Influence of Grinding Wheel Dressing on the Roughness of Final Surface and Cutting Force during GGG60 Grinding

2016 ◽  
Vol 686 ◽  
pp. 218-223 ◽  
Author(s):  
Martin Novák ◽  
Natasa Naprstkova ◽  
Hiroshi Kasuga
Keyword(s):  
Surface Roughness ◽  
Impact Assessment ◽  
Cutting Force ◽  
Surface Integrity ◽  
Cutting Forces ◽  
Geometric Shape ◽  
Grinding Wheel ◽  
Final Surface

Dressing of grinding wheel is important value, which can influence final surface. Therefore, it is necessary to address this issue some attention. Dressing is used for sharpening of clogged and blunted grinding wheel and adjustement of their geometric shape. The article deals with one of the experiments that are carried out in this area at FPTM JEPU in Ústí nad Labem. Experiments refer specifically to impact assessment of dressing size on the final selected values of surface integrity. Within the article, the assessment covered the surface roughness Ra, Rz and Rt. At the same time were also scanned using a dynamometer Kistler components of the cutting forces and even here it was possible to observe the influence of the dressing size of the grinding wheel on these values.

Surface integrity of quenched steel 1045 machined by CBN grinding wheel and SiC grinding wheel

2017 ◽  
Vol 8 (2) ◽  
pp. 179-187 ◽  
Author(s):  
Kankan Ji ◽  
Xingquan Zhang ◽  
Shubao Yang ◽  
Liping Shi ◽  
Shiyi Wang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Compressive Stress ◽  
Surface Integrity ◽  
Grinding Wheel ◽  
Micro Hardness ◽  
Content Type ◽  
Quenched Steel ◽  
Cut Depth ◽  
Cbn Grinding Wheel

Purpose The purpose of this paper is to evaluate surface integrity of quenched steel 1045 ground drily by the brazed cubic boron nitride (CBN) grinding wheel and the black SiC wheel, respectively. Surface integrity, including surface roughness, sub-surface hardness, residual stresses and surface morphology, was investigated in detail, and the surface quality of samples ground by two grinding wheels was compared. Design/methodology/approach In the present work, surface integrity of quenched steel 1045 machined by the CBN grinding wheel and the SiC wheel was investigated systematically. All the specimens were machined with a single pass in the down-cutting mode of dry condition. Surface morphology of the ground specimen was observed by using OLYMPUS BX51M optical microscopy. Surface roughness of seven points was measured by using a surface roughness tester at a cut-off length of 1.8 mm and the measurement traces were perpendicular to the grinding direction. Sub-surface micro-hardness was measured by using HVS-1000 digital micro-hardness tester after the cross-section surface was polished. The residual stress was tested by using X-350A X-ray stress analyzer. Findings When the cut depth is increased from 0.01 to 0.07 mm, the steel surface machined by the CBN wheel remains clear grinding mark, lower roughness, higher micro-hardness and higher magnitude of compressive stress and fine microstructure, while the surface machined by the SiC grinding wheel becomes worse with increasing of cut depth. The value of micro-hardness decreases, and the surface roughness increases, and the surface compressive stress turns into tensile stress. Some micro-cracks and voids occur when the sample is processed by the SiC grinding wheel with cut depth 0.07 mm. Originality/value In this paper, the specimens of quenched steel 1045 were machined by the CBN grinding wheel and the SiC wheel with various cutting depths. The processing quality resulted from the CBN grinding wheel is better than that resulted from the SiC grinding wheel.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Study on Surface Integrity of PTFE Finished by Ultra-Precision Cutting and Surface Performance

2005 ◽  
Vol 291-292 ◽  
pp. 475-482 ◽  
Author(s):  
Koichi Okuda ◽  
Masayuki Nunobiki
Keyword(s):  
Thin Film ◽  
Surface Roughness ◽  
Cutting Force ◽  
Surface Integrity ◽  
Water Repellency ◽  
Diamond Cutting ◽  
Finished Surface ◽  
Ultra Precision ◽  
Surface Performance ◽  
The Relationship

This study aims at clarifying the relationship between the surface integrity of PTFE finished by an ultra-precision diamond cutting and the adhesion strength of a metal thin film. As the first step of this study, the basic properties such as surface integrity in the diamond cutting of PTFE and the effect of the surface roughness on the textile water repellency are demonstrated in this report. The following remarks were found. The measured roughness of finished surface largely exceeded the theoretical roughness, while the cutting force was very small comparing with aluminum and the flow type chips were formed. The surface with a smaller roughness tended to repel water.

