Experimental Investigation on Dry Point Grinding Process Based on Green Manufacturing

2010 ◽  
Vol 431-432 ◽  
pp. 470-473
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
Point Contact ◽  
Ground Surface ◽  
Green Manufacturing ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Cooling Conditions ◽  
Dry Grinding ◽  
Grinding Power

Due to point contact cause, the point grinding process have the lower grinding power and heat to measure and the better cooling conditions. For green manufacturing, the point grinding process has the significance to reduce the consumption of grinding fluid and improve the ground surface integrity and the process greenness. This study analyzes the geometric configuration of the contact area between the wheel and the workpiece in point grinding process, establishes the geometric and mathematic models of the contact area, and investigates the relations between the grinding parameters. The dry point grinding experiments are performed on the ground surface integrity. These investigations show that the dry grinding can be achieved in point grinding process under less depth of cut and the higher grinding speed for the high machining greenness demand.

Study on MQL in Point Grinding Process for Green Manufacturing

2010 ◽  
Vol 97-101 ◽  
pp. 2356-2360 ◽  
Author(s):  
Shu Dong Xiu ◽  
Zhi Jie Geng
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
Ground Surface ◽  
Green Manufacturing ◽  
Cooling Condition ◽  
Geometric Configuration ◽  
Grinding Process ◽  
Pressure Condition ◽  
Dry Grinding ◽  
Grinding Power

In point grinding process, the contact area of point grinding is much smaller than that of conventional cylindrical grinding under same conditions, so the grinding power and heat to measure is lower and the cooling condition is improved obviously. For green manufacturing, the point grinding process has the significance to reduce the consumption of grinding fluid and improve ground surface integrity and greenness. This study analyzes the geometric configuration of the contact area between wheel and workpiece in point grinding process, establishes the geometric and mathematic models of the contact area, and investigates the relations between the grinding parameters and the grinding power by the simulations. The MQL and semi-dry point grinding experiments are performed on the ground surface integrity. These investigations show that the MQL and semi-dry grinding can be achieved in point grinding process under less contact area and higher jet pressure condition for the high greenness demand.

Experimental Study on Point Grinding Technical Parameters Affecting Coolant Jet Parameters

2009 ◽  
Vol 416 ◽  
pp. 13-17 ◽  
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Peng Bo Xiu
Keyword(s):  
Contact Area ◽  
High Speed ◽  
Dynamic Pressure ◽  
Point Contact ◽  
Green Manufacturing ◽  
Mathematic Model ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Edge Contact ◽  
Grinding Power

Point grinding is a new type of high and super-high speed grinding process with a point contact zone and less grinding force. Because of the lower grinding power, the grinding heat in point grinding process is much less than that of the conventional grinding process. Therefore, the less grinding coolant jet parameters can be used during point grinding process. That is very propitious to the environment and resource, as well as the green manufacturing. Based on the mathematic model of the edge contact area of point grinding, the simulations of the edge contact area with point grinding angles and depth of cut was performed to study the grinding power. In addition, the relations between the grinding power and the depth of cut and vertical grinding angle were investigated. The dynamic pressure and velocity distributions in the airflow layer around the wheel edge were analyzed more by means of experiment. The point grinding experiment for grinding coolant jet parameters was performed.

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

Study on Effect of Grinding Fluid Supply Parameters on Surface Integrity in Quick-Point Grinding for Green Manufacturing

2008 ◽  
Vol 53-54 ◽  
pp. 209-214 ◽  
Author(s):  
Shi Chao Xiu ◽  
Ya Dong Gong ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
High Speed ◽  
Point Contact ◽  
Green Manufacturing ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Fluid ◽  
Fluid Supply ◽  
High Speed Grinding ◽  
Grinding Power

In high and super-high speed grinding process, there is an airflow layer with high speed around the circle edge of the grinding wheel that hinders the grinding fluid into contact layer, namely, the air barrier effect. The speed of airflow layer is directly proportional to the square of the wheel speed. Quick-point grinding is a new type of high and super-high speed grinding process with a point contact zone and less grinding power. The edge effect of the air barrier is weakened because the thin CBN wheel is applied in the process. By the analysis of dynamic pressure and velocity distributions in the airflow layer around the wheel edge, the mathematic models of the flow and jet pressure of grinding fluid for effective supply in the process were established and the process of optimization calculation of the jet nozzle diameter for green manufacturing was also analyzed based on the thermodynamics and the technical character of quick-point grinding process. The quick-point grinding experiment for surface integrity influenced by grinding fluid supply parameters was performed.

