Influence of Wear Volume on Surface Quality in Grinding Process Based on Wear Prediction Model

2021 ◽  
Author(s):  
Wei Cao ◽  
Zhao Han ◽  
Ziqi Chen ◽  
Zili Jin ◽  
Jiajun Wu ◽  
...  
Keyword(s):  
Surface Quality ◽  
Surface Profile ◽  
Wear Test ◽  
Test Method ◽  
Wear Volume ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Wear Prediction ◽  
The Relationship ◽  
Temperature Surface

Abstract In the grinding process, the workpiece would not only be cut by abrasive grains, but also have adhesive wear caused by high temperature and heavy load, which makes the surface quality of the workpiece worse. In this paper, a wear test method considering speed, force, wear coefficient, temperature and hardness was proposed. A new wear prediction physical model was established based on finite element method and numerical simulation technology. The wear test was carried out on a grinding machine. The comprehensive research on the relationship between force, temperature, surface morphology and wear volume of grinding process was studied. The relationship between workpiece speed, grinding depth, cooling lubrication conditions and wear volume of grinding process was studied. The results show that the wear model can achieve numerical prediction and trend prediction of grinding temperature, surface profile and wear volume, the relative errors between the theoretical and actual values of wear and grinding temperature are 9.84% and 2.07% respectively. This study provides a support for wear prediction and surface quality control of grinding process from the perspective of temperature and micro material removal form.

scholarly journals Grinding Force and Heat of Titanium Alloy Abrasive Belt and Its Effect on Surface Integrity

2021 ◽  
Author(s):  
Ying Liu ◽  
Jiayu Xu ◽  
Guijian Xiao ◽  
Kun Zhou ◽  
Gang Liu
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
Surface Integrity ◽  
Grinding Force ◽  
Maximum Temperature ◽  
Grinding Process ◽  
Feed Speed ◽  
Grinding Temperature ◽  
Linear Speed ◽  
Abrasive Belt

Abstract Key rotating parts such as integral blisks and blades of aero-engines are widely made of titanium alloys. Abrasive belt grinding is one of the effective methods to improve the surface integrity. However, the grinding process produces greater grinding force and higher Grinding temperature,which have an impact on surface quality. At present, the force-heat coupling relationship in the grinding process and its influence on surface quality have not been explored. In this paper, a titanium alloy belt experiment is carried out to detect the force and temperature in the grinding process, this paper explores the influence of the grinding process parameters on the grinding force and temperature, and analyzes the influence on surface integrity of the force and temperature in the grinding process. The results show that the decrease of the belt linear speed, the increase of the feed speed and the grinding depth leads to the increase of the grinding force, the decrease of the feed speed, the increase of the belt linear speed and the grinding depth cause the temperature to rise. The effect of grinding depth on grinding force and grinding temperature is the most significant. And High grinding force and grinding temperature will cause the surface quality to deteriorate and even more serious defects. However, when the maximum temperature of the grinding temperature field reaches above 120°C, the surface roughness of the workpiece decreases from 1.596μm to 1.093μm, and the height of the surface undulation is reduced from 32μm to 19μm. This paper provides a reference for improving the surface integrity of the grinding process.

Boron Influence on Structures and Properties in Nickel-Based Alloys

2013 ◽  
Vol 395-396 ◽  
pp. 251-258 ◽  
Author(s):  
Chuan Hui Chen ◽  
Yang Bai ◽  
Wei Chen ◽  
Xu Chu Ye
Keyword(s):  
Wear Resistance ◽  
Wear Test ◽  
Vacuum Arc ◽  
Wear Volume ◽  
Precipitated Phase ◽  
Structures And Properties ◽  
Vacuum Arc Furnace ◽  
Nickel Base ◽  
The Relationship ◽  
Dsc Curves

Nickel-base alloys with different boron contents were prepared by vacuum arc furnace. The effect of the boron contents to metallography was characterized simultaneously by XRD and SEM with EDS part. The thermal behavior was analyzed by DSC curves which mainly represents the eutectic temperature of alloys. The Vickers hardness and ball-on-flat wear test were carried out to reveal the relationship between metallographic phase formation and wear resistance. The results indicated that main composites are eutectic Ni-Cr as matrix and CrB, Ni3B as precipitated phase. A considerable amount of dislocation and stacking faults exist in the specific orientation (200) of Ni3B. 2.0~4.0%B alloys melt at 1060oC, while the boride-poor alloy melts at 1085oC. 3.0~4.0%B alloys performed the best on wear resistance. Wear volume reduces along with increasing hardness at the beginning, and then keeps invariant. Borides are main reinforcing phases, which affects hardness and wear resistance greatly.