Comparison of surface integrity of Ti6Al4V titanium alloy manufactured by laser deposition and traditional method after end milling

2020 ◽  
pp. 095440622097213
Author(s):  
Ben Wang ◽  
Qi Zhang ◽  
Minghai Wang ◽  
Yaohui Zheng ◽  
Xianjun Kong
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Orthogonal Experiment ◽  
High Strength ◽  
Laser Deposition ◽  
Ti Alloy ◽  
Ti6al4v Titanium Alloy

Ti alloy has been widely applied in aerospace due to its high strength, good corrosion resistance, and excellent high-temperature performances. The quality and usability of Ti alloy parts are closely related to surface integrity. In this study, a comparative analysis of the milling surface integrity between laser deposition manufacturing and traditional Ti6Al4V samples was conducted. End milling surfaces of additive and traditional Ti6Al4V samples were observed with an orthogonal experiment under different milling parameters from the perspectives of cutting force, surface morphology, surface roughness, subsurface damages, and microhardness. Results demonstrate that the additive Ti6Al4V sample has a slightly higher cutting force and surface roughness relative to traditional Ti6Al4V. This is related to the higher hardness and plasticity of the additive Ti6Al4V sample. There are unmelted powder particle defects on the milling surface of the additive Ti6Al4V sample and serious cracking defects on the subsurface of the additive Ti6Al4V sample. The microhardness of the work hardening layer and base of the additive Ti6Al4V sample is higher than that of traditional Ti6Al4V. Moreover, the additive Ti6Al4V sample presents higher work hardening and a larger depth of the hardening layer. These findings demonstrate that material properties and manufacturing processes can influence surface integrity significantly.

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.

Investigation of Surface Integrity on TC4-DT in High Speed Grinding with CBN Wheel

2014 ◽  
Vol 1027 ◽  
pp. 140-145
Author(s):  
Yao Guang Chen ◽  
Wen Zhuang Lu ◽  
Jun Xu ◽  
Yan Song Zhu ◽  
Dun Wen Zuo
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
High Speed ◽  
Linear Velocity ◽  
Grinding Wheel ◽  
Cbn Wheel ◽  
Increasing Trend ◽  
High Speed Grinding ◽  
Weak Influence ◽  
Quality Surface

A series of grinding experiments were carried out with CBN wheel to focus on the surface integrity of titanium alloy TC4-DT in high speed grinding . In order to get the proper process parameters to control the surface integrity of the TC4-DT, surface roughness, subsurface morphology and microhardness variations have been studied. In addition to the use of CBN wheel, scanning electron microscopy (SEM), 3-d contour instrument and microhardness tester was applied. The results show that the surface roughness is decreased obviously when grinding wheel linear velocity rises from 60m/s to 80m/s. While the grinding speed rises from 80m/s to 100m/s, the surface roughness value increases slightly. Moreover, the surface roughness value increases with the grinding depth and the increasing trend is obvious in the process of machining. The microstructure analysis shows that during high speed grinding with CBN wheels, good quality surface with 10μm grinding depth can be obtained. Table feed rate has weak influence on the grinding surface topography. The microhardness analysis indicates that surface microhardness increases sharply with the increasing of grinding wheel linear velocity in high speed grinding.

The Effect of Cutting Force Vibration on Machining Quality for Reaming ZL102 Alloy with PCD Step Reamer

2018 ◽  
Vol 764 ◽  
pp. 279-290
Author(s):  
X.D. Wang ◽  
W.L. Ge ◽  
Y.G. Wang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Thrust Force ◽  
Maximum Amplitude ◽  
Spindle Speed ◽  
Machining Process ◽  
Cutting Fluid ◽  
Hole Quality ◽  
Force Vibration

The characteristics of cutting forces vibration and its effects to the hole quality in reaming aluminum cast alloy using a poly-crystalline diamond (PCD) step reamer in dry and wet conditions were studied. First, centrifugal force vibration model of the PCD step reamer during machining process was established and through the analysis of the model, it can be concluded that the maximum amplitude of the vibration is positively related to the angular velocity of the reamer. Then, thrust force and cutting torque were measured by a Kistler Dynamometer during reaming process and these vibration frequency and amplitude were analyzed by fast Fourier transformation (FFT). Hole quality was evaluated by hole diameter and surface roughness. Results show that, as the spindle speed increases, the stability of thrust force and cutting torque deteriorates gradually, and there was a severe vibration in the cutting force and the surface roughness when the spindle speed reached 10000 rpm in wet and 7000 rpm in dry cutting conditions. Compared the variation of hole surface roughness and vibration characteristic of cutting forces, it can be observed that the trends are very consistent, the surface roughness deteriorates when cutting forces become unstable. Therefore,the cutting forces stability was an important factor that influence the hole quality. Cutting fluid has a positive effect to stabilize the reaming process and was beneficial to improve the hole quality.

