Effects of Cutting Edge Truncation on Ultrasonically Assisted Grinding

2008 ◽  
Vol 389-390 ◽  
pp. 368-374 ◽  
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe ◽  
Akira Kyusojin
Keyword(s):  
Ground Surface ◽  
Grinding Force ◽  
Cutting Edge ◽  
Mirror Surface ◽  
Skilled Workers ◽  
Oscillation Effect ◽  
Die Steel ◽  
Grinding Tool ◽  
Grinding Technique ◽  
Face Grinding

High precision mold grinding technique to obtain mirror surface is required which realizes minimization or omission of final polishing by skilled workers. In the previous reports, ultrasonically diamond grinding experiments were carried out to confirm ultrasonically oscillation effect for die steel face grinding. Mirror surface was obtained successfully and little abrasive worn out was found. In the above technique, the cutting edge shape of a tool affects the ground surface resulting from transcription of cutting edge. In other words, cutting edge truncation of grinding tool is required to be smooth and glossy surface. This paper describes the cutting edge truncation of diamond electroplated tools which are used in ultrasonically assisted grinding. Experiments were carried out to confirm truncation effects on the ground surface and grinding force. It was confirmed that cutting edge truncation is effective method to obtain mirror surface and excessive truncation causes large grinding force and chattering.

Optimization of Cutting Edge Truncation Depth for Ultrasonically Assisted Grinding to Finish Mirror Surface

2009 ◽  
Vol 76-78 ◽  
pp. 88-93 ◽  
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe ◽  
Akira Kyusojin
Keyword(s):  
Ground Surface ◽  
Optimization Techniques ◽  
Cutting Edge ◽  
Mirror Surface ◽  
Skilled Workers ◽  
Ultrasonic Oscillation ◽  
Oscillation Effect ◽  
Grinding Conditions ◽  
Grinding Technique ◽  
Face Grinding

High precision mold grinding technique to obtain mirror surface is required which realizes minimization or omission of final polishing by skilled workers. In the previous reports, ultrasonic diamond grinding experiments were carried out to confirm ultrasonic oscillation effect for die steel face grinding. Smooth and glossy surfaces were obtained successfully and little abrasive worn out was found. In the above techniques require cutting edge truncation because the cutting edge shape of a tool affects the ground surface resulting from transcription of cutting edge. This paper describes optimization techniques for the cutting edge truncation of diamond electroplated tools which are used in ultrasonically assisted grinding. Experiments were carried out to confirm truncation effects on the ground surface and grinding force. It was confirmed that roughness was proportional to inverse of thrust force. Minimum roughness in grinding conditions were estimated from the proportional diagrams. The minimum roughness shows limit of roughness on an each grinding condition.

Effects of Cutting Edge Truncation on Ultrasonically Assisted Grinding

2011 ◽  
Vol 325 ◽  
pp. 97-102
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe ◽  
Mohd Fauzi Ismail ◽  
Shoichi Kaihotsu
Keyword(s):  
Ground Surface ◽  
Cutting Edge ◽  
Surface Finishing ◽  
Mirror Surface ◽  
Skilled Workers ◽  
Surface Finishes ◽  
Molded Parts ◽  
Grinding Conditions ◽  
Injection Molded ◽  
Ground Surface Roughness

Dies for injection molded parts require high-quality surface finishes in terms of both appearance and integrity. Manual finishing by skilled workers is required to produce such surfaces, but this takes several days. To minimize the amount of polishing required, a new finishing technique that employs ultrasonically assisted diamond grinding was proposed in a previous report. Cutting edge truncation prior to grinding is required to produce a mirror surface. In this study, the effect of cutting edge truncation was investigated and the relationships between the ground surface roughness and the cutting torque and the thrust force were considered to optimize the grinding conditions for mirror surface finishing.

scholarly journals Temperature simulation of blank ground with face solid and segment disks in CAE-Solid Works complex

