scholarly journals Prediction of Ground Surfaces by Using the Actual Tool Topography

2019 ◽  
Vol 3 (2) ◽  
pp. 40
Author(s):  
Rolf Hockauf ◽  
Volker Böß ◽  
Thilo Grove ◽  
Berend Denkena
Keyword(s):  
Ground Surface ◽  
Grinding Wheel ◽  
Workpiece Surface ◽  
Precise Knowledge ◽  
Processing Step ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool ◽  
First Time ◽  
Laser Triangulation Sensor

This paper presents a prediction model for ground surfaces that uses the actual grinding wheel topography to perform a grinding simulation. Precise knowledge of expected machined surfaces plays an important role in process planning. Here, the main criterion is the achievement of the components’ function after manufacturing. Therefore, it is essential to consider the surface roughness to enable a function-orientated workpiece surface. The presented approach uses a real grinding tool topography, which is measured by a 3D laser triangulation sensor in the machine tool. After a data processing step, the measured topography is imported into a material removal simulation. A kinematic simulation of the realistic ground surface enables the data-based confirmation of the envelope profile theory for the first time.

COMPARISON OF EXPERIMENTALLY MEASURED AND SIMULATED WORKPIECE AND GRINDING WHEEL TOPOGRAPHY USING A NEW DRESSING MODEL

2016 ◽  
Vol 40 (1) ◽  
pp. 1-17 ◽  
Author(s):  
Abdalslam Darafon ◽  
Andrew Warkentin ◽  
Robert Bauer
Keyword(s):  
Surface Finish ◽  
Metal Removal ◽  
Ground Surface ◽  
Cutting Edge ◽  
Edge Density ◽  
Grinding Wheel ◽  
Workpiece Surface ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Conditions

This paper presents a new empirical model of the dressing process in grinding which is then incorporated into a 3D metal removal computer simulator to numerically predict the ground surface of a workpiece as well as the dressed surface of the grinding wheel. The proposed model superimposes a ductile cutting dressing model with a grain fracture model to numerically generate the resulting grinding wheel topography and workpiece surface. Grinding experiments were carried out using “fine”, “medium” and “coarse” dressing conditions to validate both the predicted wheel topography as well as the workpiece surface finish. For the grinding conditions used in this research, it was observed that the proposed dressing model is able to accurately predict the resulting workpiece surface finish for all dressing conditions tested. Furthermore, similar trends were observed between the predicted and experimentally-measured grinding wheel topographies when plotting the cutting edge density, average cutting edge width and average cutting edge spacing as a function of depth for all dressing conditions tested.

Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Sebastian Barth ◽  
Michael Rom ◽  
Christian Wrobel ◽  
Fritz Klocke
Keyword(s):  
Research Work ◽  
Distribution Functions ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Edge Zone ◽  
Application Behavior ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool

The prediction of the grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used grinding wheel is still a great challenge for today's manufacturers and users of grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the grinding wheel, which comes into contact with the workpiece during the grinding process. The topography of a grinding wheel mainly depends on the structure of the grinding wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the grinding wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent grinding wheel structure is known. This paper presents an innovative approach for modeling the grinding wheel structure and the resultant grinding wheel topography. The overall objective of the underlying research work was to create a mathematical-generic grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a grinding wheel. This model enables the user to determine the resulting grinding wheel structure and the grinding wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) grinding wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of grinding tools, which takes into account the entire grinding wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of grinding wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the grinding wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of grinding processes.

