The method of assessment of the grinding wheel cutting ability in the plunge grinding

2012 ◽  
Vol 2 (3) ◽  
Author(s):  
Krzysztof Nadolny
Keyword(s):  
Working Conditions ◽  
Comparative Assessment ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Plunge Grinding ◽  
Abrasive Grains ◽  
Ceramic Bond ◽  
Method Of Assessment ◽  
Grinding Kinematics

AbstractThis article presents the method of comparative assessment of the grinding wheel cutting ability in the plunge grinding kinematics. A new method has been developed to facilitate multicriterial assessment of the working conditions of the abrasive grains and the bond bridges, as well as the wear mechanisms of the GWAS, which occur during the grinding process, with simultaneous limitation of the workshop tests range. The work hereby describes the methodology of assessment of the grinding wheel cutting ability in a short grinding test that lasts for 3 seconds, for example, with a specially shaped grinding wheel, in plunge grinding. The grinding wheel macrogeometry modification applied in the developed method consists in forming a cone or a few zones of various diameters on its surface in the dressing cut. It presents an exemplary application of two variants of the method in the internal cylindrical plunge grinding, in 100Cr6 steel. Grinding wheels with microcrystalline corundum grains and ceramic bond underwent assessment. Analysis of the registered machining results showed greater efficacy of the method of cutting using a grinding wheel with zones of various diameters. The method allows for comparative tests upon different grinding wheels, with various grinding parameters and different machined materials.

The effect of sulfurization on the grinding wheel cutting ability in the internal cylindrical grinding of nickel superalloys

2016 ◽  
Vol 231 (1) ◽  
pp. 140-154
Author(s):  
Krzysztof Nadolny ◽  
Walery Sienicki ◽  
Michał Wojtewicz
Keyword(s):  
Experimental Tests ◽  
Active Surface ◽  
Bearing Steel ◽  
Grinding Wheel ◽  
Nickel Superalloys ◽  
Grinding Wheels ◽  
Adhesive Properties ◽  
Plunge Grinding ◽  
Abrasive Grains ◽  
Internal Cylindrical Grinding

One possible way of preventing excessive growth of smearings/loads on the grinding wheel active surface is the introduction of compounds such as sulfur, graphite, or wax into the grinding wheel volume which exerts an active influence on adhesion during the process of impregnation. Limiting the formation of smearings/loads on the grinding wheel active surface is of crucial importance to achieve effective grinding of hard-to-cut materials (such as nickel superalloys) which are characterized by considerable ductility and a strong chemical affinity to abrasive grains, among other things. This article presents the results of experimental tests performed on plunge grinding and the influence of sulfur impregnation of grinding wheels on the smearing/load intensity on the grinding wheel active surface during the process of internal cylindrical plunge grinding of openings made from Inconel® alloy 600 and Incoloy® alloy 800HT®. Bearing steel 100Cr6 was included in the tests as a reference material. Grinding wheels were impregnated with a new method of gravitational sulfurization combined with centrifuging. The experiments carried out show that the adhesive properties of sulfur allowed for considerable limitation of smearing/loading of the grinding wheel active surface with machined material. This mainly concerned limiting the formation of the largest and most technologically undesirable smearings/loads of the intergranular spaces. The presence of sulfur in the grinding wheel volume had a minor influence on the intensity of smearings/loads in the microareas of the active abrasive grains’ apexes. The tests also showed an increase of 32%–49% in the value of parameter Sa in the surfaces ground with grinding wheels impregnated with sulfur for all the examined materials.

scholarly journals New Abrasive Materials and Their Influence on the Surface Quality of Bearing Steel After Grinding

10.14311/1598 ◽  
2012 ◽  
Vol 52 (4) ◽  
Author(s):  
Ondrej Jusko
Keyword(s):  
Surface Quality ◽  
Bearing Steel ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Abrasive Material ◽  
Abrasive Grains ◽  
Measurement Results ◽  
New Type

This paper focuses on the influence of various types of abrasive grains on cutting properties during the grinding process for bearing steel. In this experiment, not only conventional super-hard abrasive materials but also a new type of abrasive material were employed in grinding wheels. The measurement results were compared, and an evaluation was made of the cutting properties of the new abrasive material. The options were then evaluated for their practical applicability. The measurement results indicated that a grinding wheel with Abral and SG grains is the most suitable for grinding hardened bearing steel in order to achieve the best roughness and geometrical accuracy.

