Finite Element Simulation of Axial Creep-Feed Grinding Engineering Ceramics Based on ANSYS/LS-DYNA

2012 ◽  
Vol 472-475 ◽  
pp. 927-931
Author(s):  
Xin Li Tian ◽  
Fu Qiang Li ◽  
Ya Tao Mao ◽  
Bao Guo Zhang ◽  
Jian Quan Wang
Keyword(s):  
Grinding Force ◽  
Grinding Forces ◽  
Engineering Ceramics ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Element Simulation ◽  
Grinding Conditions ◽  
Grinding Mechanism ◽  
Single Grain ◽  
Diamond Grain

Introducing the grinding mechanism of axial creep-feed grinding ceramics with a single diamond grain. Establishing the simulation model of a single grain grinding engineering ceramics by axial creep-feed grinding and analyzing the simulation results of the grinding force in the X,Y,Z axis. Finally, the impacts of the wheel speed, axial feed rate and workpiece speed upon grinding forces were discussed by simulating the single diamond abrasive grinding process under different grinding conditions.

Grinding Force in Creep Feed Grinding of Titanium Alloy with Monolayer Brazed CBN Wheels

2012 ◽  
Vol 565 ◽  
pp. 94-99 ◽  
Author(s):  
Chang Yong Yang ◽  
Jiu Hua Xu ◽  
Wen Feng Ding
Keyword(s):  
Titanium Alloy ◽  
Boron Nitride ◽  
Cubic Boron Nitride ◽  
Grinding Force ◽  
Grinding Forces ◽  
Specific Grinding Energy ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Force Ratio ◽  
Composite Filler

In this paper, grinding forces of titanium alloy Ti-6Al-4V are measured during creep feed grinding with brazed cubic boron nitride (CBN) wheels. The effects of process parameters on grinding force, force ratio and specific grinding energy are investigated in detail. The grinding force is low and force ratio is about 1.5, and the specific grinding energy of titanium alloys Ti-6Al-4V is about 65J/mm3. Also, CBN wheels brazed with composite filler of Ag-Cu-Ti and 0.5wt.% lanthanum show better grinding performance than the counterpart brazed with Ag-Cu-Ti filler in this investigation.

Analysis of Influence Factors for the Contact Length between Wheel and Workpiece in Surface Grinding

2007 ◽  
Vol 359-360 ◽  
pp. 128-132 ◽  
Author(s):  
Cong Mao ◽  
Zhi Xiong Zhou ◽  
De Wang Zhou ◽  
Du Yi Gu
Keyword(s):  
Influence Factors ◽  
Contact Length ◽  
Grinding Force ◽  
Grinding Temperature ◽  
Grinding Forces ◽  
Contact State ◽  
Grinding Conditions ◽  
Grinding Mechanism ◽  
Thermocouple Method ◽  
Critical Contact

In order to understand the grinding mechanism and analyze the grinding operation, it is necessary to study the contact phenomena between wheel and workpiece during grinding operation. The contact length, the grinding temperature distribution within the contact zone, and the grinding forces are measured in-process by using Critical Contact State mode, thermocouple method, and 3-axis piezoelectric dynamometer, respectively. It is found that the grinding conditions and the properties of work material have effects on the contact length, moreover, the mechanism of which is discussed in this paper. The results show that the contact length significantly interacts with grinding force and grinding temperature in the grinding zone.

Modeling and Simulation of Single Abrasive-Grain Cutting Process in Creep Feed Grinding

2016 ◽  
Vol 693 ◽  
pp. 1241-1246 ◽  
Author(s):  
Zhen Guo Nie ◽  
Gang Wang ◽  
Yong Liang Lin ◽  
Xiang Su ◽  
Yi Ming Rong
Keyword(s):  
Modeling And Simulation ◽  
High Speed ◽  
Influence Factors ◽  
Simulation Method ◽  
Maximum Temperature ◽  
Grinding Forces ◽  
Abrasive Grain ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Single Grain

Single abrasive-grain cutting is the key research point in grinding process. Because of the narrow space and quick velocity, modeling and simulation method is an approach way to study the single grain cutting. This paper studied the distribution of flow stress and plastic strain, the temperature field near cutting grain. Then experiment was conducted to measure the cutting forces in single grain cutting test. The validation shows good correctness and accuracy of FEA model. Then orthogonal simulation test was carried out to research the influence factors for the grinding forces and temperature distribution. It is found that creep feed grinding has a large grinding forces than high speed grinding in the grain scales. But the maximum temperature value is affected both by depth and speed distinctly.

Wheel Working Surface Topography and Grinding Force Distributions in Creep Feed Grinding

2018 ◽  
Vol 12 (2) ◽  
pp. 223-229 ◽  
Author(s):  
Masakazu Fujimoto ◽  
Susumu Ohishi ◽  
Ryosuke Hinaga ◽  
Yuki Kubo ◽  
◽  
...  
Keyword(s):  
Wear Behavior ◽  
Grinding Force ◽  
Cutting Edge ◽  
Grinding Forces ◽  
Topographic Features ◽  
Distribution Form ◽  
Working Surface ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Edge Wear

This paper discusses the topographic features of wheel working surfaces and the grinding force distributions in wheel-work contact zones of creep feed grinding. Grain cutting edge wear is observed by a Scanning Electron Microscope (SEM) and quantitatively evaluated in terms of attritious wear flat percentage, which is able to characterize the wear behavior. By measuring the normal and tangential grinding force distribution in the grinding zone, the distribution form of grinding forces can be approximated to be triangular and the grinding forces increased rapidly due to workpiece burn. It is shown that the variation of the grinding force and the distribution are closely related to cutting edge wear characteristics.