Wear analysis of the composite coating in a long sliding time by dissipated energy approach

2017 ◽  
Vol 24 (6) ◽  
pp. 853-864
Author(s):  
Jin Zhong Shao ◽  
Jun Li ◽  
Cui Cui Qu ◽  
Rui Song ◽  
Lv Lin Bai ◽  
...  
Keyword(s):  
Protective Layer ◽  
Wear Test ◽  
Energy Approach ◽  
Dissipated Energy ◽  
Curvilinear Relationship ◽  
Wear Volume ◽  
Wear Process ◽  
Friction Heat ◽  
Two Stages ◽  
The Relationship

AbstractA wear test of Ti2Ni/TiNi-based coating reinforced by TiC/TiB against a YG6X [94 wt.% tungsten carbide (WC) and 6 wt.% cobalt (Co)] ball in a sliding time of 712 h was carried out using a ball-on-disc reciprocating motion mode. The relationship between accumulated dissipated energy (∑E) and accumulated wear volume (∑V) was accurately established via the dissipated energy approach. Three wear stages were found: initial wear stage (0–200 min), breaking-in wear stage (200–14,520 min), and steady wear stage (14,520–42,720 min). At the initial wear stage, the relationship between ∑E and ∑V satisfied the equation ∑V=42.5288∑E+0.019. The curvilinear relationship in the other two stages was fitted into the equation ∑V=-0.0029∑E4+0.064∑E3-0.5353∑E2+2.0653∑E+0.9938. The wear mechanism in the entire wear process was revealed. ∑E at the initial wear stage was mainly used for debris formation. At the breaking-in wear stage, ∑E was dissipated by generating the friction heat, which led to the formation of a protective layer. At the steady wear stage, ∑E was used to generate friction heat as well as to damage and restore the protective layer. The detection results of the protective layer via energy dispersive spectroscopy showed that this layer was composed of oxides and WC debris.

An evaluation of ECT sample height for small flute board grades and Box Manufacturer’s Certification compliance

TAPPI Journal ◽  
2009 ◽  
Vol 8 (6) ◽  
pp. 24-28
Author(s):  
CORY JAY WILSON ◽  
BENJAMIN FRANK
Keyword(s):  
Compressive Strength ◽  
Compressive Load ◽  
Test Sample ◽  
Test Methods ◽  
Test Method ◽  
Initial Development ◽  
Sample Height ◽  
Relationship Of ◽  
The Relationship ◽  
Corrugated Fiberboard

TAPPI test T811 is the specified method to ascertain ECT relative to box manufacturer’s certification compliance of corrugated fiberboard under Rule 41/ Alternate Item 222. T811 test sample heights were derived from typical board constructions at the time of the test method’s initial development. New, smaller flute sizes have since been developed, and the use of lighter weight boards has become more common. The T811 test method includes sample specifications for typical A-flute, B-flute, and C-flute singlewall (and doublewall and triplewall) structures, but not for newer thinner E-flute or F-flute structures. This research explores the relationship of ECT sample height to measured compressive load, in an effort to determine valid E-flute and F-flute ECT sample heights for use with the T811 method. Through this process, it identifies challenges present in our use of current ECT test methods as a measure of intrinsic compressive strength for smaller flute structures. The data does not support the use of TAPPI T 811 for ECT measurement for E and F flute structures, and demonstrates inconsistencies with current height specifi-cations for some lightweight B flute.

