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.

Influence of granularity of grinding stone on grinding force and material removal in the rail grinding process

2018 ◽  
Vol 233 (2) ◽  
pp. 355-365 ◽  
Author(s):  
Wen-jian Wang ◽  
Kai-kai Gu ◽  
Kun Zhou ◽  
Zhen-bing Cai ◽  
Jun Guo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Friction Coefficient ◽  
Material Removal ◽  
Grinding Force ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Material Removal Mechanisms ◽  
Rail Grinding ◽  
Grinding Efficiency ◽  
Grinding Stone

The objective of this study is to explore the influence of grinding stone granularity on the grinding force and rail material removal behaviors using a rail grinding friction machine. The results indicate that with the increase in granularity, the grinding force, and friction coefficient in the grinding interface obviously increase, which brings about a rise in the hardness and grinding temperature-rise of rail specimens. The increase in the grinding stone granularity causes a fall in the grinding volume and surface roughness of rail materials and brings about stronger vibration in the grinding interface owing to different material removal mechanisms. In view of the experimental results, the optimization of grinding stone granularity is significant for improving the rail grinding efficiency and surface quality.

scholarly journals Effects of Grinding Passes and Direction on Material Removal Behaviours in the Rail Grinding Process

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2293 ◽  
Author(s):  
Shuyue Zhang ◽  
Kun Zhou ◽  
Haohao Ding ◽  
Jun Guo ◽  
Qiyue Liu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Three Dimensional ◽  
Element Model ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Ratio ◽  
Rail Grinding ◽  
Three Dimensional Finite Element

A three-dimensional finite element model of rail grinding was established to explore the effects of grinding passes and grinding direction on the material removal behaviour of grinding rails during the grinding process. The results indicate that as the number of grinding passes increases, a decrease in the grinding force reduces both the amount of removed rail material and the surface roughness. There is a decrease in the grinding ratio caused by the increase in the wear on the grinding wheel and the decreased removal of the rail material. When the grinding direction changes, the wear of the grinding wheel decreases, which is contrary to the increasing trend of the amount of removed rail material, the grinding ratio, the surface roughness and the grinding force.

scholarly journals Optimization of Grinding Parameters for the Workpiece Surface and Material Removal Rate in the Belt Grinding Process for Polishing and Deburring of 45 Steel

2020 ◽  
Vol 10 (18) ◽  
pp. 6314
Author(s):  
Fengping Li ◽  
Yao Xue ◽  
Zhengya Zhang ◽  
Wenlei Song ◽  
Jiawei Xiang
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Weighting Coefficient ◽  
Grinding Process ◽  
Feed Speed ◽  
Belt Grinding ◽  
Optimal Value ◽  
Grinding Efficiency

Surface roughness and the material removal rate (MRR) are two important indicators during the grinding process. The former determines the surface quality while the latter reflects the grinding efficiency directly. In this paper, the two indicators are taken into consideration simultaneously and differently by converting them into a comprehensive goal with using weighting objective method. A prediction model was established for each comprehensive goal with each different combination of surface roughness and MRR weighting coefficient. The optimal value of abrasive size, contact force, belt linear speed, and feed speed were obtained under different grinding situations by using a central composite design (CCD) combined with response surface analysis. The experimental results showed that the comprehensive goal can be used effectively as an indicator to control the grinding performance and improve the optimization process.

Development of a New Plate Polishing Technique with an Instantaneous Tiny-Grinding Wheel Cluster Based on Magnetorheological Effect

2008 ◽  
Vol 53-54 ◽  
pp. 155-160 ◽  
Author(s):  
Qiu Sheng Yan ◽  
Ai Jun Tang ◽  
Jia Bin Lu ◽  
Wei Qiang Gao
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Abrasive Particles ◽  
Magnetorheological Effect ◽  
Material Removal Model ◽  
Mr Effect ◽  
Removal Model

A new plate polishing technique with an instantaneous tiny-grinding wheel cluster based on the magnetorheological (MR) effect is presented in this paper, and some experiments were conducted to prove its effectiveness and applicability. Under certain experimental condition, the material removal rate was improved by a factor of 20.84% as compared with the conventional polishing methods with dissociative abrasive particles, while the surface roughness of the workpiece was not obviously increased. Furthermore, the composite of the MR fluid was optimized to obtain the best polishing performance. On the basis of the experimental results, the material removal model of the new plate polishing technique was presented.

