Thermocouple Fixation Method for Grinding Temperature Measurement

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
Bin Shen ◽  
Guoxian Xiao ◽  
Changsheng Guo ◽  
Stephen Malkin ◽  
Albert J. Shih
Keyword(s):  
Temperature Measurement ◽  
Ground Surface ◽  
Minimum Quantity Lubrication ◽  
Fixation Method ◽  
Depth Of Cut ◽  
Grinding Temperature ◽  
Energy Partition ◽  
Workpiece Material ◽  
Wet Grinding ◽  
Thermocouple Junction

A new thermocouple fixation method for grinding temperature measurement is presented. Unlike the conventional method using a welded thermocouple, this new method uses epoxy for affixing the embedded thermocouple within a blind hole in the workpiece subsurface. During grinding, the thermocouple junction is exposed and bonded to provide direct contact with the ground surface by the smearing of the workpiece material. Experiments were conducted to evaluate this simplified thermocouple fixation method including the effect of thermocouple junction size. Heat transfer models were applied to calculate the energy partition for grinding under dry, wet, and minimum quantity lubrication (MQL) conditions. For shallow-cut grinding of cast iron using a vitreous bond aluminum oxide wheel, the energy partition using a small wheel depth of cut of 10 μm was estimated as 84% for dry grinding, 84% for MQL grinding, but only 24% for wet grinding. Such a small energy partition with wet grinding can be attributed to cooling by the fluid at the grinding zone. Increasing the wheel depth of cut to 25 μm for wet grinding resulted in a much bigger energy partition of 92%, which can be attributed to fluid film boiling and loss of cooling at the grinding zone.

Temperature Measurement and Burn Mechanism of Stainless Steel 1Cr11Ni2W2MoV in Grinding

2012 ◽  
Vol 723 ◽  
pp. 433-438 ◽  
Author(s):  
Hong Xia Zhang ◽  
Wu Yi Chen ◽  
Xiu Zhuo Fu ◽  
Li Xia Huang
Keyword(s):  
Stainless Steel ◽  
Temperature Measurement ◽  
High Efficiency ◽  
Surface Hardness ◽  
Ground Surface ◽  
Temperature Response ◽  
Point Of View ◽  
Workpiece Material ◽  
Grinding Burn ◽  
Grinding Conditions

An experimental study was carried out to investigate the temperature measurement method and burn mechanism in the surface grinding of a stainless steel 1Cr11Ni2W2MoV with SG abrasive wheels. The temperature response at the wheel-workpiece interface was measured using a pair of thermocouple composed of the workpiece material and a single enameled constantan wire which was implanted in the workpiece. Changes in the ground surface morphology and metallography of the specimens in different grinding conditions were analyzed. Plastically deformed coating layers and micro-cracks were observed on ground surface by SEM (Scanning Electronic Microscopy) when grinding burn occurs. Grinding burn mechanism was unveiled from a metallographic point of view. When the average temperature exceeded phase alteration temperature of 1Cr11Ni2W2MoV, the original gray strip martensite structure was replaced by tempered sorbite structure, which caused a sharp reduction of the workpiece surface hardness. The results provided a theoretical and experimental basis for technical optimization in the grinding of high temperature stainless steel with high efficiency and high quality.

Temperatures in Grinding Cemented Carbide (YT30) with a Vacuum Brazed Diamond Wheel

2011 ◽  
Vol 487 ◽  
pp. 16-23
Author(s):  
You Ji Zhan ◽  
Yuan Li ◽  
Hui Huang ◽  
Xi Peng Xu
Keyword(s):  
Feed Rate ◽  
Diamond Wheel ◽  
Cemented Carbide ◽  
Maximum Temperature ◽  
Depth Of Cut ◽  
Grinding Temperature ◽  
Energy Partition ◽  
Dry Grinding ◽  
Grinding Conditions ◽  
Material Removal Mode

An experimental investigation is reported on the temperatures and energy partitions involved in the grinding of cemented carbide (YT30) with a vacuum brazed diamond wheel. The grinding temperature at the wheel-workpiece interface was measured using a pair of grindable foil thermocouples and the energy partition to the workpiece was evaluated by matching the analytical temperatures to the measured results. Effects of the various grinding conditions, including wheel velocity, feed rate and depth of cut, on the temperatures and the energy partition were investigated. It was determined that the wheel velocity was the most significant factor in governing the temperature relative to the depth of cut and feed rate. The maximum temperature rise at the contact zone was below 25°C in the present study. Microscopic examination of the ground surfaces and the ground detritus revealed that brittle fracture was the dominant material-removal mode. This may be one of the reasons for the low grinding temperature in grinding YT30 with a vacuum brazed diamond wheel. The energy partition values to the workpiece obtained under different grinding conditions varied from 3.3% to 20% for dry grinding YT30.

