Modeling Material Removal Rate of Heavy Belt-Grinding in Manufacturing of U71Mn Material

2016 ◽  
Vol 693 ◽  
pp. 1082-1089 ◽  
Author(s):  
Rong Quan Wang ◽  
Jian Yong Li ◽  
Yue Ming Liu ◽  
Wen Xi Wang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Low Cost ◽  
Belt Grinding ◽  
Abrasive Particles ◽  
Grinding Conditions ◽  
Modeling Material ◽  
Abrasive Cutting

The heavy belt-grinding is a new machining method, which combined the characters of heavy-duty grinding and belt-grinding together, with high efficiency and low cost. In the present paper the removal rate model of heavy belt-grinding in manufacturing of U71Mn steel is established. It is assumed that the distribution of the abrasive particles protrusion height of the abrasive belt surface closes to Gaussian distribution. The model is presented by calculating the removal volumes of all abrasive grains contributing to cutting action based on the probability theory, elastic-plastic mechanics and abrasive cutting theory. It is analysis that the material removal rate depends essentially on the mechanical properties of the workpiece and the belt and the grinding conditions. It is proportional to the average pressure, belt velocity and the indentation depth and is inverse proportion to the grain size.

Research on Material Removal of a New Micro Machining Technology Based on the Magnetorheological Effect of Abrasive Slurry

2007 ◽  
Vol 364-366 ◽  
pp. 914-919 ◽  
Author(s):  
Juan Yu ◽  
Qiu Sheng Yan ◽  
Jia Bin Lu ◽  
Wei Qiang Gao
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Magnetic Particles ◽  
High Efficiency ◽  
Rotation Speed ◽  
Optical Glass ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Machining Time ◽  
Abrasive Particles

Based on the magnetorheological (MR) effect of abrasive slurry, the particle-dispersed MR fluid is used as a special instantaneous bond to cohere abrasive particles and magnetic particles so as to form a dynamic, flexible tiny-grinding wheel to polish optical glass, ceramic and other brittle materials of millimeter or sub-millimeter scale with a high efficiency. Experiments were conducted to reveal the effects of different process parameters, such as grain sizes of abrasive particles, machining time, machining gap between the workpiece and the rotation tool, and rotation speed of the tool, on material removal rate of glass surface. The results indicate the following conclusions: material removal rate increases when the grain size of abrasives is similar to that of magnetic particles; machining time is directly proportional to material removal, but inversely proportional to material removal rate; machining gap is inversely proportional to material removal; polishing speed has both positive and negative influence on material removal rate, and greater material removal rate can be obtained at a certain rotation speed. In addition, the difference of the machining characteristics between this new method and the traditional fixed-abrasive machining method is analyzed.

Development of a New Plate Polishing Technique with an Instantaneous Tiny-Grinding Wheel Cluster Based on Magnetorheological Effect

2008 ◽  
Vol 53-54 ◽  
pp. 155-160 ◽  
Author(s):  
Qiu Sheng Yan ◽  
Ai Jun Tang ◽  
Jia Bin Lu ◽  
Wei Qiang Gao
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Abrasive Particles ◽  
Magnetorheological Effect ◽  
Material Removal Model ◽  
Mr Effect ◽  
Removal Model

A new plate polishing technique with an instantaneous tiny-grinding wheel cluster based on the magnetorheological (MR) effect is presented in this paper, and some experiments were conducted to prove its effectiveness and applicability. Under certain experimental condition, the material removal rate was improved by a factor of 20.84% as compared with the conventional polishing methods with dissociative abrasive particles, while the surface roughness of the workpiece was not obviously increased. Furthermore, the composite of the MR fluid was optimized to obtain the best polishing performance. On the basis of the experimental results, the material removal model of the new plate polishing technique was presented.

Wear Characteristics of the Sub-Aperture Tools and Material Removal Rate in Precision Grinding with Loose Abrasives

2007 ◽  
Vol 329 ◽  
pp. 69-74
Author(s):  
H. Cheng ◽  
H.Y. Tam ◽  
Y. Gao ◽  
Yong Bo Wu ◽  
Y. Wang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Process Analysis ◽  
Actual Process ◽  
Correlative Function ◽  
Glass Specimen ◽  
Grinding Tool ◽  
The Relationship

This paper proposes a sub-aperture grinding tool for loose abrasive computer controlled surfacing, which is designed to perform epicyclic motion and rotate around its centre at a rapid rate, whilst the entire mechanism revolves around a secondary centre at a slower rate. In actual process, the wear of the tool could affect the material removal function, and make the process unstable, thus in fact, it is difficult to make a deterministic manufacturing. The focus of the present paper is on wearing characteristics of sub-aperture tools and the wear evenness as the main objectives. To make a further study, material removal function of the tool is firstly established through theoretically modelling, next, a correlative function with weighted factors is built, which is suitable for specifying the wearing degree of the tool. Finally, to discover the relationship between the material removal rate and the tool wearing characteristics, and to optimize the grinding process, analysis and experiments are then carried out on a K9 glass specimen by means of three kinds of tool materials, i.e., polyurethane pad, aluminum plate and pitch based on the proposed technique and model. The results indicated that the required high efficiency and precision could be achieved by choosing proper processes.

