics Based on ANSYS/LS-DYNA

2012 ◽  
Vol 472-475 ◽  
pp. 927-931
Author(s):  
Xin Li Tian ◽  
Fu Qiang Li ◽  
Ya Tao Mao ◽  
Bao Guo Zhang ◽  
Jian Quan Wang
Keyword(s):  
Grinding Force ◽  
Grinding Forces ◽  
Engineering Ceramics ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Element Simulation ◽  
Grinding Conditions ◽  
Grinding Mechanism ◽  
Single Grain ◽  
Diamond Grain

Introducing the grinding mechanism of axial creep-feed grinding ceramics with a single diamond grain. Establishing the simulation model of a single grain grinding engineering ceramics by axial creep-feed grinding and analyzing the simulation results of the grinding force in the X,Y,Z axis. Finally, the impacts of the wheel speed, axial feed rate and workpiece speed upon grinding forces were discussed by simulating the single diamond abrasive grinding process under different grinding conditions.

Grinding Force in Creep Feed Grinding of Titanium Alloy with Monolayer Brazed CBN Wheels

2012 ◽  
Vol 565 ◽  
pp. 94-99 ◽  
Author(s):  
Chang Yong Yang ◽  
Jiu Hua Xu ◽  
Wen Feng Ding
Keyword(s):  
Titanium Alloy ◽  
Boron Nitride ◽  
Cubic Boron Nitride ◽  
Grinding Force ◽  
Grinding Forces ◽  
Specific Grinding Energy ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Force Ratio ◽  
Composite Filler

In this paper, grinding forces of titanium alloy Ti-6Al-4V are measured during creep feed grinding with brazed cubic boron nitride (CBN) wheels. The effects of process parameters on grinding force, force ratio and specific grinding energy are investigated in detail. The grinding force is low and force ratio is about 1.5, and the specific grinding energy of titanium alloys Ti-6Al-4V is about 65J/mm3. Also, CBN wheels brazed with composite filler of Ag-Cu-Ti and 0.5wt.% lanthanum show better grinding performance than the counterpart brazed with Ag-Cu-Ti filler in this investigation.

scholarly journals Microscopic Wear Characteristics of Ceramic Grinding Wheel in Creep Feed Grinding

2022 ◽  
Vol 16 (1) ◽  
pp. 5-11
Author(s):  
Masakazu Fujimoto ◽  
Keisuke Shimizu ◽  
◽  
Keyword(s):  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Workpiece Surface ◽  
Wear Characteristics ◽  
Working Surface ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Wear Mode ◽  
Ceramic Grinding

This paper deals with the microscopic wear characteristics of ceramic (Seeded Gel, SG) grinding wheels used in creep feed grinding. Creep feed grinding experiments with SG grinding wheels were carried out compared to rose-pink alumina (RA) grinding wheels. To clear the wear characteristics of the wheel working surface in creep feed grinding, changes in the shapes of grain cutting edges were observed by a field emission-scanning electron microscope (FE-SEM). This is a self-sharpening phenomenon based on micro fractures generated on the top of SG grain cutting edges. On the other hand, large fracture and attritious wear effected RA grain cutting edges. In addition, the features of any grain cutting edges were evaluated using attritious wear flat percentage. Changes in attritious wear flat percentage of SG grits maintained constant value and were stable. From these results, the influence of wear mode of the grinding wheel on grinding characteristics parameter, such as grinding force and workpiece surface roughness, is understood.

