Advanced Materials Research Vol. 1017

Abstract: Form accuracy and smooth surface is required in precision grinding. And the form accuracy and surface roughness are improved year by year. However, the more the surface roughness becomes smooth, the more the grinding marks become remarkable. The grinding mark deteriorates the uniformity of ground surface. In this study, relationship between the uniformity of non-axisymmetric aspherical ground surface and grinding condition is analyzed theoretically. As a result, it is found that there are optimum grinding conditions.

Abstract: The relationship between heat treatment processes and grinding performance of cold die steel 9Mn2V had been built in this paper. Serious meshy segregation of carbide, excessive amounts of retained austenite, coarse and inhomogeneous distribution of material structure were significant causes of grinding burn and grinding crack. In order to improve the abrasion-resistance and mechanical properties of workpiece material, cryogenic and tempering treatment were added. Disappear of meshy segregation of carbide, network carbide was within second grade, retained austenite content was within 4%, martensite became much more fine and homogeneous, all of these advantages could be obtained by adopting cryogenic and tempering treatment in twice. The grinding experiment results indicated that workpiece material 9Mn2V which using this process could provide superior grinding performance.

Abstract: In the present research work, a new precision sawing technique is proposed, by which the ceramic workpiece is ultrasonically vibrated along the blade radial direction during the sawing operation using a diamond blade. In this study, experiments are conducted to study the sawing force characters of ultrasonic vibration-assisted sawing (UVAS) and conventional sawing (CS). The influences of the sawing parameters on the sawing force and force ratio are investigated. The results show that the sawing force in UVAS is smaller than those in CS. It was found that applying ultrasonic vibration to the sawing operation decreased the normal sawing force 18%-38% and tangential sawing force by 10%-25%. The force ratio in UVAS is lower than that in CS, which reveals that diamonds are easier to cut into the ceramic workpiece and the material machinability is improved.

Abstract: To reduce the environmental impact of abrasive polishing, we have investigated using a compact robot and fixed-abrasive polishing. We look at a five-joint closed-link compact robot with a fine diamond stone on its main axis to polish a glass plate. In this method, we measured the chatter vibration in glass polishing motion due to the low stiffness of the robot arm. Therefore, we estimated a dynamic characteristic of the robot arm by a hammering test and measured the friction coefficient between the glass plate and the abrasive stone. From these results, we attempted a novel polishing method to prevent its self-vibration using micro-oscillating pressing force with a voice coil motor. As a result, the proposed method of polishing a glass plate with a compact robot and a fine diamond stone was found to be effective.

Abstract: This study was performed to develop a non-destructive inspection system to detect grinding burn, which is capable of quantitative 100% inspection inside a production line. An eddy current sensor, which has advantages of short inspection time and low cost, was used. It was shown that the grinding burn detection technique had been developed and is possible to detect grinding burn by using this technique, in the 1st report¹⁾ and the 2nd report²⁾. In this report, an experiment of in-process detection of grinding burn was conducted, by applying the grinding burn detection technique which we have developed. The eddy current sensor has been combined with an in-process gauge in order to keep the clearance between the sensor probe and the work piece constant. It was shown that grinding burn can be detected successfully during cylindrical machining.

Abstract: Engineers and designers constantly strive to design machines that have high life cycle, can run faster, and can manufacture products having higher geometrical accuracy. However, manufacturing processes often produce parts with surfaces that are unsatisfactory from the viewpoint of geometrical precision or quality of surface texture. In general, electronic, optical, and tactual methods are used for exploring and evaluating the surface texture and the surface geometry. With the advancements in the reverse engineering technology, computer based numerical analysis of the data obtained from 3D imaging devices, referred to as registration, has also emerged as a tool for shape inspection. Registration expedites shape inspection by augmenting the process of error measurement. The existing registration methods suffer from problems that limit the extensive use of the existing approaches, thereby making them application specific. In this research, we propose a novel approach for reducing the number of data points used for registration without compromising with registration accuracy. We propose a segmentation based registration approach that utilizes the features extracted from the models, thus reducing the data size. The registered data sets can be compared to each other for evaluating the differences in shape. The difference information can further be used to appropriately modify the manufacturing process parameters for obtaining highly accurate products.