Influence of Hand Disc Grinding on Surface Integrity of Nickel-Based Alloys: Numerical Approach

2013 ◽  
Author(s):  
Sawsen Youssef ◽  
Olivier Calonne ◽  
Hédi Hamdi
Keyword(s):  
Heat Flux ◽  
Surface Integrity ◽  
Ground Surface ◽  
Maximum Temperature ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Feed Speed ◽  
Applied Forces ◽  
Grinding Power ◽  
Disc Grinding

For complex part geometry, hand grinding is one of finishing and super finishing process the most used in mechanical industry. Surface integrity is today one major concern for industrials. The surface integrity is defined by a set of important characteristics of ground surface as surface geometric parameters (roughness, …), mechanical behaviour of the subsurface (hardness, residual stress, …) and structural changes of the material in the near surface. High heat and pressure, high strain and strain rate observed during hand grinding process, strongly influence surface integrity. Therefore, the surface behaviour, in terms of resistance to corrosion and crack initiation depends on how the process was conducted. The purpose of this study is to understand the effects of thermal and mechanical plastic deformation induced on the surface of components. The action of the disc-grinding wheel on the workpiece is modelled by a moving heat flux on the surface. The challenge is to be able to find the shape and intensity of thermomechanical load entering the workpiece in accordance with the hand disc grinding process and taking into account specific parameters of the process. In a first part, a mechanical description of the action of the disc-wheel on the surface is proposed in order to develop an analytic formulation of the grinding power and the heat flux density. They are function of the disc-grinding wheel velocity, the feed speed and the applied forces. This expression is then used in a finite element modelling to perform thermomechanical simulations of the hand disc-grinding process. In a first stage, heating and cooling are computed. They give maximum temperature reached, temperature gradients and cooling kinematic. In a second stage, thermomechanical computation is conducted in order to compute residual stresses induced by this abrasion process. A discussion based on experimental results obtained by XRD method is then proposed and some local explanation are given on the way the material structure has changed leading to a structural hardening in the 50 first microns beneath the ground surface.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

Study on the Formation of Grind-Hardening of Steel AISI 1066

2007 ◽  
Vol 329 ◽  
pp. 57-62 ◽  
Author(s):  
Ju Dong Liu ◽  
Gui Cheng Wang ◽  
B.L. Wang ◽  
K.M. Chen
Keyword(s):  
Hardened Layer ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Micro Hardness ◽  
Cooling Conditions ◽  
Dry Grinding ◽  
Structures And Properties ◽  
Grind Hardening ◽  
Steel Aisi ◽  
Grinding Technique

Grind-hardening was done on Steel AISI 1066 with a conventional surface grinder and a corundum grinding wheel, and research was conducted to probe into structures and properties of the hardened layer under varied depth of cut and cooling conditions. Results show that the hardened layer do not change noticeably in their martensitic structures and micro-hardness, which is ranged between 810870HV; But when the depth of cut increased or the dry grinding technique is adopted, the concentration of martensites and carbonides becomes lower, while the amount of residual austenites increases, and the completely hardened zone gets thicker. This conclusion serves as an experimental basis for the active control of properties of the grind-hardened layer of Steel AISI 1066.

Study on Factors which Make CBN Insert can Turn S45C Steel Have Surface Roughness Less than Ra 0.4

2019 ◽  
Vol 805 ◽  
pp. 3-7
Author(s):  
Manus Sriswat ◽  
Kittipong Kimapong ◽  
Atthakorn Chanchana
Keyword(s):  
Surface Roughness ◽  
Contact Area ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Standard Type ◽  
Good Surface ◽  
Cylindrical Parts