Investigation of Grinding Force and Surface Integrity of IC10 in Creep Feed Grinding

2020 ◽  
Author(s):  
Jun-chen Li ◽  
Wen-hu Wang ◽  
Rui-song Jiang ◽  
Xiao-fen Liu ◽  
Huang Bo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal ◽  
Normal Force ◽  
Removal Rate ◽  
Tangential Force ◽  
Grinding Force ◽  
Wheel Speed ◽  
Creep Feed Grinding ◽  
Creep Feed

Abstract The IC10 superalloy material is one of the most important materials for aero-engine turbine blade due to its excellent performances. However, it is difficult to be machined because of its special properties such as terrible tool wear and low machined efficiency. The creep feed grinding is widely used in machining IC10 superalloy due to the advance in reducing tool wear, improving material removal rate and surface quality. The creep feed grinding is a promising machining process with the advantages of high material removal rate due to large cutting depth, long cutting arc and very slow workpiece, and its predominant features might have significant influence on the grinding force and surface quality for the workpiece. Hence, it is of great importance to study the grinding force and surface integrity in creep feed grinding IC10 superalloy. In this paper, a series of orthogonal experiments have been carried out and the effects of grinding parameters on the grinding force and the surface roughness are analyzed. The topographies and defects of the machined surface were observed and analyzed using SEM. The results of the experiments show that the tangential force is decreased with the workpiece speed increasing. However, there is no significant change in tangential force with the increasing of grinding depth and wheel speed. The normal force is decreased with the workpiece speed increasing when the workpiece speed is less than 150 mm/min, but when the workpiece speed is more than 150 mm/min the normal force is increased tardily. Moreover, the normal force is increased sharply with the increase of grinding depth and is increased slowly with the increase of wheel speed. In general, the surface roughness is increased with workpiece speed and grinding depth increasing, while the trend of increase corresponding that of workpiece speed is more evident. The value of the surface roughness is decreased with wheel speed increasing. And it is found out that the main defect is burning of the IC10 superalloy material in creep feed grinding by energy spectrum analysis of some typical topography in this study.

Grinding Energy Distributions and Wear Behaviors of Grain Cutting Edges in cBN Deep Grinding

2020 ◽  
Vol 14 (1) ◽  
pp. 59-65
Author(s):  
Masakazu Fujimoto ◽  
◽  
Yuka Hiraizumi ◽  
Kazutaka Hirata ◽  
Susumu Ohishi
Keyword(s):  
Electron Microscope ◽  
Scanning Electron Microscope ◽  
Energy Distribution ◽  
Contact Zone ◽  
Grinding Force ◽  
Force Distribution ◽  
Energy Distributions ◽  
Distribution Form ◽  
Edge Wear ◽  
Scanning Electron

This paper deals with the grinding energy distributions in wheel-workpiece contact zone and the wear behaviors of grain cutting edges in cBN deep grinding. By measuring the tangential grinding force distribution in the grinding zone, the grinding energy distribution form could be approximated to be triangular. However, the grinding energy distribution forms changed a little occurring workpiece burn. The wear behaviors of the grain cutting edges were observed by a Scanning Electron Microscope (SEM) and quantitatively evaluated in terms of attritious wear flat percentage. It is shown that the variation of the grinding energy distributions has an effect on the cutting edge wear characteristics.

Pulse Dressing in Creep Feed Grinding

1989 ◽  
Vol 203 (1) ◽  
pp. 51-55
Author(s):  
S M Rezaei ◽  
T R A Pearce ◽  
T D Howes
Keyword(s):  
Turbine Blades ◽  
Grinding Wheel ◽  
Grinding Forces ◽  
Dressing Method ◽  
Form Accuracy ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Nickel Base

Machining of the roots and shrouds of turbine blades is normally performed by continuous dress creep feed grinding. In this process, the grinding wheel is continuously dressed during the grinding operation, maintaining constant grinding forces and form accuracy. However, continuous-dressing has incurred higher wheel usage. In the tests described in this paper, creep feed grinding of nickel-base alloys was initially performed by continuous dressing to determine the burn barrier and the optimum dresser infeed rate. Pulse dressing, whereby the wheel is kept sharp by a series of dressing pulses, was then applied throughout the grinding cycle in such a way that the grinding forces were kept below the burn barrier. It was shown that wheel usage was reduced by a factor of two with the pulse dressing method. The effect of different grinding coolants under continuous and pulse dressing conditions is also discussed.