2017 ◽  
Vol 2 (11) ◽  
pp. 23-29 ◽  
Author(s):  
Алексей Морозов ◽  
Aleksey Morozov ◽  
Владимир Гусев ◽  
Vladimir Gusev
Keyword(s):  
Surface Layer ◽  
Solid State ◽  
Thermal Damage ◽  
Initial Conditions ◽  
Ground Surface ◽  
State Model ◽  
Cutting Surface ◽  
Grinding Tool ◽  
Solid Works ◽  
Face Grinding

Flat face grinding is characterized with large areas of a cutting surface contact with a blank under machining which re-sults in intensive heat generations in a cutting area which is able to cause a thermal damage of the surface layer. Thereupon there is developed a designed heat model of a blank, the initial conditions are defined, and there is created a solid-state model of an abrasive segment with a trapezoidal face cutting surface and a temperature simulation of the blank ground with a solid and discrete face tool is carried out in a modern CAE- Solid Works complex. The result of modeling have shown that the application of the discrete face grinding tool equipped with abrasive segments allows decreasing a temperature of the surface machined by 26-30% as compared to a face grinding tool with a solid cutting surface, which decreases considerably the likelihood of defects appearance in a ground surface layer of a part.

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.

Mirror Surface Machining of Steel by Elliptical Vibration Cutting with Diamond-Coated Tools Sharpened by Pulse Laser Grinding

2018 ◽  
Vol 12 (4) ◽  
pp. 573-581 ◽  
Author(s):  
Hiroshi Saito ◽  
Hongjin Jung ◽  
Eiji Shamoto ◽  
Shinya Suganuma ◽  
Fumihiro Itoigawa ◽  
...  
Keyword(s):  
Low Cost ◽  
Mirror Surface ◽  
Elliptical Vibration Cutting ◽  
Surface Machining ◽  
Vibration Cutting ◽  
Die Steel ◽  
Elliptical Vibration ◽  
Coated Tools ◽  
Ultrasonic Elliptical Vibration ◽  
Rapid Tool

Low-cost mirror surface machining of die steel is proposed in this research by applying elliptical vibration cutting with diamond-coated tools sharpened by pulse laser grinding (PLG). It is well known that conventional diamond cutting cannot be applied to die steel owing to rapid tool wear. Several attempts have been reported to prevent rapid tool wear, such as using ultrasonic elliptical vibration cutting. The ultrasonic elliptical vibration cutting developed by the authors to achieve mirror surface finish on die steel and prevent rapid wear is widely used in the industry. However, high-cost single-crystalline diamond tools that are finished using a time-consuming lapping process are required to obtain mirror surfaces. The authors, meanwhile, have recently developed the PLG process to efficiently sharpen the cutting edges of hard tool materials such as cubic boron nitride. Therefore, a practical mirror surface machining method for die steel is proposed in this research, namely elliptical vibration cutting with low-cost diamond-coated tools sharpened by the efficient PLG process. The results of the machining experiments confirmed that practical mirror surface machining of die steel can be achieved by the proposed method.

On Material Removal Mechanism in High Speed Single Grit Scratch-Grinding of Cryo-Treated Al2024-T351 Aluminium Alloy

2020 ◽  
Vol 1009 ◽  
pp. 123-128
Author(s):  
Sweety Satpathy ◽  
Amitava Ghosh
Keyword(s):  
Tensile Strength ◽  
Material Removal ◽  
High Speed ◽  
Scratch Test ◽  
Grinding Force ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Grinding Tool ◽  
Side Flow ◽  
Single Grit Scratch

Feasibility of utilizing cryogenic technology to improve the shearability of Al2024-T351 alloy is experimentally investigated by carrying out a single grit scratch-grinding test. A single grit brazed diamond grinding tool is developed for the study. Al2024-T351 work specimens are treated with liquid nitrogen for 6 hours before the scratch test. Although there was no significant change in the tensile strength of the material, the surface experiences change in the microhardness. It helps in arresting the side flow and ploughing of the material during high speed scratch grinding. The scratched grooves on cryo-treated samples, compare to those of untreated specimens, shows signs of cleaner shear-cuts, superior finish and produces less grinding force during grinding

Wheel Life and Cutting-Edge Wear in Mirror-Grinding Using a Coarse-Grained cBN Wheel Treated by Microdressing