Grinding process is necessary final process of making cylindrical parts with less than Ra 0.4 surface roughness. Generally we cannot obtain good surface quality without grinding process. As the experience of the authors, using CBN (Cubic Boron Nitride) insert to turning cylindrical parts could be obtained Ra 0.438 surface roughness. The surface roughness result is similar to ground parts. This result becomes the main focus of the study. Authors study to find out factors affecting CBN performance in turning with CBN to obtain less than Ra 0.4 surface roughness. According to the study, it was found that tool contact area allied to surface roughness. The experiment is turning S45C medium carbon steel under the following condition: Cutting speed is 300 m./min, Feed is 0.05 mm./rev and depth of cut is 0.1 mm. Experiment under the same condition in different contact area. Modify contact area of CBN insert to be 5,10,15,20 and 25 mm. and testing in order. CBN insert standard type contact area is 0 mm. Compare test results of modified CBN inserts with standard type result. The results of experiments were as follows: 1) Turning steel with CBN contact area 10 mm. was obtained Ra 0.456 surface roughness, 2) Turning steel with CBN contact area 15 mm. was obtained Ra 0.293 surface roughness, Thus less than Ra 0.4 surface roughness.

Some investigations in grindability improvement of Inconel 718 under ecological grinding

2018 ◽  
Vol 233 (3) ◽  
pp. 727-744 ◽  
Author(s):  
Manoj Kumar Sinha ◽  
Rajeshkumar Madarkar ◽  
Sudarsan Ghosh ◽  
Venkateswara Rao Paruchuri
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Ground Surface ◽  
Minimum Quantity Lubrication ◽  
Energy Dispersive ◽  
Grinding Forces ◽  
X Ray ◽  
Minimum Quantity ◽  
Grinding Performance ◽  
Dry Grinding

This work explores the improvement in grinding characteristics of Inconel 718 (IN718) using soluble oil under minimum quantity lubrication and liquid nitrogen (LN2) environments. The coolant flow rate in minimum quantity lubrication and LN2 grinding has been regulated through indigenously developed setups. Grinding performance has been studied in terms of on-machine measured grinding forces and centre line average surface roughness ( Ra). The obtained grinding characteristics have been compared with the outcomes under dry and wet grinding. Surface integrity of ground surface, wheel morphology, and chip formation characteristics has been studied using scanning electron microscope, energy dispersive X-ray spectroscopy, and atomic force microscopy. Analysis of variance has been carried out to capture the variability in the experimental data for tangential forces and Ra. The main effect of the factors and their first-order interactions have been considered, and second-order regression equations have been developed using response surface methodology. LN2 grinding has been proved to be more efficient as it yielded lowest grinding forces, least oxidation, minimal ground surface damage and better surface integrity. The occurrence of almost circular chips in dry grinding indicates severe oxidation, whereas small C-type chips formed under minimum quantity lubrication and LN2 conditions indicate effective cooling under these environments. The energy dispersive X-ray spectroscopy analysis of the ground surfaces also supports these results through the occurrence of the highest oxidation in dry grinding. From this work, it has been concluded that LN2 and minimum quantity lubrication grinding offer a clean and effective means to improve grinding performance of IN718 compared to dry and wet grinding.

Analysis of Microstructure of Grinding Strengthening Layer in Point Grinding under Small Depth of Cut Conditions

2012 ◽  
Vol 472-475 ◽  
pp. 974-977 ◽  
Author(s):  
Shi Chao Xiu ◽  
Ming He Liu ◽  
Jian Hen Wei
Keyword(s):  
Quality Control ◽  
Surface Integrity ◽  
Thermal Load ◽  
Theoretical Basis ◽  
Surface Hardness ◽  
Ground Surface ◽  
Working Life ◽  
Depth Of Cut ◽  
Layer Formation ◽  
Small Depth

Grinding strengthening and hardening can change and improve the ground surface integrity directly by the composite process of thermal load and mechanical force during process. The thickness and distribution of strengthening layer in ground surface makes the key role to measure the surface integrity of workpiece. The hardness and size of strengthening layer can influence the fatigue strength working life of the workpiece significantly. Based on the grinding strengthening test of 45 steel specimens, the strengthened layer microstructure, thickness and surface hardness were analyzed. This study illustrates the mechanism of grinding strengthened layer formation and also provides the theoretical basis for grinding strengthening and hardening layer quality control and grinding strengthening process making properly under small depth of cut conditions.

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