Grindability study of hard to cut AISI D2 steel upon ultrasonic vibration-assisted dry grinding

2021 ◽  
pp. 095440892110516
Author(s):  
Abhimanyu Chaudhari ◽  
Mohd Zaheer Khan Yusufzai ◽  
Meghanshu Vashista
Keyword(s):  
Ultrasonic Vibration ◽  
Vibration Amplitude ◽  
Roughness Parameter ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Wet Grinding ◽  
Dry Grinding ◽  
Aisi D2 ◽  
Negative Environmental Impact

Ultrasonic vibration-assisted dry grinding is a sustainable hybrid manufacturing technology that decreases the negative environmental impact of coolant, reduces manufacturing costs, and improves surface integrity. The present investigation analyses the mechanisms associated with ultrasonic vibration-assisted dry grinding of AISI D2 tool steel with an alumina grinding wheel. It also compares the influence of traditional dry grinding and traditional wet grinding modes with the ultrasonic vibration-assisted dry grinding mode at different ultrasonic vibration amplitudes. Ultrasonic vibration was applied to the sample in the longitudinal feed direction. Further, kinematics of the abrasive grit path during the traditional grinding and ultrasonic vibration-assisted dry grinding is presented schematically. In this research, the impacts of ultrasonic vibration amplitude as well as the depth of cut on the process yields such as ground surface topography, grinding force, specific grinding energy, force ratio, surface finish, microstructure, and hardness were investigated experimentally. Experimental results revealed that the highest decline in tangential and normal grinding forces in ultrasonic vibration-assisted dry grinding at ultrasonic vibration amplitude 10 µm and the reduction in surface roughness parameter ( Ra, Rq, and Rz) in ultrasonic vibration-assisted dry grinding was 43.23%, 42.59%, and 33.69%, respectively, in comparison to those in traditional dry grinding and 26.35%, 26.94%, and 27.48%, respectively, in comparison to those in traditional wet grinding. It was observed that ultrasonic vibration-assisted dry grinding is beneficial as the profile produced by ultrasonic vibration-assisted dry grinding has a comparatively flat tip, and profile points are shifted to the bottom of the mean line. This study is expected to assist ultrasonic vibration-assisted dry grinding of hard materials.

Energy Partition in Conventional Surface Grinding

1999 ◽  
Vol 121 (3) ◽  
pp. 393-398 ◽  
Author(s):  
T. Kato ◽  
H. Fujii
Keyword(s):  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
Ground Surface ◽  
Surface Grinding ◽  
Maximum Temperature ◽  
Energy Partition ◽  
Grinding Wheels ◽  
Workpiece Material ◽  
Wheel Material ◽  
Film Method

In order to estimate the energy partition to the workpiece in surface grinding, the temperatures at various depths from the ground surface of the workpiece were measured using the PVD (physical vapor deposition) film method developed by the authors. In this method a thin film deposited on the workpiece is used as a thermal sensor. The energy partition for various grinding wheels was estimated with the maximum temperature rise at the surface obtained by extrapolating the temperatures measured at various depths. It was found that the partition changes significantly from 0.3 to 0.8, depending on the combination of the workpiece material and the wheel material in conventional dry surface grinding.

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.

scholarly journals Effects of hybrid Al2O3–CuO nanofluids on surface roughness and machining forces during turning AISI 4340

2021 ◽  
Vol 3 (2) ◽  
Author(s):  
Shahin Haghnazari ◽  
Vahid Abedini
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Rotational Speed ◽  
Minimum Quantity Lubrication ◽  
Weight Percent ◽  
Cutting Fluid ◽  
Hybrid Nanofluid ◽  
Workpiece Material ◽  
Machining Forces ◽  
Aisi 4340