Evaluation of the cutting forces, the surface roughness, and the tool wear characteristics during machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool

2021 ◽  
pp. 095440892110480
Author(s):  
Abdullah Altin
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Signal To Noise ◽  
Ceramic Cutting Tool ◽  
Cutting Speeds

In this research, we had studied the sensitivity for machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool. The investigation had focused on the effects of the cutting speed, on the cutting forces, and on the surface roughness based on Taguchi’s experimental design. The effects of machining parameters were determined using Taguchi’s L27 orthogonal array. The signal-to-noise ratio was calculated for the average of surface roughness and the cutting forces, and the smaller were used to determine the optimal cutting conditions. The analysis of variance and the signal-to-noise ratio had effects on the parameters on both surface roughness and cutting. Three different types of cutting tools had been used in the experiment, namely KYON 4300, KYS 25, and KYS 30. The cutting force of Fz was considered to be the main cutting force. Depending on the material which had been used as cutting tool, the Fz had the lowest cutting speed and the lowest surface roughness with the KYS25 ceramic tool. The cutting force and the surface roughness of KYON 4300 cutting tool had shown better performance than other cutting tools. The flank wear and notch were found to be more effective in the experiments. The long chips were removed at low and medium cutting speeds, while the sawdust with one edge and narrow pitch at high cutting speeds was obtained.

scholarly journals Optimization of parameters in cylindrical and surface grinding for improved surface finish

2018 ◽  
Vol 5 (5) ◽  
pp. 171906 ◽  
Author(s):  
Dinesh Kumar Patel ◽  
Deepam Goyal ◽  
B. S. Pabla
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Finish ◽  
Surface Characteristics ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cylindrical Grinding ◽  
Grinding Parameters ◽  
Wheel Material

Surface integrity has attracted the attention of researchers for improving the functional performance of engineering products. Improvement in surface finish, one of the important parameters in surface integrity, has been attempted by researchers through different processes. Grinding has been widely used for final machining of components requiring smooth surfaces coupled with precise tolerances. Proper selection of grinding wheel material and grade with grinding parameters can result in an improved surface finish and improved surface characteristics. The present work reports the study of the effect of grinding parameters on surface finish of EN8 steel. Experiments were performed on surface grinding and cylindrical grinding for optimization of grinding process parameters for improved surface finish. Grinding wheel speed, depth of cut, table feed, grinding wheel material and table travel speed for surface grinding operation, and work speed for cylindrical grinding operation were taken as the input parameters with four types of grinding wheels (Al 2 O 3 of grades K and L, and white alumina of grades J and K). The surface roughness was taken as an output parameter for experimentation. The grinding wheel material and grade have been observed to be the most significant variables for both cylindrical grinding and surface grinding. Surface roughness in the case of surface grinding is better compared to that of cylindrical grinding, which can be attributed to vibrations produced in the cylindrical grinding attachment. Surface roughness ( R a ) values of 0.757 µm in cylindrical grinding and 0.66 µm in surface grinding have been achieved.

scholarly journals An Improved Cutting Force Model for Ultrasonically Assisted Grinding of Hard and Brittle Materials

2021 ◽  
Vol 11 (9) ◽  
pp. 3888
Author(s):  
Renke Kang ◽  
Jinting Liu ◽  
Zhigang Dong ◽  
Feifei Zheng ◽  
Yan Bao ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Experimental Studies ◽  
Brittle Materials ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Force Model ◽  
Cutting Force Model ◽  
Fillet Radius ◽  
Hard And Brittle Materials

Cutting force is one of the most important factors in the ultrasonically assisted grinding (UAG) of hard and brittle materials. Many theoretical and experimental studies show that UAG can effectively reduce cutting forces. The existing models for UAG mostly assume an ideal grinding wheel with abrasives in both the end and lateral faces to accomplish material removal, whereas the important role of the transition fillet surface is ignored. In this study, a theoretical cutting force model is presented to predict cutting forces with the consideration of the diamond abrasives in the end face, the lateral face, and the transition fillet surface of the grinding tool. This study analyzed and calculated the vibration amplitudes and the cutting forces in both the normal and tangential directions. It discusses the influences of the input parameters (rotation speed, feed rate, amplitude, depth and radius of transition fillet) on cutting forces. The study demonstrates that the fillet radius is an important factor affecting the grinding force. With an increase in fillet radius from 0.2 to 1.2 mm, the grinding force increases by 139.6% in the axial direction and decreases by 70% in the feed direction. The error of the proposed cutting force model is 10.3%, and the experimental results verify the correctness of the force model.

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