2016 ◽  
Vol 10 (5) ◽  
pp. 753-758 ◽  
Author(s):  
Yoshio Ichida ◽  
Keyword(s):  
Wear Behavior ◽  
Mesh Size ◽  
Cutting Edge ◽  
Coarse Grained ◽  
Mirror Surface ◽  
Wheel Surface ◽  
Roll Steel ◽  
Cbn Wheel ◽  
Average Grain Size ◽  
Mirror Grinding

This paper presents the wheel life and wear behavior of the cutting edges of a coarse-grained, microdressed cubic boron nitride (cBN) wheel used in mirror-grinding of hardened roll-steel. Many grain-cutting edges with smooth, ductile-mode cut surfaces and numerous brittle-mode-fractured micro dents are formed on the wheel’s working surface after microdressing with a fine-grained diamond dresser. Cylindrical mirror-grinding experiments are conducted using a metal-bonded cBN wheel with a mesh size of #140 (Average grain sizeda=105 μm). A mirror surface with a roughness below 0.2 μmRzcan be efficiently formed with the wheel surface treated by the abovementioned microdressing method. This wheel surface can perform mirror-grinding with precision for more than nine hours. A flat plane formed via attritious wear of the cutting edge gradually extends with increasing accumulated stock removal, and simultaneously, the unevenness due to wear streaks on this flat plane increases. This increase in the unevenness of the worn flat plane is the main factor causing an increase in the roughness of the mirror surface.

Grinding a Hard-to-Grind Materials with Ultrasonic-Assisted Fluid

2014 ◽  
Vol 8 (3) ◽  
pp. 478-483 ◽  
Author(s):  
Jun Ishimatsu ◽  
◽  
Atsushi Iwaita ◽  
Hiromi Isobe ◽  
Keyword(s):  
Stainless Steel ◽  
Pure Titanium ◽  
Ground Surface ◽  
High Accuracy ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Machining Processes ◽  
Fluid Supply ◽  
Ultrasonic Assisted ◽  
Wheel Loading

Grinding is one of the machining processes used in the manufacture of high-accuracy parts. When materials which easily adhere to the grinding wheel are used, such as aluminum, stainless steel, and titanium, wheel loading must be considered, as this could have a limiting effect. In this research, the application of ultrasonic energy to the grinding fluid is carried out with a specially-designed effector inserted into the fluid supply flow with the expectation that loading will be removed from the wheel. The experiment is carried out on stainless steel and pure titanium. The grinding force and accession of temperature are investigated during grinding, and the reduction of both grinding force and thermal escalation is confirmed. Burn marks on the ground surface of titanium are also prevented.

Study on Grinding Force Distribution on Cup Type Electroplated Diamond Wheel in Face Grinding of Cemented Carbide

2014 ◽  
Vol 1017 ◽  
pp. 9-14 ◽  
Author(s):  
T. Fujiwara ◽  
Shinya Tsukamoto ◽  
Kazuhito Ohashi ◽  
Takashi Onishi
Keyword(s):  
High Performance ◽  
Outer Part ◽  
Diamond Wheel ◽  
Grinding Force ◽  
Cemented Carbide ◽  
Grinding Wheel ◽  
Force Distribution ◽  
Force Variation ◽  
Face Grinding ◽  
Peak Value

In order to establish a high performance grinding method of cemented carbide, the grinding force distribution on the working surface of the cup type electroplated diamond grinding wheel is experimentally analyzed with the grinding force variation of face grinding, which is carried out on the narrow workpiece. The grinding force distribution is obtained by the successive difference of the grinding force variation. The grinding state becomes steady as soon as beginning of the interference of grinding wheel in workpiece, because the edge profile of workpiece is formed as same as the envelope of the grinding wheel. Main conclusions obtained in this study are as follows. In the region of the front edge of the grinding wheel, relatively large grinding force occurs, then in the region of the rear edge of the grinding wheel, the grinding force becomes smaller. In the left right-side end of the wheel, the grinding forces are larger than the center of the wheel. It is made clear that the grinding force distribution shows the peak value near the outer part of the wheel, and the peak value is larger in the center part of the wheel, on the contrary, the peak width become broad in both the left and right-side end of the wheel.

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