Determination of a Dynamic Grinding Model

1997 ◽  
Vol 119 (2) ◽  
pp. 289-293 ◽  
Author(s):  
H. E. Jenkins ◽  
T. R. Kurfess ◽  
S. J. Ludwick
Keyword(s):  
Material Removal ◽  
Process Model ◽  
Normal Force ◽  
Removal Rate ◽  
Control Process ◽  
Power Input ◽  
Grinding Process ◽  
Abrasive Machining ◽  
Dimensional Precision

In precision abrasive machining, it is important to control process variables such as the material removal rate, normal force and power input, as these factors influence surface finish, dimensional precision, and material damage. In this research, a linear grinding process model, with enhancements over past models, is developed relating normal force to material removal rates. Two experimental procedures for the determination of the grinding model’s parameters are presented. Simulations are performed to validate the grinding model. The determined model is found to be a valid representation of the grinding process that should prove useful in adaptive control with real-time parameter estimation.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Non-Contact Ultrasonic Abrasive Machining of Wire-Electrical Discharge Machined SUS304 Steel

2017 ◽  
Author(s):  
K. L. Tan ◽  
S. H. Yeo
Keyword(s):  
Material Removal ◽  
Cavitation Erosion ◽  
Removal Rate ◽  
Recast Layer ◽  
Ultrasonic Machining ◽  
Abrasive Machining ◽  
Efficient Removal ◽  
Abrasive Particles ◽  
The Poor ◽  
Lower Material

Non-contact ultrasonic abrasive machining (NUAM) is a variant of ultrasonic machining (USM). In NUAM, material is removed predominantly by cavitation erosion in abrasive slurry. Due to a significantly lower material removal rate than traditional USM, NUAM is investigated for its applicability on surface modification and finishing in this study. Experiments were conducted on SUS304 steel samples machined by wire electrical discharged machining (WEDM). Due to the thermal spark phenomenon during WEDM, a thermal recast layer, of thickness approximately 15 μm, is often left over on the specimen’s surface after the process. The undesired thermal recast layer contributes to the poor surface integrity of specimens. A NUAM system was configured using a 40 kHz ultrasonic system. Ultrasonic vibration amplitude of 70 μm at the horn tip was used to generate cavitation bubbles in the abrasive slurry. NUAM was found to be effective in removing the unstable thermal recast layers by means of cavitation erosion. As a result, the average surface roughness, Ra, of the specimens improved from approximately 2.5 μm to ∼1.7 μm after 20 minutes of processing time. Furthermore, the addition of abrasive particles was observed to aid in more efficient removal of thermal recast layers than a pure cavitation condition.

Investigation of Grinding Force and Surface Integrity of IC10 in Creep Feed Grinding

2020 ◽  
Author(s):  
Jun-chen Li ◽  
Wen-hu Wang ◽  
Rui-song Jiang ◽  
Xiao-fen Liu ◽  
Huang Bo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal ◽  
Normal Force ◽  
Removal Rate ◽  
Tangential Force ◽  
Grinding Force ◽  
Wheel Speed ◽  
Creep Feed Grinding ◽  
Creep Feed

Abstract The IC10 superalloy material is one of the most important materials for aero-engine turbine blade due to its excellent performances. However, it is difficult to be machined because of its special properties such as terrible tool wear and low machined efficiency. The creep feed grinding is widely used in machining IC10 superalloy due to the advance in reducing tool wear, improving material removal rate and surface quality. The creep feed grinding is a promising machining process with the advantages of high material removal rate due to large cutting depth, long cutting arc and very slow workpiece, and its predominant features might have significant influence on the grinding force and surface quality for the workpiece. Hence, it is of great importance to study the grinding force and surface integrity in creep feed grinding IC10 superalloy. In this paper, a series of orthogonal experiments have been carried out and the effects of grinding parameters on the grinding force and the surface roughness are analyzed. The topographies and defects of the machined surface were observed and analyzed using SEM. The results of the experiments show that the tangential force is decreased with the workpiece speed increasing. However, there is no significant change in tangential force with the increasing of grinding depth and wheel speed. The normal force is decreased with the workpiece speed increasing when the workpiece speed is less than 150 mm/min, but when the workpiece speed is more than 150 mm/min the normal force is increased tardily. Moreover, the normal force is increased sharply with the increase of grinding depth and is increased slowly with the increase of wheel speed. In general, the surface roughness is increased with workpiece speed and grinding depth increasing, while the trend of increase corresponding that of workpiece speed is more evident. The value of the surface roughness is decreased with wheel speed increasing. And it is found out that the main defect is burning of the IC10 superalloy material in creep feed grinding by energy spectrum analysis of some typical topography in this study.

PDE-Constrained Gaussian Process Model on Material Removal Rate of Wire Saw Slicing Process

2011 ◽  
Vol 133 (2) ◽  
Author(s):  
Hongxu Zhao ◽  
Ran Jin ◽  
Su Wu ◽  
Jianjun Shi
Keyword(s):  
Gaussian Process ◽  
Material Removal Rate ◽  
Material Removal ◽  
Process Model ◽  
Removal Rate ◽  
Kriging Model ◽  
Random Errors ◽  
Gaussian Process Model ◽  
Thickness Uniformity ◽  
Wire Saw

