Papers by Author: Niklas Kramer

Abstract: In this paper the geometry of the grinding wheel effective topography is analyzed. Existing and newly developed abrasive grain geometry models are investigated. Further, different abrasive distribution systems are developed and the grinding wheel surface is generated. The 3D stereomicroscopy at the Scanning Electron Microscope offers the opportunity to measure a three-dimensional profile of the grinding wheel. Hence, the investigations of the real grinding wheel surface can be used as a verification of the developed surface model. Abbott-Firestone-Curves are used as a comparison of the model based topography and the real grinding wheel surface. The variation of the grain geometry and distribution offers the opportunity to adapt the simulation to the grinding wheel specification.

Abstract: When grinding material compounds, different material properties cause significantly changed cutting conditions. Grinding forces, wheel wear and wear mechanisms as well as temperature load of the system differ due to these changes in mechanism, leading to deviant surface qualities and geometrical errors. If consistent quality at the compound’s transition from one material into the other is needed, these errors need to be compensated. In this paper geometry error sources are evaluated by comparing error cause models to experimental results.

Abstract: In modern grinding processes the field of application for vitrified bonded wheels is constantly increasing. Regarding the grinding itself, the advantages of these wheels are obvious. But their ability to be dressed offers further benefits as well. Usually in-machine dressing is favorable. Nevertheless, in-machine dressing causes non-productive-times during which no part production is possible. To reduce this disadvantage, a powerful monitoring is needed in order to minimize the number of needed dressing strokes and to verify the created grinding wheel geometry. The approach applicable for industry is to use an acoustic emission sensor for monitoring, which is usually integrated in modern grinding machines to minimize the air grinding time. This article also provides basic knowledge about Acoustic Emission.

Abstract: Eco-efficiency of manufacturing processes is increasingly important. Here grinding is supposed to be unfavorable because of the need for coolant and a high energy consumption per removed material volume. Nevertheless, it can be not be substituted by an alternative process due to the superior quality of ground parts. The overall eco-efficiency of grinding can be improved by different approaches. A better understanding of grinding processes and a modified setup of the process chain minimizes the material to be removed by grinding. Design changes of the machine tool can significantly reduce the energy consumption of additional devices as coolant supply units without a loss of flexibility. Adapted process parameters increase eco-efficiency and can also improve cost effectiveness while maintaining part quality.