scholarly journals Operational Behavior of Graded Diamond Grinding Wheels For End Mill Cutter Machining

2021 ◽  
Author(s):  
Berend Denkena ◽  
Benjamin Bergmann ◽  
Daniel Raffalt
Keyword(s):  
Wear Behavior ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Bonding Layer ◽  
End Mill ◽  
Knowledge Based ◽  
Edge Quality ◽  
Grinding Tool ◽  
Mill Cutter

Abstract The varying related material removal rate during deep grinding of cemented carbide end mill cutters results in an unevenly wear of the grinding wheel. This causes a reduced geometrical precision of the manufactured tools. Consequently, the intervals between dressing steps are reduced and the dressing infeed increases. The aim of this research project is therefore to design a tailored grinding tool with uniform wear behavior. To address this situation, the grinding tool load is determined simulatively along the width of the grinding wheel. From this an equation is derived to adapt the bonding layer properties to the local load differences. First investigations show that two different concentrations zones in the abrasive layer of the grinding wheel improves the wear behavior already. This indicates that a further reduction of the wear difference is possible by a more uniform gradient. A simulation is performed to define a knowledge based gradient with more than two concetration zones. This allows a more precise load optimized adaptation of the grinding layer properties to the geometry to be ground in terms of wear behavior. Grinding tools manufactured on this basis are used for flute grinding of end mill cutters. A reduction of the wear difference over the grindig wheel width of 52% and an improved cutting edge quality of these are demonstrated.

scholarly journals Influence of End Mill Manufacturing on Cutting Edge Quality and Wear Behavior

2021 ◽  
Vol 5 (3) ◽  
pp. 77
Author(s):  
Berend Denkena ◽  
Alexander Krödel-Worbes ◽  
Sascha Beblein ◽  
Markus Hein
Keyword(s):  
Wear Behavior ◽  
Cutting Edge ◽  
End Mills ◽  
Edge Quality ◽  
Manufacturing Process Chain ◽  
The Individual ◽  
Application Specific ◽  
Milling Tools ◽  
Edge Preparation

One of the decisive factors for the performance of milling tools is the quality of the cutting edge. The latter results from the process control of the individual steps along the tool manufacturing process chain, which generally includes the sintering or pressing of the blanks, grinding, cutting edge preparation, and coating of the tools. However, the targeted and application-specific design of the process steps in terms of high economic efficiency is currently limited by a lack of knowledge regarding the influence of the corresponding process parameters on the resulting cutting edge quality. In addition, there is a lack of suitable parameters that adequately represent the characteristics of the cutting edge microtopography. This publication therefore investigates the influence of manufacturing processes on cutting edge quality and wear behavior of end mills. On this basis, different characterization parameters for the cutting edge quality are derived and evaluated with regard to their ability to predict the wear behavior.

Influence of the CAM Parameters and Selection of End-Mill Cutter when Assessing the Resultant Surface Quality in 3D Milling

2014 ◽  
Vol 474 ◽  
pp. 267-272 ◽  
Author(s):  
Michal Fabian ◽  
Peter Ižol ◽  
Dagmar Draganovská ◽  
Miroslav Tomáš
Keyword(s):  
Ball Milling ◽  
Surface Quality ◽  
End Mill ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Different Types ◽  
Mill Cutter ◽  
Milling Tools ◽  
Selection Of

The paper deals with the effects of CAM data needed to produce desired quality of shaped surfaces in forming dies making. In general, the input CAM data have strong influence to the final surface quality. The shaped surfaces 3D milling has been modeled as end ball milling of the surfaces with defined inclination. The end ball milling is the most common way to finish shaped surfaces. Directions of the milling tools motion and applied cutting conditions have been used to simulate data when setting milling strategies. The resultant machined surface quality has been identified in terms of the surface roughness. The paper introduces recommendations applicable to the programming of the different types of milling strategy when producing form surfaces.