Modeling and Simulation of Single Abrasive-Grain Cutting Process in Creep Feed Grinding

2016 ◽  
Vol 693 ◽  
pp. 1241-1246 ◽  
Author(s):  
Zhen Guo Nie ◽  
Gang Wang ◽  
Yong Liang Lin ◽  
Xiang Su ◽  
Yi Ming Rong
Keyword(s):  
Modeling And Simulation ◽  
High Speed ◽  
Influence Factors ◽  
Simulation Method ◽  
Maximum Temperature ◽  
Grinding Forces ◽  
Abrasive Grain ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Single Grain

Single abrasive-grain cutting is the key research point in grinding process. Because of the narrow space and quick velocity, modeling and simulation method is an approach way to study the single grain cutting. This paper studied the distribution of flow stress and plastic strain, the temperature field near cutting grain. Then experiment was conducted to measure the cutting forces in single grain cutting test. The validation shows good correctness and accuracy of FEA model. Then orthogonal simulation test was carried out to research the influence factors for the grinding forces and temperature distribution. It is found that creep feed grinding has a large grinding forces than high speed grinding in the grain scales. But the maximum temperature value is affected both by depth and speed distinctly.

Wear Behavior of a Vitrified Bond CBN Wheel by Ultrasonic-Assisted Creep Feed Profile Grinding of Inconel 718

2011 ◽  
Vol 325 ◽  
pp. 122-127
Author(s):  
Taghi Tawakoli ◽  
Bahman Azarhoushang ◽  
Abdolreza Rasifard
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Wear Behavior ◽  
High Heat ◽  
Burr Formation ◽  
Grinding Forces ◽  
Profile Grinding ◽  
Creep Feed ◽  
Process Reliability ◽  
Ultrasonic Assisted

Generally in the grinding of modern aviation materials such as nickel-based superalloys, problems frequently occur in terms of burr formation, profile loss of the wheel, high heat generation in the contact zone, high grinding forces as well as low process reliability. A recent and promising method to overcome these technological constraints is the use of ultrasonic assistance, where high-frequency and low amplitude vibrations are superimposed on the movement of the workpiece. This paper presents the design of an ultrasonically vibrated block sonotrode and the experimental investigation of ultrasonically assisted profile grinding of Inconel 718. The profile wear, radial wear of the wheel, grinding forces and surface roughness by ultrasonic-assisted and conventional profile grinding were measured and compared. The obtained results show that the application of ultrasonic vibration can decrease the radial wear of the wheel, profile wear, grinding forces and surface roughness considerably.

Control of Cutting Force for Creep-Feed Grinding Processes Using a Multi-Level Fuzzy Controller

2006 ◽  
Vol 129 (4) ◽  
pp. 480-492 ◽  
Author(s):  
Chengying Xu ◽  
Yung C. Shin
Keyword(s):  
Real Time ◽  
Grinding Force ◽  
Open Architecture ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Stable Range ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Multi Level

In this paper, a multi-level fuzzy control (MLFC) technique is developed and implemented for a creep-feed grinding process. The grinding force is maintained at the maximum allowable level under varying depth of cut, so that the highest metal removal rate is achieved with a good workpiece surface quality. The control rules are generated heuristically without any analytical model of the grinding process. Based on the real-time force measurement, the control parameters are adapted automatically within a stable range. A National Instrument real-time control computer is implemented in an open architecture control system for the grinding machine. Experimental results show that the cycle time has been reduced by up to 25% over those without force control and by 10–20% compared with the conventional fuzzy logic controller, which indicates its effectiveness in improving the productivity of actual manufacturing processes. The effect of grinding wheel wear is also considered in the creep-feed grinding process, where the grinding force/power can be maintained around the specified value by the proposed MLFC controller as the wheel dulls gradually.

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