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.

High efficiency axial deep creep-feed grinding machining technology of engineering ceramics materials

2012 ◽  
Vol 27 (5) ◽  
pp. 902-906
Author(s):  
Fang Guo ◽  
Baoguo Zhang ◽  
Hong Lu ◽  
Xinli Tian ◽  
Jianquan Wang ◽  
...  
Keyword(s):  
High Efficiency ◽  
Engineering Ceramics ◽  
Creep Feed Grinding ◽  
Creep Feed

Forces and Chip Morphology of Nickel-Based Superalloy Inconel 718 during High Speed Grinding with Single Grain

2013 ◽  
Vol 589-590 ◽  
pp. 209-214 ◽  
Author(s):  
Jia Yan Zhao ◽  
Yu Can Fu ◽  
Jiu Hua Xu ◽  
Lin Tian ◽  
Lu Yang
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Groove Surface ◽  
Nickel Based Superalloy ◽  
High Speed Grinding ◽  
Grinding Mechanism ◽  
Single Grain ◽  
Diamond Grain

Single-grain grinding test plays an important part in studying the high speed grinding mechanism of materials. In this paper, a new experimental system for high speed grinding test with single diamond grain is presented. The differences of surface topography and chip morphology of Inconel 718 machined by single diamond grain and single CBN grain were evaluated. The grinding forces and corresponding maximum undeformed chip thickness were measured under different grinding speeds. The chips, characterized by crack and segment band feature like the cutting segmented chips, were collected to study the high speed grinding mechanism of nickel-based superalloy. The results show that the grinding speed has an important effect on the forces and chip formation, partly due to the temperature variation. As the speed increases, the groove surface becomes smoother.

Study on Grinding Machinability of Titanium Alloy Using SiC Abrasive

2011 ◽  
Vol 487 ◽  
pp. 34-38 ◽  
Author(s):  
Guo Giang Guo ◽  
X.H. Zheng ◽  
Z.Q. Liu ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Titanium Alloy ◽  
High Temperature ◽  
Surface Topography ◽  
Specific Energy ◽  
Ground Surface ◽  
Grinding Force ◽  
Grinding Forces ◽  
Grinding Mechanism ◽  
Dry Conditions ◽  
Metallurgical Structure

Experimental results of Ti-6-2-4-2S, Ti-6-4 and Ti-5-5-5-1-1 are detailed in this paper with conventional surface grinding using SiC abrasive under dry conditions. Measurements of grinding forces, surface topography and metallurgical structure of ground surface were taken to investigate the grinding mechanism of these materials. The results showed grinding force ratios to these materials were between 1.35 to 2.25 at all material remove rates, but the specific energy to Ti-5-5-5-1-1 and Ti-6-2-4-2S were little higher than Ti-6-4. Evaluation of ground surface topography indicated they were visually free of crack and burn. At the same grinding parameters, Ti-5-5-5-1-1 had the maximum depth of heat-affected zone because of its poor high temperature properties.

Pulse Dressing in Creep Feed Grinding

1989 ◽  
Vol 203 (1) ◽  
pp. 51-55
Author(s):  
S M Rezaei ◽  
T R A Pearce ◽  
T D Howes
Keyword(s):  
Turbine Blades ◽  
Grinding Wheel ◽  
Grinding Forces ◽  
Dressing Method ◽  
Form Accuracy ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Nickel Base

Machining of the roots and shrouds of turbine blades is normally performed by continuous dress creep feed grinding. In this process, the grinding wheel is continuously dressed during the grinding operation, maintaining constant grinding forces and form accuracy. However, continuous-dressing has incurred higher wheel usage. In the tests described in this paper, creep feed grinding of nickel-base alloys was initially performed by continuous dressing to determine the burn barrier and the optimum dresser infeed rate. Pulse dressing, whereby the wheel is kept sharp by a series of dressing pulses, was then applied throughout the grinding cycle in such a way that the grinding forces were kept below the burn barrier. It was shown that wheel usage was reduced by a factor of two with the pulse dressing method. The effect of different grinding coolants under continuous and pulse dressing conditions is also discussed.

Research on the Force Characteristics in Ultrasonic Grinding Nano-Zirconia Ceramics

2008 ◽  
Vol 375-376 ◽  
pp. 258-262 ◽  
Author(s):  
Guo Fu Gao ◽  
Bo Zhao ◽  
Dao Hui Xiang ◽  
Qing Hua Kong
Keyword(s):  
Mechanical Property ◽  
Grinding Force ◽  
Depth Of Cut ◽  
Acoustic System ◽  
Zirconia Ceramics ◽  
Grinding Forces ◽  
Engineering Ceramics ◽  
Local Resonance ◽  
Ultrasonic Grinding ◽  
Force Characteristics

Nano-ceramics possessed ascendant mechanical property and physical characteristics contrast with traditional engineering ceramics, and its machining with ultrasonic assistance has been considered one of the most efficient methods. In the present paper a novel ultrasonic grinding vibration device has been developed and the theoretical model of grinding force has been created for ultrasonic vibration grinding. The influences of grinding parameters on grinding forces were tested with self-designd acoustic system based on local resonance. According to the test data, the effect of depth of cut and wheel velocity on the grinding force with/without ultrasonic assistance was analyzed. Both in common and ultrasonic grinding the normal grinding force and tangential grinding force descend against the wheel velocity, while ascend along with the depth of cut. In any case the grinding force in ultrasonic grinding was not more that that in common grinding.

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