Optimization of Cutting Parameters in Machining GFRP Using End Mill Cutter through DoE and Verification through Genetic Algorithm

2017 ◽  
Vol 867 ◽  
pp. 134-147
Author(s):  
Shanmugasundaram Sankar ◽  
V. Kumaresan Manivarma
Keyword(s):  
Genetic Algorithm ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
End Mill ◽  
Mill Cutter ◽  
Maximum Material Removal Rate

This article discusses optimization of critical parameters such as cutting speed, feed, depth of cut and method of machining while machining Glass Fiber Reinforced Plastic (GFRP) in vertical machining center using standard end mill cutter made up of High Speed Steel (HSS) for lesser cutting load, maximum material removal rate for better surface finish and dimensional accuracy through design of experiments. In composite material machining, surface finish is the critical deciding factor in determining surface quality. In this study, as per Taguchi’s L9 orthogonal array, predictable and unpredictable parts are followed to evaluate the consequence of cutting parameters on the machined component. The study includes surface roughness measurement using surface profilometer continued by physical measurement of machined pocket dimension. The experimental results, suggest suitable machining parameters in order to achieve the above target goal. In addition, C++ program is developed to cross check the most favorable machining parameters for maximum material removal rate using genetic algorithm. It is inferred from the study that the genetic algorithm results coincides very closely with the result given by the method of design of experiments.

Research on Heat Transfer and Calculation Method of Workpiece Surface Temperature in High Speed Grinding

2011 ◽  
Vol 325 ◽  
pp. 28-34
Author(s):  
Bei Zhi Li ◽  
Da Hu Zhu ◽  
Zhen Xin Zhou ◽  
Jing Zhu Pang ◽  
Jian Guo Yang
Keyword(s):  
Heat Transfer ◽  
Surface Temperature ◽  
High Speed ◽  
Removal Rate ◽  
Convective Heat Transfer Coefficient ◽  
Calculation Model ◽  
Grinding Wheel ◽  
Workpiece Surface ◽  
High Speed Grinding

The surface quality of workpiece depends largely on workpiece surface temperature in grinding. The key parameters on workpiece surface temperature calculation model have been researched and the calculation model constructed in this paper, including the convective heat transfer coefficient (CHTC) (hf), heat flux (qch) and the grain contact half-width (r0) which are assumed to be constant in workpiece surface temperature model given by Rowe. And the improved Rowe model has been proposed (Rowe/Li model) which not only involves the grinding process parameters such as the speed of wheel and workpiece, but also the geometric parameters of workpiece, grinding wheel and abrasive. The experimental results of the surface temperature in high-speed grinding are very close to the results by Rowe / Li model. Relative to the Rowe model, the obtained surface temperature by Rowe / Li model has decreased by about 35-40%. Under the conditions of the same material removal rate, high-speed grinding, namely, increasing wheel speed can effectively reduce the surface temperature and improve the grinding quality.

scholarly journals Investigation of the Wear Behavior of Abrasive Grits in a Dry Machining Inconel 718 Narrow-Deep-Groove with a Single-Layer Cubic Boron Nitride Grinding Wheel

2021 ◽  
Author(s):  
Guang Li ◽  
Guoxing Liang ◽  
Xingquan Shen ◽  
Ming Lv ◽  
Donggang Liu ◽  
...  
Keyword(s):  
Boron Nitride ◽  
Inconel 718 ◽  
Wear Behavior ◽  
Cubic Boron Nitride ◽  
Single Layer ◽  
Grinding Wheel ◽  
Bonding Layer ◽  
Side Edge ◽  
Deep Groove ◽  
Cbn Grinding Wheel

