scholarly journals Experimental Analysis of a Grinding Wheel by Increasing Multiple Passes in Dressing

2020 ◽  
pp. 203-210
Author(s):  
Mohammed Abdul Kadar ◽  
Elanchezhian J ◽  
Kalaimagal S
Keyword(s):  
Water Jet ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cutting Condition ◽  
Abrasive Particles ◽  
Dressing Tool ◽  
Cutting Surface ◽  
Optimum Cutting ◽  
Conventional Machine ◽  
Number Of Passes

When sharpness of grinding wheel becomes dull, a dressing is an operation performed because of glazing and loading, dulled grains and chips are removed (crushed or fallen) with a proper dressing tool to make sharp cutting edges and simultaneously, make recesses for chips by properly extruding to grain cutting edges. The basic dressing operation consists of removal of grains and swarfloaded, generation and exposure of the new cutting edges on the cutting surface of the grinding wheel. The former is obtained by digging out the swarf and the latter is achieved by fracturing the existing abrasive grains and allowing desired protrusion of abrasive particles on the cutting surface. Both of the above operations are carried out using a diamond dresser (3 carat). A part of this work focuses on finding the optimum dressing parameters (depth of cut of the dresser and the number of passes) which gives optimum cutting condition for grinding using conventional method of grinding using diamond dresser, Water Jet Machine and Abrasive Water Jet Machine. The trial run on the conventional machine with different parameters was performed. The results obtained prove the possibility of using directly in the industrial practices.

Dry Machining of Brass Using Titanium Carbonitride (TiCN) Coated Tool

2013 ◽  
Vol 372 ◽  
pp. 495-500
Author(s):  
Tasnim Firdaus Ariff ◽  
Mohd Syahidan Kamarudin ◽  
Mohd Amiruddin Haron
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Cutting Parameters ◽  
Titanium Carbonitride ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Machining ◽  
Wear Rates ◽  
Optimum Cutting ◽  
The Cost

Dry machining is environmentally friendly, clean and safe to be performed. Regardless of decreasing tool life due to lack of lubricants, choosing dry machining over wet machining may be a wiser choice since the cost of purchasing and disposing the cutting fluids can contribute to a higher cost. Wear rates, tool wear intensities and material removal rates (MRR) of TiCN coated tools using both dry and traditional wet machining on brass were studied with the aim in finding the optimum cutting condition from four different cutting speeds (207, 279, 372 and 498 m/min) with two sets of cutting parameters; depth of cut and feed rate (d = 0.1 mm, f = 0.2 mm/rev and d = 0.2 mm, f = 0.4 mm/rev). Temperatures at the tool-chip interface were measured to analyze the effects of temperature rise during dry machining. Cost analysis on machining cost per piece between dry and wet machining was performed. The optimum cutting condition for wet and dry machining of brass using TiCN coated cutting tool was found to be 498 m/min at d = 0.2 mm, f = 0.4 mm/rev. The tool tip temperature obtained from dry machining did not influence tool wear since the temperature rise is quite similar to the wet machining temperatures. The machining for the dry machining reduced to about 25-76% per piece when compared with wet machining.

Study on the Cutting Properties of the Singer Layer Metal Bonded cBN Grinding Wheel by Electroplating in Grinding of Heat-Treated Steel SKD11

2019 ◽  
Vol 889 ◽  
pp. 80-86
Author(s):  
Truong Hoanh Son ◽  
Tran Thi Van Nga
Keyword(s):  
Depth Of Cut ◽  
Grinding Wheel ◽  
Wheel Surface ◽  
Abrasive Particles ◽  
Sem Image ◽  
Grinding Ratio ◽  
Heat Treated ◽  
Two Factors ◽  
Cbn Grinding Wheel ◽  
Heat Treated Steel

This article presents preliminary investigations on the cutting ability of the singer layer metal-bonded cBN grinding wheel manufactured by electroplating method at Vietnamese laboratory. The cutting ability of the grinding wheel is evaluated by two factors: grinding ratio G and surface roughness of workpiece. These results are compared to those of the Japanese grinding wheels. The experimental results showed that the fabricated cBN grinding wheel has good cutting ability with high grinding ratio G. The value of the grinding ratio was 600 to 1800 in the grinding process of SKD11 steel (hardness of 62-63HRC) at the grinding speed V of 12.56m/s, feed rate S of 300mm/min, depth of cut t of 0.01mm. The maximum grinding ratio (1800) is equivalent to the average grinding ratio of the Japanese grinding wheel. The grinding ratio is also maintained up to 26 cutting hours. The good grinding surface was achieved with the average Ra of 2.5μm. In addition, the bonding of cBN abrasive to the wheel body was observed with scanning electron microscope (SEM) of the surface of grinding wheel after the cutting process. The SEM image shown that the cBN abrasive particles were not removed from the wheel surface.