Potential for improving efficiency of the internal cylindrical grinding process by modification of the grinding wheel structure—Part I: Grinding wheels made of conventional abrasive grains

2016 ◽  
Vol 231 (4) ◽  
pp. 621-632 ◽  
Author(s):  
Krzysztof Nadolny ◽  
Witold Habrat
Keyword(s):  
Sol Gel ◽  
Active Surface ◽  
Positive Influence ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Abrasive Grains ◽  
Wide Range ◽  
Internal Cylindrical Grinding ◽  
Different Diameters

This article offers an overview of 14 grinding wheel construction modifications used in the peripheral grinding of flat-shaped internal and external cylindrical surfaces, when grinding wheels made of conventional abrasive grains are used (Al2O3, sol-gel alumina, SiC, etc.). The text contains characteristics of grinding wheels with mixed grains, glass-crystalline bond, a centrifugal provision of the coolant into the grinding zone, aggregate grains, zones of different diameters, radial rough grinding zone, extended finish grinding segments, active surface macro- and micro-discontinuities, as well as multiporous, impregnated (self-lubricating), sandwich, sectional and segment grinding wheels. Each of the presented structural modifications was described by giving construction scheme, used abrasive grains, range of applications, advantages as well as disadvantages. Modifications of the grinding wheel construction allow for effective improvement of both the conditions and the results of the grinding process. A wide range of the known modifications allows for their proper selection depending on the required criteria of effective evaluation and taking into account the specific characteristics of conventional abrasive grains. As a result, it is possible to obtain positive influence on a number of technological factors of the grinding process. The described modifications of the grinding wheel structure can be also an inspiration and the basis for creating new solutions in this field.

scholarly journals An Original Tribometer to Analyze the Behavior of Abrasive Grains in the Grinding Process

2018 ◽  
Author(s):  
Leire Godino ◽  
Iñigo Pombo ◽  
Jose Antonio Sanchez ◽  
Borja Izquierdo
Keyword(s):  
Wear Mechanisms ◽  
Wear Behavior ◽  
Grinding Wheel ◽  
Crystallographic Structure ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Original Design ◽  
Wheel Wear ◽  
Good Tool ◽  
Abrasive Grains

Manufacturing of grinding wheels is continuously adapting to new industrial requirements. New abrasives and new wheel configurations, together with wheel wear control allow for grinding process optimization. However, the wear behavior of the new abrasive materials is not usually studied from a scientific point of view due to the difficulty to control and monitor all the variables affecting the tribochemical wear mechanisms. In this work an original design of pin on disk tribometer is developed in a CNC grinding machine. An Alumina grinding wheel with special characteristics is employed and two types of abrasive are compared: White Fused Alumina (WFA) and Sol-Gel Alumina (SG). The implemented tribometer reaches sliding speeds of between 20 and 30 m/s and real contact pressures up to 190 MPa. The results show that the wear behavior of the abrasive grains is strongly influenced by their crystallographic structure and the tribometer appears to be a very good tool for characterizing the wear mechanisms of grinding wheels, depending on the abrasive grains.

scholarly journals An Original Tribometer to Analyze the Behavior of Abrasive Grains in the Grinding Process