Hochharte Schleifscheiben als 4-Stoffsystem*/Superabrasive grinding wheels as quaternary system - Influence of secondary grains in vitrified-bonded cBN grinding wheels

2016 ◽  
Vol 106 (06) ◽  
pp. 407-411
Author(s):  
E. Prof. Uhlmann ◽  
J. Thalau
Keyword(s):  
State Of The Art ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grain Sizes ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool ◽  
Process Behavior ◽  
External Cylindrical Grinding ◽  
Stand Der Technik

Der Schleifbelag hochharter CBN (kubisches Bornitrid)-Schleifscheiben in keramischer Bindung enthält neben der Primärkörnung in der Regel eine Sekundärkörnung, die aus einem konventionellen Schleifmittel besteht. Im 3-Stoffsystem, das dem Stand der Technik entspricht, wird die Sekundärkörnung als Bindungsbestandteil betrachtet, der vorrangig die Härte des Belages beeinflusst. Computertomografische Analysen und Untersuchungen von Schleifscheibentopografien zeigen jedoch, dass die Sekundärkörnung sowohl einen Einfluss auf das Gefüge als auch auf die Gestalt des Schneidenraums der Schleifscheibe hat. Technologische Untersuchungen zum Quer-Umfangs-Außen-Rundschleifen mit Schleifwerkzeugen, die sich in der Sekundärkorngröße unterscheiden, bestätigen diese Beobachtungen und zeigen einen Einfluss der Sekundärkörnung sowohl auf die Prozesskennwerte als auch auf das Arbeitsergebnis.   The grinding layer of vitrified-bonded superabrasive grinding wheels contains, in addition to its primary cBN-grains, in many cases secondary conventional abrasive grains. The ternary system considers secondary grains according to the state of the art as part of the bonding, which primarily affect the bond hardness. However, computer tomographic measurements and the analysis of grinding wheel topographies indicate that the secondary grains affect both the inner structure of the grinding wheel as well as the characteristic of the grinding wheel topography which directly influences the interaction of grinding tool and workpiece. Technological investigations on external cylindrical grinding across the circumference using grinding wheels with different secondary grain sizes confirm those observations and show a direct influence of the secondary grains on the grinding process behavior as well as on the grinding results.

T-Dress, A Novel Approach in Dressing and Structuring of Grinding Wheels

2012 ◽  
Vol 565 ◽  
pp. 217-221 ◽  
Author(s):  
Taghi Tawakoli ◽  
Amir Daneshi
Keyword(s):  
Ground Surface ◽  
Decisive Role ◽  
Bearing Steel ◽  
Formation Condition ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grinding Forces ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Ground Surface Roughness

Since the grinding wheel topography directly influences the grinding forces and material removal mechanism, the dressing of grinding wheels has a decisive role in the desired product quality achievement. A new dressing concept is introduced in this paper in order to reach the optimum chip formation condition. The novel dresser, T-Dress, creates a new structure on the grinding wheel owing to which remarkable reduction in grinding forces occur. These lead to the lower heat generation in the wheel-workpiece contact zone and consequently lower thermal damages. The experiments prove about 40% lower grinding forces in grinding of bearing steel materials, 100Cr6, when dressing with T-Dress compared to the case of dressing with conventional profile rollers with almost no difference in the ground surface roughness values.

New Kinematic in Dressing of Grinding Wheels

2013 ◽  
Author(s):  
T. Tawakoli ◽  
A. Daneshi
Keyword(s):  
Ground Surface ◽  
Formation Condition ◽  
Grinding Wheel ◽  
Grinding Forces ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Roller Body ◽  
Dressing Force ◽  
Ground Surface Roughness ◽  
Remarkable Reduction

Grinding is the most important process in manufacturing of many precision components. The grinding wheel topography that is generated through dressing operation can directly influence the grinding forces and material removal mechanism. A new dressing concept is addressed in this investigation in order to reach the optimum chip formation condition. The innovative dressing profile roller, “T Dress”, creates a new structure on the wheel owing to which remarkable reduction in grinding forces occurs. The experiments prove about 40% reduction in grinding forces with no great difference in the ground surface roughness values when dressing with the T Dress. Dressing costs reduction owing to less diamond grits used on the roller body as well as about 25% lower dressing force are other advantages which were achieved with utilizing the T-Dress.