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.

The Adaptive Control of Grinding Force of CNC Cam Grinder Based on Neural Network

2012 ◽  
Vol 217-219 ◽  
pp. 2051-2055
Author(s):  
Ming Li Xie ◽  
Ling Lu
Keyword(s):  
Neural Network ◽  
Adaptive Control ◽  
Control Method ◽  
Metal Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Control Measures ◽  
Numerical Control ◽  
Grinding Wheel ◽  
Grinding Process

In the process of cam grinding, the fluctuation of grinding force can lead to the abnormal wear of the grinding wheel, the decrease of the grinding surface quality and even the damage of the grinding process system. The paper took the grinding process of numerical control cam grinding machine as research subject, the grinding force mathematical model was built, the indirect test and control measures were researched and an adaptive control method based on neural network was proposed and applied to the grinding force control of the cam grinding process. At last, the controller was designed and the grinding simulation was performed with MATLAB, which proved that the system could solve the fluctuation of grinding force during the process of cam grinding and the controller was equipped with good dynamic characteristic. The results indicate that the method can realize the purpose of optimal metal removal rate and enhance the grinding quality of cams.

An Intelligent System for Online Optimization of the Cylindrical Traverse Grinding Operation

2006 ◽  
Vol 220 (3) ◽  
pp. 355-363 ◽  
Author(s):  
B W Kruszyński ◽  
P Lajmert
Keyword(s):  
Material Removal ◽  
Intelligent System ◽  
Removal Rate ◽  
Feedforward Neural Network ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Optimization Scheme ◽  
Wheel Wear ◽  
Simulation Research ◽  
Traverse Grinding

This paper presents an intelligent system for optimization of the cylindrical traverse grinding process whose objective is to maximize the material removal rate with constraints on workpiece out-of-roundness and waviness errors, on surface finish, and on grinding temperature. A theoretical analysis of wheel wear development in the traverse grinding process is presented. Next, the results of an experimental test are discussed to establish the most efficient strategy for grinding allowance removal. In the optimization scheme a feedforward neural network is employed to obtain a model which describes relations between the process input parameters and the grinding results. Then this model is used to optimize adaptively the traverse grinding process. The performance of the proposed optimization system is evaluated by simulation research.

Analysis of Residual Stress Induced by Hand Grinding Process

2011 ◽  
Vol 681 ◽  
pp. 327-331 ◽  
Author(s):  
Sawsen Youssef ◽  
O. Calonne ◽  
Eric Feulvarch ◽  
P. Gilles ◽  
Hédi Hamdi
Keyword(s):  
Residual Stress ◽  
Experimental Study ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Cup Wheel

Grinding cup wheel is often used in the case of hand grinding which allows an important material removal rate but with secondary concern of surface integrity. Integrity is strongly affected by the process and consequently influences the surface behaviour in terms of resistivity to stress corrosion and crack initiation. This operation is difficult to master in terms of results on the surface and subsurface due to its manual nature. The paper presents results of an experimental study to investigate the residual stresses induced by this hand grinding process.

Genetic Programming for Grinding Surface Roughness Modelling

2012 ◽  
Vol 565 ◽  
pp. 183-189
Author(s):  
Xun Chen ◽  
Asma Alabed
Keyword(s):  
Surface Roughness ◽  
Genetic Programming ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
High Accuracy ◽  
Grinding Process ◽  
Reliable Prediction ◽  
Modelling Process

Grinding process is commonly selected for finishing operation because grinding has high accuracy and surface finish with a relatively high material removal rate. One of the most common issues in grinding process planning is to determine grinding condition for required surface roughness. This paper presents a feasibility study on grinding surface roughness modelling using genetic programming (GP) method. It has successfully demonstrated that GP could provide reliable prediction and has advantages over other established methods in terms of dealing with missing data during modelling process.

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