Titanium Alloy Milling Using Abrasive Water Jet for Repair Application: Modifications in Surface Quality and Material Integrity Following Plain Water Jet Cleaning

2021 ◽  
Vol 1016 ◽  
pp. 1374-1380
Author(s):  
Xavier Sourd ◽  
Mehdi Salem ◽  
Redouane Zitoune ◽  
Akshay Hejjaji ◽  
Damien Lamouche
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
Surface Hardness ◽  
Water Jet ◽  
Depth Of Cut ◽  
Plain Water ◽  
Abrasive Water Jet ◽  
Abrasive Particles ◽  
Versatile Technique ◽  
Titanium Alloy Ti6al4v

Abrasive Water Jet (AWJ) machining has proven to be an effective and versatile technique for milling various kinds of materials, even with low machinability such as aerospace grade titanium alloy Ti6Al4V. Many studies have been performed in order to master this technology and produce geometrically accurate shapes. However, in the context of bonding repairs which require surfaces free from foreign bodies, AWJ machining presents a significant drawback in form of abrasive grit embedment. The goal of this present work is then to investigate the effect of a post-AWJ machining cleaning operation using Plain Water Jet process (PWJ – i.e. without abrasive particles) on the surface quality and material properties. For this, several characterization techniques were employed. It was concluded that the contamination has been reduced by 65% without noticeable changes in depth of cut and crater volume. The AWJ milling operation produced surface and subsurface hardening as well as biaxial compressive residual stress, mostly piloted by the jet pressure. PWJ cleaning reduced the depth of hardening without clear modification in surface hardness.

Optimization of Cutting Conditions for Multi-Pass Operations Considering Probabilistic Nature in Machining Processes

1977 ◽  
Vol 99 (1) ◽  
pp. 210-217 ◽  
Author(s):  
K. Iwata ◽  
Y. Murotsu ◽  
F. Oba
Keyword(s):  
Dynamic Programming ◽  
Stochastic Programming ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Optimum Cutting ◽  
The Cost ◽  
Probabilistic Nature ◽  
Number Of Passes

This paper deals with the problem of optimizing the number of passes required together with the cutting speed, the feed, and the depth of cut at each pass for a given total depth of cut to be removed from a workpiece, considering both the probabilistic nature of the objective function and the constraints in the machining processes. Applying the concept of dynamic programming and stochastic programming, the problem is formulated in an analytically tractable form and a new algorithm is developed for determining the optimum value of the cutting speed, feed, depth of cut, and number of passes, simultaneously. For illustration, a typical example is solved to obtain the cost-minimizing cutting conditions in a turning operation, and the effect on the optimum cutting conditions of the various factors such as total depth of cut, uncertainty of the tool life, and constraints are discussed.

Evaluation and investigation of grinding process of biomedical polymer (PEEK)

2021 ◽  
pp. 095440892110225
Author(s):  
Mohammad Khoran ◽  
Bahman Azarhoushang ◽  
Hossein Amirabadi
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Speed Ratio ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cutting Condition ◽  
Grinding Process ◽  
Wheel Topography ◽  
Overlap Ratio

Polyether ether ketone (PEEK) has been widely used in the medical engineering due to its high strength to weight ratio, creep and wear-resistance, and anti-allergically properties. Grinding is generally used to produce PEEK parts with high accuracy and surface quality requirements. In this research, the tool loading and the effect of cryogenic cooling in the grinding of PEEK are studied for the first time. It is shown that the generated heat in the grinding process, which is mainly influenced by the tool micro-topography, process parameter, and coolant lubricant has an important role in the surface integrity of PEEK. Additionally, the influence of specific material removal rate and the dressing speed ratio on the specific grinding energy of PEEK was studied. The input parameters of the grinding process that are investigated in this study include cutting speed (vs), depth of cut (ae), and feed rate (vft). To investigate the grinding wheel topography, the effects of dressing overlap ratio (Ud) and the dressing speed ratio (qd) were also investigated. Grinding force, surface roughness, and loading of the grinding wheel were considered as output parameters. The experiments were designed based on response surface methodology and the optimum cutting condition was obtained based on this method. The depth of cut and the dressing overlap ratio had respectively the maximum and minimum impact on the surface roughness and cutting forces. Additionally, the tool loading was mainly influenced by the cutting speed.

