Papers by Keyword: Grinding

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Authors: Stefan Mihić, Sorin Cioc, Ioan Marinescu, Michael C. Weismiller
Abstract: Fluids have an important role in grinding. Correct fluid application results in enhanced process stability, better work piece quality, and tool life. This paper shows that Computational Fluid Dynamics (CFD) models can be used to simulate the fluid flow and heat transfer in a grinding process, replacing numerous experiments that are expensive, time-consuming, and have limited capabilities. The most important properties of created 3-D model are described, along with results obtained. The results show very detailed distributions of temperatures, pressures, and flow rates in and around the grinding region. The data obtained is essential in studying the influence of the grinding fluid on the grinding process, as well as in determining the best fluid composition and supply parameters for a given application. The results agree well with experimental global flow rates and temperature values and show the feasibility of 3-D CFD-based simulations in grinding applications. The parametric studies of influence of several fluid physical properties on useful flow rates and temperatures were presented as well.
Authors: Zhi Qiang Liang, Hong Chao Jian, Xi Bin Wang, Wen Xiang Zhao, Su Yan Zhang, Yusuke Otani, Si Yi Xue
Abstract: Micro-drilling become more widely used from precision mechanics to electronics. Nowadays, the main commercial tools are planar point micro-drills. However, that geometry often causes a high thrust force, high temperature, and rapid wear during micro-drilling. Furthermore, it is difficult to adjust the four flank surfaces to accurately intersect at one point, particularly when the drill diameter becomes smaller. To solve this problem, non-coaxial helical drills points have been proposed by some researchers, and is characterized by a continuous helical flank instead of the piecewise planar flank. Its drilling performance is improved compared with planar drill point. This study presents a 5-axis coordinated CNC grinding method of the non-coaxial helical drill flank. Mathematical models of the drill flank and its engagement line between cylinder grinding wheel and drill tool are established, and then the path of the grinding wheel with respect to the drill tool is obtained. In order to verify the availability of the proposed methods, three dimension (3D) grinding simulation of non-coaxial helical drills with diameter 0.5mm was carried out using the CAD software, and then were fabricated on a 6-axis Makino CNC tool grinder. The ground micro-drills examined by 3D laser scanning microscope show good identity with the simulated result. These indicate that the manufacturing model presented in this paper provides a practical and efficient method to grind the flank of a non-coaxial helical micro-drill.
Authors: Zhan Qiang Liu, Xing Ai, Zhao Hui Wang
Abstract: This paper presents a comparison study of surface hardening by grinding versus machining. The technological, economical and ecological merits of machining hardening and grind-hardening process for steels are described. The mechanisms of machining hardening and grind-hardening of steels are investigated and compared. The phase transformation, plastic deformation and white layer generation are the principal factors contributing to the hardened surface layer by machining and grinding. The influences of the process parameters on the penetrated hardness are given for both grind-hardening and machining hardening operations. The future development trends of the grind-hardening and machining hardening are also presented.
Authors: Jing Liang Jiang, Pei Qi Ge, Ying Zhang, De Xiang Wang
Abstract: For the purpose of obtaining mathematical force model in grinding process, the contacting grain numbers and the single grain forces should be taken into considered. In this paper, a mathematical model was established for single grain forces calculation. A Matlab program is edited and the calculation results were obtained and discussed. In the work of this paper, only plowing and cutting forces were take into considered because that the sliding forces were proved to be neglected based on Hertz contact theory. Because of different micro-interacting mechanisms of plowing and cutting grains with workpiece material, different force models were developed separately.
Authors: Jun Zhao, Ji Zhao, Lei Zhang, Cheng Fan, Fei Fei Han
Abstract: Getting the real-time information of spatial data, height and length of weld bead is the key point during the process of grinding and polishing large-scale part. To tackle this problem, a robot visual system is completed by building the double CCD and the laser on the mobile robot. Combining the image search algorithm with the image preprocessing algorithm in time domain, the laser single pixel feature line is obtained. The positions of each point in feature line are optimized by curve fitting so that the right spatial data and dimension are obtained. The result shows the proposed method can provides the precise information of weld bead, and the accuracy of measurement is within 0.15mm, as steady as repeatability.