Abstract The wear behavior of a single-layer electroplated cubic boron nitride (cBN) grinding wheel was investigated in creep feed profile grinding Inconel 718 narrow-deep-groove with a width of 2 mm. In this paper, the protrusion height of cBN grits on the side edge of the grinding wheel was measured by three-dimensional optical profiler, and a scanning electron microscope was used to detect the topography of worn cBN grit and the nickel bonding layer. The investigation results indicated that the steady wear stage of the grinding wheel shared more than 84.6% of the wheel lifespan, and the machining precision of the grinding wheel was kept at a high level. The fracture mode of the cBN grit was proven to be cleavage. The source of the cleavage cracks was observed on the surface of wear flat or the side surface of the cBN grit. The holding strength of cBN grit could be weakened due to the joint surface breakage, the displacement of grit, or the cracks of the nickel bonding layer. The transition layer was contributed to the decrease of the bonding strength. Severe macro fractures and the concentration of pulled out grits were observed on the transition edge and the inner area of the side edge, separately. This study provides a deep understanding of the wear mechanism of a single-layer electroplated cBN grinding wheel.

Research on the Chemical-Mechanical Grinding (CMG) Tools for Al2O3Ceramic

2011 ◽  
Vol 325 ◽  
pp. 270-275
Author(s):  
Heng Zhen Dai ◽  
Zhu Ji Jin ◽  
Shang Gao ◽  
Z.C. Tao
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Removal Rate ◽  
Physicochemical Characteristics ◽  
Grinding Wheel ◽  
Chemical Compositions ◽  
Mechanical Grinding ◽  
Grinding Performance ◽  
Grinding Tool ◽  
Better Than

Aiming at the severe surface/subsurface damage of Al2O3ceramic ground by diamond grinding wheel, the chemical-mechanical grinding (CMG) tools were studied in this paper. According to the principle of CMG, three types of CMG tools with different abrasives were developed. The chemical compositions of the grinding tools were selected and optimized considering the physicochemical characteristics of Al2O3ceramic. By comparing the surface roughness and material removal rate (MRR) of Al2O3ceramic respectively ground with SiO2 , Fe2O3 and MgO grinding tools, the grinding performance of those grinding tools were evaluated. The experiment results showed that the grinding performance of SiO2 grinding tool was the best. The surface roughness and MRR versus SiO2 grinding tool were all better than other grinding tools, and can reach 28 nm and 15 μm/h respectively. The grinding performance of Fe2O3 grinding tool was the worst.

High Performance Grinding Zirconia Ceramics by Brazed Monolayered Diamond Wheels

2007 ◽  
Vol 359-360 ◽  
pp. 38-42
Author(s):  
Shu Sheng Li ◽  
Jiu Hua Xu ◽  
Bing Xiao ◽  
Yu Can Fu ◽  
Hong Jun Xu
Keyword(s):  
High Performance ◽  
Removal Rate ◽  
Chip Thickness ◽  
Distribution Patterns ◽  
Diamond Wheel ◽  
Grinding Wheel ◽  
Zirconia Ceramics ◽  
Dressing Method ◽  
Specific Material

A new segmented grinding wheel of the brazed monolayer diamond was developed with a defined grains pattern on the wheel surface. Results of grinding zirconia using brazed segmented diamond wheel were presented. The experiment results showed that the grinding forces ratio becomes higher with the increasing of the specific material removal rate and the specific energy falls with the increasing of the maximum undeformed chip thickness during grinding zirconia process. In this investigation, brazed diamond wheels with defined distribution patterns was conditioned by touch-dressing method so that grit tips get micro-conditioned and allow the underlying grits to participate and consequently improve the quality of finish. All the ground surfaces of zirconia were generated by the combined removal modes of brittle and ductile.