Influence of Solid Contaminants in Metal Working Fluids on the Grinding Process

2013 ◽  
Vol 769 ◽  
pp. 61-68 ◽  
Author(s):  
Björn Beekhuis
Keyword(s):  
Machine Tool ◽  
Surface Quality ◽  
Solid Particles ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Metal Working ◽  
Machined Surface ◽  
Working Fluids ◽  
Abrasive Particles

Metal working fluids (MWF) are widely used in grinding processes to lubricate and to remove the heat and chips from the contact zone. Apart from the chips, abrasive particles from the worn grinding wheel contaminate the metalworking fluid. The solid contaminants, in particular the abrasive particles crumbled from the grinding wheel, are believed to cause several negative effects like for example damaging the guideways of the machine tool. Furthermore, it is assumed that a pronounced interaction of the solid particles and the machined surface will decrease the achievable surface quality of the ground surfaces. Cleaning units are employed within the fluid circuit to prevent failure of the machine tool and to ensure the desired surface quality. The economic efficiency of such cleaning plants cleaning plants depends strongly on the choice of the grade of filtration (the particle size which has to be retained). A grade of filtration which exceeds the actual needs of the machining process adds unnecessary costs for operating the cleaning unit. To enable cost efficient design of filtration units the interaction between solid contaminants and the machining process has to be understood. The results of grinding experiments (face grinding of workpieces made of AISI 52100) confirm a significant increase of the surface waviness when corundum particles are added to the MWF. The underlying effect is an extraordinary tool wear combined with a locally varying effective depth of cut. The excess particles block the pores of the grinding wheel and are transported into the grinding gap. An increasing ratio of the size of solid contaminants and the size of the bonded grains on the wheel accelerates the wear of the tool.

Forces during Grinding Operation and its Relation to the Dressing Cycle

2016 ◽  
Vol 1136 ◽  
pp. 78-83
Author(s):  
Anand Nambiar ◽  
Kou Matsumoto ◽  
Masaru Yamamoto ◽  
Kazuhito Ohashi ◽  
Shinya Tsukamoto
Keyword(s):  
Tangential Force ◽  
Dimensional Accuracy ◽  
Force Sensor ◽  
Grinding Wheel ◽  
Cutting Condition ◽  
Grinding Forces ◽  
Abrasive Particles ◽  
Force Variation ◽  
Grinding Machines ◽  
Force Components

While grinding with CNC cylindrical grinding machines, there are many factors that determine the precision and accuracy of the finished product. These may include dimensional accuracy, surface roughness, circularity (roundness), cylindricity, etc. But all these factors pertain to the work. The condition of the tool, in this case, the cutting edges of the grinding wheel, also greatly influence the profile and precision of the work. So, in order to maintain the precision of the work, there is a need to repeatedly and regularly maintain the cutting edges in a good cutting condition, by the process of dressing. In other words, when the swarf gets adhered to the grinding wheel, the abrasive particles can no longer perform machining with the same efficiency, due to increase in contact surface area between the abrasive particles and the work. This dissertation describes a technique that can be adopted to continuously monitor the grinding forces generated during the grinding operation, by using an in-process 2-dimensional piezoelectric force sensor, which can simultaneously measure the force and break it down into its two force components. The force sensor not only calculates the force generated, but also quantifies the force variation. By analyzing the variation in the radial and tangential force components individually, and by conducting Fourier analysis on the observed data, it is found that deterioration of the grinding wheel and the dress pattern can be continuously monitored and controlled.

OPTIMUM FLANK WEAR OF TiAlN-COATED TOOL: TOWARD PRODUCTIVE ROUGH CUTTING OF INCONEL 625

2019 ◽  
Vol 26 (08) ◽  
pp. 1850230
Author(s):  
A. AKHAVAN FARID ◽  
MOHAMMAD LOTFI ◽  
M. JAHANBAKHSH
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Optimum Cutting

Long tool life and high material removal rate (MRR) are the two essential requirements in rough cutting of materials. The rapid rate of the flank wear propagation in machining of nickel-based superalloys has induced the utilization of low cutting parameters when the goal was set to maximize the tool life based on the machining time or cutting length. However, this method may not provide an effective rate for the material being cut. This work presents two mathematical models to find the optimum cutting parameters results for the minimum flank wear and maximum MRR. Experimental tests were carried out based on the central composite design (CCD) in rough cutting of Inconel 625 by using TiAlN-coated insert. Maximum flank wear was measured to determine the tool wear propagation. The wear mechanisms which contribute in the tool wear were analyzed by using scanning electron microscope (SEM) to evaluate the effects of cutting parameters on the flank wear propagation. The results showed that cutting speed and depth of cut had the most significant effect on the tool wear. However, optimum cutting condition was achieved by reducing the cutting speed when feed rate and depth of cut maintained at the highest level. This was associated to the interaction of cutting speed and depth of cut, and predominant of abrasion and notching at their highest levels, respectively.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

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.

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