Metals ◽  
2018 ◽  
Vol 8 (7) ◽  
pp. 557 ◽  
Author(s):  
Leire Godino ◽  
Iñigo Pombo ◽  
Jose Sanchez ◽  
Borja Izquierdo
Keyword(s):  
Wear Mechanisms ◽  
Wear Behavior ◽  
Numerical Control ◽  
Grinding Wheel ◽  
Crystallographic Structure ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Original Design ◽  
Wheel Wear ◽  
Abrasive Grains

Manufacturing of grinding wheels is continuously adapting to new industrial requirements. New abrasives and new wheel configurations, together with wheel wear control allow for grinding process optimization. However, the wear behavior of the new abrasive materials is not usually studied from a scientific point of view due to the difficulty to control and monitor all the variables affecting the tribochemical wear mechanisms. In this work, an original design of pin-on-disk tribometer is developed in a CNC (Computer Numerical Control) grinding machine. An Alumina grinding wheel with special characteristics is employed and two types of abrasive are compared: White Fused Alumina (WFA) and Sol-Gel Alumina (SG). The implemented tribometer reaches sliding speeds of between 20 and 30 m/s and real contact pressures up to 190 MPa. The results show that the wear behavior of the abrasive grains is strongly influenced by their crystallographic structure and the tribometer appears to be a very good tool for characterizing the wear mechanisms of grinding wheels, depending on the abrasive grains.

scholarly journals The methodology of the grinding wheel active surface evaluation in the aspect of their machining potential

Mechanik ◽  
2018 ◽  
Vol 91 (8-9) ◽  
pp. 690-697 ◽  
Author(s):  
Wojciech Kacalak ◽  
Dariusz Lipiński ◽  
Filip Szafraniec ◽  
Katarzyna Tandecka
Keyword(s):  
Active Surface ◽  
Complex Problem ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Abrasive Grains ◽  
Conditioning Process ◽  
Wheel Topography

Estimation of the machining capacity of grinding wheels after the conditioning process, during their operation and after the grinding process is an important and complex problem. The article presents a methodology for the evaluation of wheel topography using a new height indicator and sharpness of abrasive grains, which enables determination of the machining potential of the wheel to be tested. Analysis of the developed parameter was carried for three different grinding wheels and for two different state after the conditioning process and after 30 minutes of grinding.

scholarly journals Modeling And Simulation of The Advanced Structured Surfaces Machined By Specially Patterned Grinding Wheels Via The Structuring Grinding Process

2021 ◽  
Author(s):  
Amr Monier ◽  
Bing Guo ◽  
Qingliang Zhao ◽  
T.S. Mahmoud
Keyword(s):  
Working Conditions ◽  
Simulation Method ◽  
Grinding Wheel ◽  
Operating Parameters ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Wheel Surface ◽  
Structured Surfaces ◽  
Structured Surface ◽  
Irregular Geometries

Abstract In this work, the ability to reshape the grinding wheels with special patterns to produce advanced structured surfaces with several geometries is studied. Firstly, a mathematical model is built for the process relating geometries of the grinding wheel, geometries of wheel patterns, the produced structured surface with the grinding operating parameters. Then, different regular and irregular geometries are designed to be patterned over the wheel surface. Afterward, a simulation method to express the patterned wheels and the structured surface at different working conditions is developed. The effects of the pattern geometries on the obtained structured surfaces are investigated.

scholarly journals THE EFFECT OF ABRASIVE GRAIN SHAPES ON QUALITY OF FERRITE MAGNETS GRINDING PROCESS

2020 ◽  
Vol 14 (2) ◽  
pp. 117-124
Author(s):  
Bayu Rahmat Saputro ◽  
Amin Suhadi
Keyword(s):  
Chemical Composition ◽  
Single Layer ◽  
Processing Parameters ◽  
Grinding Process ◽  
Model Design ◽  
Grinding Wheels ◽  
Abrasive Grains ◽  
Abrasive Grain ◽  
Shape And Size