The Analysis of Four-Axis Belt Grinding for Marine Propeller Blade

2010 ◽  
Vol 154-155 ◽  
pp. 647-653
Author(s):  
Jian Qiang Wu ◽  
Yun Huang ◽  
Zhi Huang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Structural Features ◽  
Free Form ◽  
Marine Propeller ◽  
Propeller Blade ◽  
Belt Grinding ◽  
Abrasive Belt ◽  
Grinding Machine

Marine propeller blade is composite of the free form surface, its machining method has been a difficult thing. The blade is processed by 4-axis belt grinding machine in this experiment, this paper analyze that the wear of the abrasive belt and the processing precision and the material removal rate of the blade according to the grinding performance of the blade material, the structural features of the vane, and the theory of 4-aixs belt grinding machine. Draw formulas with time for the belt wear height and the actual grinding depth. The life expectancy of the ceramic abrasive belt is the longest, and its the material removal rate is maximum in Three kinds of belt，and when the belt line speed is 30m/s or so, the material removal rate is maximum.

scholarly journals Influence of different tool polarity on short electric arc machining of GH4169

2019 ◽  
Vol 234 (1-2) ◽  
pp. 108-117 ◽  
Author(s):  
Xiaokang Chen ◽  
Jianping Zhou ◽  
Kedian Wang ◽  
Yan Xu
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electric Arc ◽  
Positive Polarity ◽  
Machining Performance ◽  
Workpiece Surface ◽  
Nickel Based Superalloy

Short electric arc machining is a recently developed high-efficiency electrical discharge machining technology. Material removal rate, tool mass wear ratio ([Formula: see text]), and workpiece surface roughness ( Ra) are important indexes used to evaluate the machining performance of short electric arc machining. In order to obtain better machining effect, the nickel-based superalloy GH4169 is machined by graphite in this article. The influence of voltage, duty cycle, and flushing pressure on short electric arc machining performance is then investigated under different tool polarity conditions. Experimental results show that higher material removal rate and lower [Formula: see text] can be obtained by negative polarity machining, while positive polarity machining can produce better surface quality. To investigate the cause of this difference, the surface integrity of GH4169 machined by different tool polarity is studied from macro and micro perspectives.

Burn threshold of high-carbon steel in high-efficiency deep grinding

2002 ◽  
Vol 216 (3) ◽  
pp. 357-364 ◽  
Author(s):  
T Jin ◽  
D J Stephenson ◽  
J Corbett
Keyword(s):  
Carbon Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
High Carbon Steel ◽  
Numerical Control ◽  
Theoretical Expression ◽  
High Carbon ◽  
Five Axis

The burn-threshold of high-carbon steel (51CrV4) in the high-efficiency deep-grinding (HEDG) process is investigated. It is found that the burn threshold in HEDG is determined by the wheel-workpiece contact length, material removal rate and wheel speed. A theoretical expression for the burn threshold has been derived, which is based on the thermal modelling for deep grinding and takes account of the grinding parameters, wheel conditions, thermal properties of the workpiece and abrasive grain, and the heat convected away by the coolant and chips. The predicted upper and lower boundaries for occurrence of workpiece burn show good agreements with the experimental observations. It is shown that burn threshold in HEDG is related to the film boiling of process coolant and the critical heat flux increases as the specific material removal rate increases. The experiments were carried out on an Edgetek five-axis computer numerical control (CNC) grinding machine, which is capable of HEDG in a relatively wide range of process parameters.

A Material Removal Rate Model Considering Interfacial Micro-Contact Wear Behavior for Chemical Mechanical Polishing

2005 ◽  
Vol 127 (1) ◽  
pp. 190-197 ◽  
Author(s):  
Yeau-Ren Jeng ◽  
Pay-Yau Huang
Keyword(s):  
Material Removal Rate ◽  
Chemical Mechanical Polishing ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Hardness ◽  
Mechanical Polishing ◽  
Wafer Surface ◽  
Rate Model ◽  
Abrasive Particles ◽  
Material Removal Rate Model

Chemical Mechanical Polishing (CMP) is a highly effective technique for planarizing wafer surfaces. Consequently, considerable research has been conducted into its associated material removal mechanisms. The present study proposes a CMP material removal rate model based upon a micro-contact model which considers the effects of the abrasive particles located between the polishing interfaces, thereby the down force applied on the wafer is carried both by the deformation of the polishing pad asperities and by the penetration of the abrasive particles. It is shown that the current theoretical results are in good agreement with the experimental data published previously. In addition to such operational parameters as the applied down force, the present study also considers consumable parameters rarely investigated by previous models based on the Preston equation, including wafer surface hardness, slurry particle size, and slurry concentration. This study also provides physical insights into the interfacial phenomena not discussed by previous models, which ignored the effects of abrasive particles between the polishing interfaces during force balancing.