Experiment Research on Grinding of Optical Glass with Indigenously Developed Monolayer Brazed Diamond Grinding Wheel

2010 ◽  
Vol 136 ◽  
pp. 279-283 ◽  
Author(s):  
Bei Zhang ◽  
Hong Jun Xu ◽  
Yu Can Fu ◽  
Hong Hua Su
Keyword(s):  
Optical Glass ◽  
Removal Rate ◽  
Ground Surface ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Diamond Grinding Wheel ◽  
Diamond Grinding ◽  
Short Service Life ◽  
Wheel Topography ◽  
Grinding Wheel Topography

Conventional grinding of optical glass will normally result in not only much lower material removal rate but also short service life of grinding tools, which causes the high fabrication cost of optical glass. This paper focuses on the precision grinding of optical glass with the indigenously developed monolayer brazed diamond grinding wheel. Before grinding process a precision dressing is conduct. The dressed grinding wheel topography is observed. Through precision dressing the grinding process achieves moderate surface finish as well as ensures certain grinding efficiency. The ground surface of the optical glass workpiece is made up of micro-pits and glazing zones and the obtained surface roughness variation with the process parameters is analyzed. The experiment shows that the developed diamond grinding wheel is suitable to the application of optical glass machining.

Einfluss der Schärfparameter auf die Schleifscheibentopographie*/Influence of the sharpening parameters on the grinding wheel topography

2019 ◽  
Vol 109 (07-08) ◽  
pp. 582-588
Author(s):  
E. Uhlmann ◽  
A. Muthulingam
Keyword(s):  
Economic Efficiency ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Conditioning Process ◽  
Wheel Topography ◽  
Process Reliability ◽  
Grinding Wheel Topography ◽  
The Relationship

Einen wesentlichen Bestandteil der Schleiftechnik ist der Konditionierprozess zur Herstellung der Schleifscheibenform und -schnittigkeit. Durch das Schärfen wird die Bindung zurückgesetzt und der notwendige Schleifkornüberstand und Spanraum geschaffen. Ein CNC-gesteuerter Schärfprozess kann zur prozesssicheren und ressourceneffizienten Einstellung der gewünschten Schleifbelagstopographie genutzt werden. Umfangreiche Schärfuntersuchungen sollen hierbei Aufschluss über die Wirkzusammenhänge zwischen Schärfeinstellgrößen und Schärfergebnis geben.   An essential part of grinding technology is the conditioning process for the generation of the grinding wheel shape and of a sharp topography. Through the sharpening process the required cutting grains are exposed from the bond and sufficient chip space is ensured by putting back the bonding. A CNC-controlled sharpening process can lead to an improvement in process reliability and the economic efficiency. Extensive experimental investigations were carried out to determine the relationship between the sharpening parameters and the sharpening result.

Einfluss der Abrichtgrößen beim Schleifen*/Influence of dressing parameters on the grinding process - Systematic research of dressing parameters on workpiece roughness and surface integrity

2016 ◽  
Vol 106 (01-02) ◽  
pp. 44-50
Author(s):  
T. Lierse ◽  
B. Karpuschewski ◽  
T. R. Kaul
Keyword(s):  
Aluminum Oxide ◽  
Surface Integrity ◽  
Cvd Diamond ◽  
Grinding Wheel ◽  
Systematic Research ◽  
Grinding Process ◽  
Wheel Topography ◽  
Grinding Wheel Topography

Dieser Beitrag zeigt, dass die durch die Abrichtparameter erzeugte Schleifscheibentopographie nicht nur die Oberflächengüte des Werkstücks, sondern auch dessen Eigenspannungszustand in der Werkstückrandzone in weiten Grenzen verändert. Die Untersuchungen zum Abrichten von Korundschleifscheiben mit einer CVD-Diamantformrolle stellen den Zusammenhang zwischen dem Abrichten unterschiedlicher Schleifscheiben zur Bauteilqualität in Form der Oberflächenrautiefe und randzonennahen Eigenspannungen her.   The quality of the workpiece rim is changed by every grinding process. The grinding wheel topography created by the dressing process has not only influence on the workpiece roughness but also on the surface integrity. The pointed research using aluminum oxide abrasive wheels dressed by CVD diamond dressing discs shows a correlation between the dressing parameters, the workpiece roughness and the surface integrity.

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