Abstract A research was conducted on the grinding process of ferrite magnet with Strontium ferrite type (SrO.6 (Fe2O3)) using electroplated single layer grinding wheels. Many cracks have been found on work pieces during this work, which is coming from grinding processes. Research is conducted starting from chemical composition test and the effect of the shape and size of the abrasive grain of grinding wheels to the quality of grinding process results by measuring crack ratio of the work piece.  In this experiment, 3 (three) model design of grinding wheels with three different size and shape of abrasive grains are made. All of processing parameters are set at the same value as ordinary process.  The experimental results shown that 3rd model have the best results from the outputs number and also the lowest reject crack ratio compared to 1st and 2nd models. This is because the 3rd model has blocky shape which its distribution structure is denser and more uniform compared to the irregular shape, so that continuous grinding on hard and brittle work pieces is more stable and suitable

Automation of calculations of cutting modes taking into account the wear of cubic boron nitride tools when applying solid lubricants

2021 ◽  
pp. 67-70
Author(s):  
Keyword(s):  
Boron Nitride ◽  
High Speed ◽  
Solid Lubricant ◽  
Cubic Boron Nitride ◽  
High Speed Steel ◽  
Solid Lubricants ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Ceramic Bond ◽  
Calculation System

The effect of a solid lubricant on the wear of cubic boron nitride grinding wheels on a ceramic bond of different hardness and grain size in the processing of high-speed steel is investigated. The dependences of the change in the wear of cubic boron nitride on the parameters of the processing mode are determined. An automated calculation system is proposed to control the consumption of cubic boron nitride grinding wheels in production conditions. Keywords: solid lubricant, grinding, high speed steel, cubic boron nitride grinding wheel, consumption, wear, grinding mode. [email protected]

scholarly journals Internal Cylindrical Grinding Process of INCONEL® Alloy 600 Using Grinding Wheels with Sol–Gel Alumina and a Synthetic Organosilicon Polymer-Based Impregnate

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 115 ◽  
Author(s):  
Wojciech Kapłonek ◽  
Krzysztof Nadolny ◽  
Krzysztof Rokosz ◽  
Jocelyne Marciano ◽  
Mozammel Mia ◽  
...  
Keyword(s):  
Sol Gel ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Alloy 600 ◽  
Abrasive Tool ◽  
Grinding Wheels ◽  
Impregnation Process ◽  
Organosilicon Polymer ◽  
Internal Cylindrical Grinding ◽  
Abrasive Tools

The development of modern jet engines would not be possible without dynamically developed nickel–chromium-based superalloys, such as INCONEL® The effective abrasive machining of above materials brings with it many problems and challenges, such as intensive clogging of the grinding wheel active surface (GWAS). This extremely unfavorable effect causes a reduction in the cutting ability of the abrasive tool as well as increase to grinding forces and friction in the whole process. The authors of this work demonstrate that introduction of a synthetic organosilicon polymer-based impregnating substance to the GWAS can significantly improve the effects of carrying out the abrasive process of hard-to-cut materials. Experimental studies were carried out on a set of a silicon-treated small-sized sol–gel alumina 1-35×10×10-SG/F46G10VTO grinding wheels. The set contained abrasive tools after the internal cylindrical grinding process of INCONEL® alloy 600 rings and reference abrasive tools. The condition of the GWAS after the impregnation process was studied, including imaging and measurements of its microgeometry using confocal laser scanning microscopy (CLSM), microanalysis of its elemental distribution using energy dispersive X-ray fluorescence (EDXRF), and the influence of impregnation process on the grinding temperature using infrared thermography (IRT). The obtained results confirmed the correctness of introduction of the impregnating substance into the grinding wheel structure, and it was possible to obtain an abrasive tool with a recommended characteristic. The main favorable features of treated grinding wheel concerning the reduction of adhesion between the GWAS and grinding process products (limitation of the clogging phenomenon) as well as reduction of friction in the grinding process, which has a positive effect on the thermal conditions in the grinding zone.

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