New Ways at the Fine Grinding

2013 ◽  
Vol 581 ◽  
pp. 255-260 ◽  
Author(s):  
Martin Novák
Keyword(s):  
Surface Quality ◽  
Traditional Approach ◽  
Surface Profile ◽  
Ground Surface ◽  
Cutting Parameters ◽  
Grinding Wheel ◽  
Roughness Parameters ◽  
Machined Parts ◽  
Machining Operations

The traditional approach to grinding is to operate within the limits of surface quality. The requirements for surface quality in grinding are higher than those in other common machining operations such as turning and milling. The surface quality of machined parts is very important for precise production and assembly. When we focus on roughness parameters after grinding, we can establish the limits of these parameters for typical grain materials: Al2O3, SiC, CBN, SG and others. Increasing demands on accuracy and quality of production leads to research concerned with the properties of these materials and the surface quality after grinding. This paper shows new possibilities for the ground surface with focus on surface roughness obtained under varying combinations of cutting conditions. The influence of the grinding wheel, cutting parameters and coolant on higher surface quality is assessed by roughness parameters Ra, Rz, Rt and the Material portion of a surface profile. These high-precision ground surfaces are shown to have a Nanometres (10-9) unit topography demonstrating that the process is able to replace other finishing technologies such as superfinishing or honing.

Study on the Behavior of the Cast-Iron Bonded Grinding Wheel to Machining Properties of Hard and Brittle Materials

2007 ◽  
Vol 24-25 ◽  
pp. 229-232
Author(s):  
S.L. Ma ◽  
Wei Li ◽  
Cong Rong Zhu ◽  
J. Zhang ◽  
H.C. Ye
Keyword(s):  
Grain Size ◽  
Cast Iron ◽  
Tungsten Carbide ◽  
Surface Quality ◽  
Ground Surface ◽  
Grinding Wheel ◽  
Different Grain Size ◽  
Grinding Efficiency ◽  
Machining Properties

Tungsten carbide which is a hard and brittle material was ground by cast-iron bonded diamond wheel with ELID (Electrolytic In-Process Dressing) technique, for the purpose of getting high efficiency, super-precision machining. Three kinds of cast-iron bonded diamond wheels with different grain size were adopted to get different grinding efficiency and surface quality of workpieces. The grinding properties of cast-iron bonded grinding wheels with different grain size and the ground surface quality of tungsten carbide are discussed in this paper. The experiment results indicate that, under the same feeding amount, the grinding efficiency of the wheel with bigger grain size is higher, and it could make the dimension accuracy of the workpiece controllable, but the wheel with smaller grain size could get better ground surface quality. The two grinding phases are decided by the ratio between the size of abrasive grain and the thickness of the oxide layer on the grinding wheel.

Considerations on Cutting Regime Influence of NC Laser Cutting Machine Tool on Processed Surface Quality

2015 ◽  
Vol 760 ◽  
pp. 475-481
Author(s):  
Cristina Biris ◽  
Octavian Bologa ◽  
Claudia Girjob ◽  
Sever Gabriel Racz
Keyword(s):  
Surface Quality ◽  
Experimental Research ◽  
Laser Cutting ◽  
Cutting Parameters ◽  
Metallic Materials ◽  
Response Functions ◽  
Roughness Parameters ◽  
Cutting Machine ◽  
Factors Of Influence

This paper presents the study of the influence of cutting parameters on surface quality in laser cutting of metallic materials. In this paper, it is shown which of the cutting parameters have the greatest influence on the quality of the processed surfaces by measuring various roughness parameters. After the experimental research was carried out a ranking of the factors of influence on the response functions was made, also graphs of dependency to various parameters of roughness were made.

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

2021 ◽  
pp. 095440622110130
Author(s):  
Barnabás Zoltán Balázs ◽  
Márton Takács
Keyword(s):  
Surface Quality ◽  
Surface Profile ◽  
Cutting Parameters ◽  
Relevant Information ◽  
Milling Process ◽  
Micro Milling ◽  
Machined Surface ◽  
Analysis Of Dynamics ◽  
Five Axis ◽  
Coated Carbide

Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

Surface Quality of Pulsed Laser Cutting of Difficult to Machine Steel

2011 ◽  
Vol 299-300 ◽  
pp. 1016-1019
Author(s):  
Tie Jun Li ◽  
Jing Tang ◽  
Li Jun Yan ◽  
Yang Wang
Keyword(s):  
Surface Quality ◽  
Laser Cutting ◽  
Pulsed Laser ◽  
Cutting Parameters ◽  
Quality Factors ◽  
Good Separation ◽  
Machine Steel ◽  
Optimum Cutting ◽  
Super Alloy

This paper presented the experiments of Nd:YAG pulsed laser cutting of titanium alloy, super-alloy and stainless steel sheet, and investigated the influences of different laser cutting parameters on the surface quality factors focusing surface morphology. In comparison with air-, argon- and nitrogen-assisted laser cutting, argon-assisted laser cutting comes with unaffected surface quality and is suitable for laser cutting with subsequent welding requirement. With analyzing the interaction between pulses overlapping rate and energy, the results show that medium pulse overlapping rate and lower pulse rate helps to improve the surface roughness with pulsed laser cutting. And the results would be beneficial to find optimum cutting parameters for good separation surface.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