Thickness uniformity of wafers is a critical quality measure in a wire saw slicing process. Nonuniformity occurs when the material removal rate (MRR) changes over time during a slicing process, and it poses a significant problem for the downstream processes such as lapping and polishing. Therefore, the MRR should be modeled and controlled to maintain the thickness uniformity. In this paper, a PDE-constrained Gaussian process model is developed based on the global Galerkin discretization of the governing partial differential equations (PDEs). Three features are incorporated into the statistical model: (1) the PDEs governing the wire saw slicing process, which are obtained from engineering knowledge, (2) the systematic errors of the manufacturing process, and (3) the random errors, including both random manufacturing errors and measurement noises. Real experiments are conducted to provide data for the validation of the PDE-constrained Gaussian process model by estimating the model coefficients and further using the model to predict the overall MRR profile. The results of cross-validation indicate that the prediction performance of the PDE-constrained Gaussian process model is better than the widely used universal Kriging model with a mean of second order polynomial functions.

scholarly journals An Experimental Study on the Precision Abrasive Machining Process of Hard and Brittle Materials with Ultraviolet-Resin Bond Diamond Abrasive Tools

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 125 ◽  
Author(s):  
Lei Guo ◽  
Xinrong Zhang ◽  
Shibin Chen ◽  
Jizhuang Hui
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Manufacturing Process ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Ultraviolet Curable

Ultraviolet-curable resin was introduced as a bonding agent into the fabrication process of precision abrasive machining tools in this study, aiming to deliver a rapid, flexible, economical, and environment-friendly additive manufacturing process to replace the hot press and sintering process with thermal-curable resin. A laboratory manufacturing process was established to develop an ultraviolet-curable resin bond diamond lapping plate, the machining performance of which on the ceramic workpiece was examined through a series of comparative experiments with slurry-based iron plate lapping. The machined surface roughness and weight loss of the workpieces were periodically recorded to evaluate the surface finish quality and the material removal rate. The promising results in terms of a 12% improvement in surface roughness and 25% reduction in material removal rate were obtained from the ultraviolet-curable resin plate-involved lapping process. A summarized hypothesis was drawn to describe the dynamically-balanced state of the hybrid precision abrasive machining process integrated both the two-body and three-body abrasion mode.

scholarly journals Model Based on an Effective Material-Removal Rate to Evaluate Specific Energy Consumption in Grinding

Materials ◽  
2019 ◽  
Vol 12 (6) ◽  
pp. 939 ◽  
Author(s):  
Amelia Nápoles Alberro ◽  
Hernán González Rojas ◽  
Antonio Sánchez Egea ◽  
Saqib Hameed ◽  
Reyna Peña Aguilar
Keyword(s):  
Energy Consumption ◽  
Material Removal Rate ◽  
Specific Energy ◽  
Chip Formation ◽  
Material Removal ◽  
Removal Rate ◽  
Specific Energy Consumption ◽  
Industrial Scale ◽  
Depth Of Cut ◽  
Grinding Process

Grinding energy efficiency depends on the appropriate selection of cutting conditions, grinding wheel, and workpiece material. Additionally, the estimation of specific energy consumption is a good indicator to control the consumed energy during the grinding process. Consequently, this study develops a model of material-removal rate to estimate specific energy consumption based on the measurement of active power consumed in a plane surface grinding of C45K with different thermal treatments and AISI 304. This model identifies and evaluates the dissipated power by sliding, ploughing, and chip formation in an industrial-scale grinding process. Furthermore, the instantaneous positions of abrasive grains during cutting are described to study the material-removal rate. The estimation of specific chip-formation energy is similar to that described by other authors on a laboratory scale, which allows to validate the model and experiments. Finally, the results show that the energy consumed by sliding is the main mechanism of energy dissipation in an industrial-scale grinding process, where it is denoted that sliding energy by volume unity decreases as the depth of cut and the speed of the workpiece increase.

An Intelligent System for Online Optimization of the Cylindrical Traverse Grinding Operation

2006 ◽  
Vol 220 (3) ◽  
pp. 355-363 ◽  
Author(s):  
B W Kruszyński ◽  
P Lajmert
Keyword(s):  
Material Removal ◽  
Intelligent System ◽  
Removal Rate ◽  
Feedforward Neural Network ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Optimization Scheme ◽  
Wheel Wear ◽  
Simulation Research ◽  
Traverse Grinding

This paper presents an intelligent system for optimization of the cylindrical traverse grinding process whose objective is to maximize the material removal rate with constraints on workpiece out-of-roundness and waviness errors, on surface finish, and on grinding temperature. A theoretical analysis of wheel wear development in the traverse grinding process is presented. Next, the results of an experimental test are discussed to establish the most efficient strategy for grinding allowance removal. In the optimization scheme a feedforward neural network is employed to obtain a model which describes relations between the process input parameters and the grinding results. Then this model is used to optimize adaptively the traverse grinding process. The performance of the proposed optimization system is evaluated by simulation research.

Analysis of Residual Stress Induced by Hand Grinding Process

2011 ◽  
Vol 681 ◽  
pp. 327-331 ◽  
Author(s):  
Sawsen Youssef ◽  
O. Calonne ◽  
Eric Feulvarch ◽  
P. Gilles ◽  
Hédi Hamdi
Keyword(s):  
Residual Stress ◽  
Experimental Study ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Cup Wheel

Grinding cup wheel is often used in the case of hand grinding which allows an important material removal rate but with secondary concern of surface integrity. Integrity is strongly affected by the process and consequently influences the surface behaviour in terms of resistivity to stress corrosion and crack initiation. This operation is difficult to master in terms of results on the surface and subsurface due to its manual nature. The paper presents results of an experimental study to investigate the residual stresses induced by this hand grinding process.

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