Abstract: The dry sliding wear behaviour of the full pearlite in a novel bimetal consisting of low carbon steel and hypoeutectoid steel has been studied by means of pin-on-disc type wear tests at room temperature. Thermomechanical treatments were performed on the bimetallic samples to obtain different interlamellar spacings. It was found that interlamellar spacing decreased with an increase in plastic strain to a great extent initially and followed by a lower extent of decrease. This decrease not only increases the hardness and strain hardening capacity of the fully pearlitic microstructure, but also is in favor of stabilizing the friction coefficient during sliding process. The observations of wear tracks show that delamination dominated the wear process when interlamellar spacing is higher than 200 nm, while pronounced oxidational wear occurred with interlamellar spacing below 200 nm.

Abstract: In order to cope with various problems associated with machining of PCD, development of a new PCD possessing excellent tool properties and good machinability at the same time has been demanded. From this point of view, the authors have developed a new PCD, “EC-PCD (Electrically Conductive PCD)”, composed of boron doped diamond particles in place of the standard non-conductive diamond. In this research, investigation into material properties of the newly developed EC-PCD is made. Through the tests, it was found that the boron doped diamond particles (the source material of the new PCD) had an electrical resistivity of 1.6×10^-4Ω·m and the thermal conductivity after sintering was lower than that of the standard PCD. In addition, it was confirmed that the electrical conductivity of the source diamond particles of the EC-PCD had not been lost even under the condition of high temperature and high pressure during the manufacture. As a result of the heat test, EC-PCD’s high resistance to oxidation at high temperatures was confirmed showing no changes in the surface condition even at 675oC while the surface of the S-PCD was largely changed at the same temperature. One of the reasons for this is guessed to be that EC-PCD is hard to react with the cobalt contained as a catalyst metal. Further, it was found in the friction tests using a steel ball that the friction coefficient of the EC-PCD was 50% higher than that of S-PCD at the room temperature though it dropped by 10-30% at the temperature of 80oC.

Abstract: The authors developed “Dynamic Friction Polishing (DF polishing) Method” utilizing a thermochemical reaction between a diamond workpiece and a metal. This method enables high efficiency abrasive-free polishing of single crystal and polycrystalline diamonds (PCD) by simply pressing them against a stainless steel (SUS304) disc rotating at a high peripheral speed (V_S>2500m/min). In the authors’ previous paper, a top of the diamond test piece (0.6mm×0.6mm, (100) plane) was removed at a rate of 2.6mm/min (0.94mm³/min) under the polishing condition of sliding speed V_S=4000m/min, loading pressure P=130MPa and polishing time t=10s. A bottleneck for practical use of this method is a high pressure over 100MPa required for pressing a diamond workpiece against a rotating stainless steel disc. In this paper, a high efficiency tool was manufactured by electro-spark deposition of highly reactive special metals on a base disc tool. Among various reactive metals Nb and W brought very high efficiency in the polishing of a single crystal diamond.

Abstract: Three-dimensional surface roughness parameters are widely applied to characterize frictional and lubricating properties, corrosion resistance, fatigue strength of surfaces. Among them, the functional parameters of surface roughness, such as S_bi, S_ci, and S_vi, are used to evaluate bearing and fluid retention properties of surfaces. In this study, the effects of grinding parameters, including wheel linear speed (V_s), workpiece linear speed (V_w), grinding depth (a_p), longitudinal feed rate (f_a), and dressing rate (F), on functional parameters were studied in grinding of cast iron. An artificial neural network (ANN) model was developed for predicting the functional parameters of three-dimensional surface roughness. The inputs of the ANN models were grinding parameters (V_s, V_w, a_p, f_a, F), and the output parameters of the models were functional parameters of surface roughness (S_bi, S_ci, S_vi). With small errors (e.g MSE = 0.09%, 0.61%, and 0.0014%. ), the ANN-based models are considered sufficiently accurate to predict functional parameters of surface roughness in grinding of cast iron.