Study of Semi-Bond Abrasive in Tiny Grinding Wheel Based on Magnetorheological Effect

2013 ◽  
Vol 395-396 ◽  
pp. 1040-1043
Author(s):  
Jing Fu Chai ◽  
Wen Qing Song ◽  
Qiong Zou
Keyword(s):  
Optical Glass ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Study Results ◽  
Ultra Precision ◽  
Magnetorheological Effect ◽  
Grinding Tool ◽  
Mr Effect ◽  
Grinding Time

To achieve ultra-precision machining efficiently, the tiny grinding wheel based on MR effect is used as a grinding tool. In this paper, the state of abrasive in cutting process was analyzed through modeling, and the grinding experiment was performed on the optical glass (K9). Study results show that, with the increasing of grinding time, the surface roughness of workpiece is reduced and tends to be uniform, but the material removal rate is reduced. The abrasive of tiny grinding wheel based on MR effect can automatically adjust its grinding pressure and depth of cut to improve the surface quality.

Development and Test of CVD-Diamond Microgrinding Wheels

2010 ◽  
Vol 447-448 ◽  
pp. 131-135 ◽  
Author(s):  
Hans Werner Hoffmeister ◽  
Ronald Wittmer
Keyword(s):  
Cutting Forces ◽  
Material Removal ◽  
Wear Behavior ◽  
Removal Rate ◽  
Cvd Diamond ◽  
Grinding Wheel ◽  
Micro Cracks ◽  
Hard And Brittle Materials ◽  
Microsystems Technology ◽  
Scanning Electron

CVD-diamond microgrinding wheels can be used in the microsystems technology, e.g. to produce microarrays consisting of glass. These novel tools have the same advantages as CVD-diamond microgrinding pins, but they can even be used with higher cutting velocities and higher material removal rates. Furthermore, micro cracks and chipping could be minimized and better surface qualities could be achieved. The tool body consists of cemented carbide. After designing a suitable geometry for these novel micro grinding tools, they had to be produced with cup wheels. The design, which has already been tested, is a grinding wheel of the type “1A1”. The CVD-diamond microgrinding wheels were analyzed with a scanning electron microscope (SEM) due to their topography and crystallite size. The microgrinding wheels were tested with regard to their grinding behavior. During the investigations, cutting forces were measured and afterwards analyzed. In addition, surface roughnesses were measured, so that the materials could be compared with regard to their grindability. The tool wear was evaluated by means of SEM-pictures. They showed the wear resisting behavior of the CVD-diamond microgrinding wheels. Even after grinding a high material removal rate in the hard ceramic aluminum nitride, only a small clogging of the microgrinding wheel was monitored. The slight increase of the cutting force is another indicator for the clogging. It can be summarized that novel grinding tools could be successfully developed and tested with hard and brittle materials. During these tests, the cutting forces and surface roughnesses as well as wear behavior and end of tool life were determined and will be shown in this publication.

Influence of Grinding to the Surface and Subsurface Quality of KDP Crystal

2008 ◽  
Vol 53-54 ◽  
pp. 203-208 ◽  
Author(s):  
Dong Jiang Wu ◽  
B. Wang ◽  
Hang Gao ◽  
Ren Ke Kang ◽  
Xian Suo Cao
Keyword(s):  
Feed Rate ◽  
Removal Rate ◽  
Optical Microscope ◽  
Subsurface Damage ◽  
Machining Process ◽  
Grinding Wheel ◽  
Dihydrogen Phosphate ◽  
Machining Time ◽  
Kdp Crystal

Potassium dihydrogen phosphate (KDP) crystal is widely used in navigates spaceflight, national defenses, energy sources and information technology fields based on its excellent nonlinear optical property. Surface quality of KDP crystal influences the property and life time of the device directly. So detection and analysis of the damage induced during machining process, especially on subsurface, should be solved. In this paper, surface damage of the KDP crystal, which machined from #600 grinding wheel with different feed rate, was detected by optical microscope. Cross section and selective etching were used to analyzing the subsurface damage. Because #600 grinding wheel mainly used in coarse grinding and the removal rate is high, the results shown that there was obvious scratch, crack and crushing on the machining surface. When the feed rate is 10+m and 40+m, the subsurface damage depth is 7.41+m and 8.96+m corresponding. This study is a kind of guide for following precision grinding, polishing machining time and removal amount.

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