COMPLEXITY-BASED ANALYSIS OF THE INFLUENCE OF MACHINING PARAMETERS ON THE SURFACE FINISH OF DRILLED HOLES IN DRILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (06) ◽  
pp. 1950087 ◽  
Author(s):  
ASHFAQ AHAMED ◽  
ATHIF AHAMED ◽  
DILAN KATUWAWALA ◽  
TEOH TIONG EE ◽  
ZI HAN TAN ◽  
...  
Keyword(s):  
Surface Quality ◽  
Fractal Theory ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Machining ◽  
Drilling Operation ◽  
Two Factors ◽  
Machining Operations

Drilling is a famous and widely used machining operation to make holes in the workpiece. The size and surface quality of drilled hole are two factors that should be considered mainly. In this research, we examine the effect of different machining parameters and conditions on the surface quality of generated hole in drilling operation. For this purpose, we employ fractal theory and investigate how the variations of depth of cut and spindle speed affect the complexity of surface texture of drilled holes in wet and dry machining conditions. Based on the obtained results, the increment of depth of cut and spindle speed in case of wet and dry machining causes lower complexity on the generated surface from drilling. In addition, the generated surface from dry machining is more complex than the generated surface from wet machining. The obtained method in this research can be applied to other machining operations in order to investigate the effect of machining parameters and conditions on the surface quality of machined workpiece.

EVALUATION OF A REGRESSION PREDICTION MODEL FOR SURFACE ROUGHNESS OF WOOD–POLYETHYLENE COMPOSITE (WPC)

2017 ◽  
Vol 24 (Supp02) ◽  
pp. 1850033
Author(s):  
WENYONG SHI ◽  
YAN MA ◽  
CHUNMEI YANG ◽  
BIN JIANG ◽  
ZHE LI
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Prediction Model ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Wood Powder ◽  
Polyethylene Composite ◽  
Milled Surface ◽  
Powder Content

Milling processing is an important way to obtain wood–polyethylene composite (WPC) end products. In order to improve the processing efficiency and surface quality of WPC and meet the practical application requirements, this paper focussed on morphology and roughness of the WPC-milled surface and studied surface quality changes under different cutting parameters and milling methods through multi-parameters milling experiments. The milling surface morphology and roughness of WPC were analyzed and measured during cut-in, cutting and cut-out sections. It also revealed the affect rule of different cutting parameters and milling methods on milled surface morphology and roughness. The results show that the milling surface roughness of WPC products with wood powder content of 70% is significantly larger than the one whose wood powder content is 60%, and defects such as holes are also relatively more. Finally, a surface roughness prediction model was established based on the mathematical regression method and its multi-factor simulation was carried out. A comparative analysis of predictive and experimental values was performed to verify the reliability of the model. It could also provide theoretical guidance and technical guarantee for high processing quality of WPC milling and cutting.

Evaluation of the Working Surface of the Grinding Wheel Using Speckle Image Analysis

2015 ◽  
Author(s):  
Arunachalam Narayanaperumal ◽  
Vijayaraghavan Lakshmanan
Keyword(s):  
Surface Quality ◽  
Surface Condition ◽  
Grinding Wheel ◽  
Optical Parameters ◽  
Wheel Surface ◽  
Wheel Wear ◽  
Speckle Image ◽  
Periodic Monitoring ◽  
Grinding Machine

The surface quality of the ground components mainly depends on the surface condition of the grinding wheel. The surface condition of the grinding wheel changes with grinding time due to wheel wear and loading. The excessive wear and loading increases the cutting force and the temperature. This in turn affects the quality of the produced component. Hence periodic monitoring of the grinding wheel surface is essential to avoid the production of the defective components. In this paper, an attempt is made to study the changes in the grinding wheel surface condition using the laser scattered images. The simple speckle imaging arrangement is fabricated and fitted into the grinding machine to capture the images of the grinding wheel after each 100 passes. The fresh wheel expected to scatter more light due to higher roughness and porosity. On the other hand, the completely glazed and worn-out wheel scatters the light less due to smoother surface. Thus, speckle image intensity distribution captures the changes in the grinding wheel surface condition. The optical parameters evaluated from the speckle images clearly indicating the changes in the grinding wheel condition. This method can be utilized to evaluate the grinding wheel condition to improve the surface quality of the component produced.

Influence of Various Conditions on Quality of Burnished Surface in Developed Roller Burnishing with Active Rotary Tool

2018 ◽  
Vol 12 (6) ◽  
pp. 921-929 ◽  
Author(s):  
Masato Okada ◽  
Makoto Shinke ◽  
Masaaki Otsu ◽  
Takuya Miura ◽  
Kuniaki Dohda ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Profile ◽  
External Appearance ◽  
Roller Burnishing ◽  
Sliding Direction ◽  
Rotary Tool ◽  
Superior Surface ◽  
Cylindrical Workpiece

Burnishing characteristics of a newly developed roller burnishing method were developed. The developed method can effectively control the sliding direction between the roller and a cylindrical workpiece by inclining the roller axis with respect to the workpiece axis. The outer surface of a round aluminum alloy bar was targeted. The influence of burnishing conditions on burnished-surface quality was investigated, and surface quality was evaluated based primarily on the surface roughness, surface profile, and external appearance. As observed, the burnished-surface quality was strongly influenced by the pressing force, roller-inclination angle, and number of tool passes. A superior surface quality could be realized by increasing the number of tool passes.

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