AbstractThis paper presents an effort to model the process parameters involved in turning of alloy steel AISI 4340 workpiece material with Al2O3 and CuO hybrid nanofluids using the minimum quantity lubrication (MQL) method. In this paper, the effect of mixing two nanoparticles (Al2O3 and CuO) with different weight percent in environmentally friendly water-based cutting fluid, the rotational speed, and the feed rate has been investigated on the surface roughness and the machining forces using the response surface method. The results of the experiments show that the hybrid nanofluid containing 0.75 CuO with 0.25 Al2O3 has the best output for the machining forces and the surface roughness. Also, in the best composition of the nanoparticles (0.75 CuO with 0.25 Al2O3), the lowest value of machining forces has been achieved at a feed rate of 0.08 mm per revolution and the rotational speed 1000 rpm as well as the lowest value of the surface roughness at a feed rate of 0.08 mm per revolution and the rotational speed 710 rpm.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

Experimental and Numerical Study on Grinding Temperature during Surface Grinding with Different Cooling Methods

2009 ◽  
Vol 416 ◽  
pp. 514-518 ◽  
Author(s):  
Qing Long An ◽  
Yu Can Fu ◽  
Jiu Hua Xu
Keyword(s):  
Numerical Study ◽  
Specific Energy Consumption ◽  
Ground Surface ◽  
Numerical Results ◽  
Surface Grinding ◽  
Grinding Temperature ◽  
Air Jet ◽  
The Difference ◽  
High Specific Energy ◽  
Cooling Methods

Grinding, characterized by its high specific energy consumption, may generate high grinding zone temperature. These can cause thermal damage to the ground surface and poor surface integrity, especially in the grinding of difficult-to-machine materials. In this paper, experimental and fem study on grinding temperature during surface grinding of Ti-6Al-4V with different cooling methods. A comparison between the experimental and numerical results is made. It is indicated that the difference between experimental and numerical results is below 15% and the numerical results can be considered reliable. Grinding temperature can be more effectively reduced with CPMJ than that with cold air jet and flood cooling method.

Energieeffizienz beim Spanen/Energy efficiency at machining - Investigations about the influence of minimun quantity lubrication (MQL) at final cutting

2017 ◽  
Vol 107 (05) ◽  
pp. 352-358
Author(s):  
S. Prof. Simon ◽  
S. Wichmann ◽  
A. Brill
Keyword(s):  
Energy Efficiency ◽  
Minimum Quantity Lubrication ◽  
Stress Conditions ◽  
Cutting Performance ◽  
Workpiece Material ◽  
Load Range ◽  
University Of Technology ◽  
Partial Load ◽  
Longitudinal Turning

Von der Brandenburgischen Technischen Universität (BTU) sind in Zusammenarbeit mit der TU Liberec Untersuchungen zur Verbesserung der Energieeffizienz an spanenden Werkzeugmaschinen durchgeführt worden. Im Gegensatz zu bereits durchgeführten Untersuchungen wurde der Fokus hier auf das Belastungsverhalten im Teillastbereich gerichtet. Die durchgeführten Untersuchungen beschränkten sich auf das Längsdrehen mit geringen Schnitttiefen. Als Werkstoffe kamen ein Baustahl und ein Vergütungsstahl zum Einsatz. Durch die Bestimmung der Leerlaufleistung der verwendeten Drehmaschine waren tatsächliche Aussagen über die Schnittleistung möglich. Für das Ermitteln des Wirkungsgrades wurden auch die Schnittleistungen bei verschiedenen Drehzahlen aufgenommen. Alle weiteren Spanungsbedingungen blieben für die Untersuchungen konstant. Im Ergebnis der Untersuchung bestätigte sich das Potenzial der Minimalmengenschmierung. Der Wirkungsgrad verbesserte sich durchschnittlich um 5 %. Beachtenswert ist der Einfluss des Einstellwinkels. Hier liegt das Optimierungspotenzial der Energieeffizienz in Summe bei 14 %. Die Untersuchungen ergaben weiterhin eine hohe Korrelation von Spanungsbedingungen, Werkstückwerkstoff und verwendetem Schmiermittel.   The Brandenburg University of Technology has carried out investigations in cooperation with the technical University of Liberec to improve the energy efficiency of cutting machine tools. In contrast to investigations already carried out, the focus here was on the loading behavior in the partial load range. The investigations carried out were limited to longitudinal turning with low cutting depths. A structural steel and a tempering steel were used as materials. By determining the no-load power of the used lathe, actual statements about the cutting performance were possible. For the determination of the efficiency, the cutting performance was recorded at different speeds. All further stress conditions remained constant for the investigations. As a result of the investigation, the potential of minimum quantity lubrication was confirmed. The efficiency improved by an average of 5 %. The influence of the angle of setting was remarkable. The optimization potential of energy efficiency was at 14 %. The investigations also revealed a high correlation between stress conditions, workpiece material and lubricant used.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

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