Quartz Wafer Machining Using MCF (Magnetic Compound Fluid) Polishing Liquid Frozen with Liquid Nitrogen

2008 ◽  
Vol 389-390 ◽  
pp. 187-192
Author(s):  
Yong Bo Wu ◽  
Kunio Shimada
Keyword(s):  
Surface Roughness ◽  
Liquid Nitrogen ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Abrasive Particles ◽  
Water Based ◽  
Quartz Wafer ◽  
Polishing Tool

This paper deals with the machining of quartz wafers using an MCF (Magnetic Compound Fluid) polishing liquid, frozen with liquid nitrogen. This type of polishing liquid is composed of water-based MF (Magnetic Fluid), iron powder, abrasive particle and α-cellulose, and consequently reacting to magnetic fields. Experiments of polishing quartz wafers using the MCF method were carried out on a previously developed apparatus. The results show that an MCF polishing liquid, frozen with liquid nitrogen, has greater material removal capability than one that has not been frozen. A frozen MCF polishing liquid containing larger abrasive particles yields a higher material removal rate, however the surface roughness deteriorates. The highest material removal rate and the best surface roughness were obtained when the percentage of water, in the frozen MCF polishing tool, was 34.7%.

scholarly journals Modeling and Analysis of the Material Removal Rate for Ultrasonic Vibration-assisted Polishing of Optical Glass BK7

2021 ◽  
Author(s):  
Yingdong Liang ◽  
Chao Zhang ◽  
Xin Chen ◽  
Tianqi Zhang ◽  
Tianbiao Yu ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Optical Glass ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Abrasive Particles ◽  
Material Removal Model

Abstract The emergence of ultrasonic vibration-assisted polishing technology has effectively improved the machining accuracy and efficiency of hard and brittle materials in modern optical industry, however, the material removal mechanism of ultrasonic vibration-assisted polishing (UVAP) still needs to be further revealed. This paper focuses on the material removal mechanism of ultrasonic vibration-assisted polishing of optical glass (BK7), the application of ultrasonic vibration to axial vibration and the atomization of polishing slurry, the material removal model was established. Based on the analysis of the relationship between the nominal distance d of the polishing pad and the actual contact area distribution, the prediction of the material removal profile is realized. In addition, the effects of different parameters on the material removal rate (MRR) were analyzed, including polishing force, spindle speed, abrasive particle size, ultrasonic amplitude, feed rate, and flow-rate of polishing slurry. Based on the motion equation of abrasive particles, the trajectory of abrasive particles in the polishing slurry was simulated, and the simulation results show that the introduction of the ultrasonic vibration field changes the motion state and trajectory of embedded and free abrasive particles. The new model can not only qualitatively analyze the influence of different process parameters on MRR, but also predict the material removal depth and MRR, providing a possibility for deterministic material removal and a theoretical basis for subsequent polishing of complex curved surfaces of optical glass.

Effect of rotation direction, traverse speed, and abrasive type during the hydroabrasive disintegration of a rotating Ti6Al4V workpiece

2020 ◽  
pp. 095440542097122
Author(s):  
Petr Hlavacek ◽  
Sergej Hloch ◽  
Akash Nag ◽  
Jana Petru ◽  
Miroslav Muller ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Traverse Speed ◽  
Machining Parameters ◽  
Abrasive Particles ◽  
Rotation Direction ◽  
Cartesian Coordinate ◽  
The Right

In this study, a new methodology is considered for determining the rotational senses (clockwise or anti-clockwise) of a workpiece during the hydroabrasive disintegration of rotating samples. The rotational directions are taken with respect to the position of the abrasive jet, that is, keeping it on the right side of the rotating workpiece when viewed from the free end in the cartesian coordinate system. Measurements were carried out for diameter deviation, material removal rate and surface roughness as a response to machining parameters such as traverse speed, workpiece rotation direction and abrasive grain. Final diameter of the workpiece (10.28–14.12 mm), material removal rate (1154–3936 mm3/min) and surface roughness (6.65–25.43 µm) values increase with increasing value of traverse speed (5–25 mm/min) using anti-clockwise rotation with Australian garnet abrasive grains. ANOVA analysis of the responses shows that traverse speed ( p = 0.000) is a statistically significant parameter for predicting all the machining responses. Abrasive type and rotational direction were statistically significant for determining diameter deviation ( p = 0.017, 0.006) and material removal rate ( p = 0.000, 0.000) but insignificant for surface roughness ( p = 0.373, 0.367). Scanning electron microscopy provided information on the surface morphology, depicting the characteristics of the disintegrated surface. Disintegrated features, like peak and valley formations, craters, holes, cutting traces and embedded abrasive particles on the surface were observed.

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