Tire Treadwear — A Comprehensive Evaluation of the Factors: Generic Type, Aspect Ratio, Tread Pattern, and Tread Composition Part I: Introduction and Details on the Organization of the Program

1986 ◽  
Vol 14 (4) ◽  
pp. 201-218 ◽  
Author(s):  
A. G. Veith
Keyword(s):  
Aspect Ratio ◽  
Comprehensive Evaluation ◽  
Test Method ◽  
Interactive Effects ◽  
Data Analyses ◽  
Main Effect ◽  
Systematic Determination ◽  
Relationship Of ◽  
The Relationship

Abstract This four-part series of papers addresses the problem of systematic determination of the influence of several tire factors on tire treadwear. Both the main effect of each factor and some of their interactive effects are included. The program was also structured to evaluate the influence of some external-to-tire conditions on the relationship of tire factors to treadwear. Part I describes the experimental design used to evaluate the effects on treadwear of generic tire type, aspect ratio, tread pattern (groove or void level), type of pattern (straight rib or block), and tread compound. Construction procedures and precautions used to obtain a valid and functional test method are included. Two guiding principles to be used in the data analyses of Parts II and III are discussed. These are the fractional groove and void concept, to characterize tread pattern geometry, and a demonstration of the equivalence of wear rate for identical compounds on whole tread or multi-section tread tires.

scholarly journals Study of ultrasonic vibration–assisted thread turning of Inconel 718 superalloy

2019 ◽  
Vol 11 (10) ◽  
pp. 168781401988377
Author(s):  
Yu He ◽  
Zhongming Zhou ◽  
Ping Zou ◽  
Xiaogang Gao ◽  
Kornel F Ehmann
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Inconel 718 ◽  
Gas Turbines ◽  
Tool Path ◽  
Machining Parameters ◽  
Thread Cutting ◽  
Workpiece Surface ◽  
Inconel 718 Superalloy ◽  
The Relationship

With excellent properties, high-temperature superalloys have become the main application materials for aircraft engines, gas turbines, and many other devices. However, superalloys are typically difficult to machine, especially for the thread cutting. In this article, an ultrasonic vibration–assisted turning system is proposed for thread cutting operations in superalloys. A theoretical analysis of ultrasonic vibration–assisted thread cutting is carried out. An ultrasonic vibration–assisted system was integrated into a standard lathe to demonstrate thread turning in Inconel 718 superalloy. The influence of ultrasonic vibration–assisted machining on workpiece surface quality, chip shape, and tool wear was analyzed. The relationship between machining parameters and ultrasonic vibration–assisted processing performance was also explored. By analyzing the motion relationship between tool path and workpiece surface, the reasons for improved workpiece surface quality by ultrasonic vibration–assisted machining were explained.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Determination of Steady-State Adhesive Wear Rate

2005 ◽  
Author(s):  
L. J. Yang
Keyword(s):  
Steady State ◽  
Wear Rate ◽  
Wear Test ◽  
Standard Test ◽  
Test Method ◽  
Testing Time ◽  
Wear Coefficient ◽  
Wear Rates ◽  
Test Methodology

Wear rates obtained from different investigators could vary significantly due to lack of a standard test method. A test methodology is therefore proposed in this paper to enable the steady-state wear rate to be determined more accurately, consistently, and efficiently. The wear test will be divided into four stages: (i) to conduct the transient wear test; (ii) to predict the steady-state wear coefficient with the required sliding distance based on the transient wear data by using Yang’s second wear coefficient equation; (iii) to conduct confirmation runs to obtain the measured steady-state wear coefficient value; and (iv) to convert the steady-state wear coefficient value into a steady-state wear rate. The proposed methodology is supported by wear data obtained previously on aluminium based matrix composite materials. It is capable of giving more accurate steady-state wear coefficient and wear rate values, as well as saving a lot of testing time and labour, by reducing the number of trial runs required to achieve the steady-state wear condition.

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

2021 ◽  
pp. 095440622110130
Author(s):  
Barnabás Zoltán Balázs ◽  
Márton Takács
Keyword(s):  
Surface Quality ◽  
Surface Profile ◽  
Cutting Parameters ◽  
Relevant Information ◽  
Milling Process ◽  
Micro Milling ◽  
Machined Surface ◽  
Analysis Of Dynamics ◽  
Five Axis ◽  
Coated Carbide

Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

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