Authors: Lei Zhang, Michael N. Morgan
Abstract: The grinding process has particular interest in that contact temperatures have great significance for quality and integrity of machined surfaces. Hardened surfaces may be damaged by softening and or being stressed, being hardened or re-hardened, burned or cracked. It is important in grinding for the fluid to remove heat from the grinding contact zone to avoid thermal damage to the workpiece surface and/or sub-surface layers. The cooling effect of grinding fluid can be quantified by the convective heat transfer coefficient (CHTC) acting in the grinding zone. This paper presents values of the CHTC based on measured grinding temperatures. The paper also presents a new convective heat transfer model based on principles of applied fluid dynamics and heat transfer. Predicted values for the CHTC calculated from the model are compared with results from experiment obtained under a range of grinding conditions and with experimental data. The results demonstrate that the new CHTC model improves the accuracy of prediction and helps explain the variation in the value of CHTC under varying process conditions. Results also show that convection efficiency strongly depends on the grinding wheel speed, grinding arc length and fluid properties.
Authors: Stepan Jermolajev, Ekkard Brinksmeier
Abstract: This paper presents a diagram of maximum contact zone temperature Tmax versus contact time Δt, based on the analysis of workpiece surface layer properties after cylindrical grinding experiments. Apart from resulting surface layer properties, process quantities (Tmax, normal and tangential grinding forces Fn, Ft) are investigated with reference to the resulting workpiece surface layer state as well. Ground workpieces are analyzed by performing Barkhausen noise level measurements together with subsequent metallographic and X-ray diffraction investigations. By mapping characteristic values Tmax and the contact time Δt to corresponding surface layer properties, a general analysis of workpiece material response to the thermo-mechanical load during grinding is possible.
Authors: Sridhar Kompella, Kai Zhang, Rajeev Pakalapati
Abstract: The use of cubic boron nitride (CBN) over conventional abrasives in ferrous and superalloy grinding has resulted in improved manufacturing throughput and beneficial mechanical properties on workpiece surfaces. However, through the innovative use of crystal synthesis techniques, the grinding performance can be further improved over existing CBN crystals. In this study, such a new CBN crystal is developed, characterized, and its grinding performance is compared to a commercially available CBN crystal. Grinding tests are conducted in AISI M2 steel and Inconel-718 superalloy using a vitrified bond configuration with applicability in a wide range of end-use applications.
Authors: Kiyoshi Suzuki, Manabu Iwai, Shinichi Ninomiya, Keizo Takeuchi, Katsutoshi Tanaka, Y. Tanaka, Tetsutaro Uematsu
Abstract: Electrically conductive cutting edges diamond grinding wheels (EC-cutting edges D wheels) have properties such as, 1) convenient precise forming by EDM, 2) realization of high cutting edge density, 3) sufficiently large chip pockets along with fine cutting edges on large diamond grits, 4) contact sensing of the cutting edges with workpiece due to electrical conductivity, 5) expected application to the grinding of various types of steels due to high thermal resistance. Until now, the grinding ability of the sharp edges generated on the electrically conductive CVD diamond thick film wheel by electrodischarge trueing (ED trueing) was confirmed by grinding experiments using a small diameter lapping wheel and a small diameter disk wheel. In this research work, metal bonded diamond wheels containing boron doped electrically conductive diamond (EC diamond) grits, which possess high oxidation temperature, were trial manufactured. From the results of grinding test for an optical glass (BK7), it was found that the wear and grinding force for the EC diamond grits wheel were significantly low compared to a conventional diamond grits wheel. Furthermore, from the results of the investigation on ED trueing performance, a high trueing efficiency along with the possibility of cutting edge tip formation was confirmed.
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