Simulation Study of the Grinding Process

1973 ◽  
Vol 95 (4) ◽  
pp. 972-978 ◽  
Author(s):  
S. S. Law ◽  
S. M. Wu
Keyword(s):  
Surface Topography ◽  
Simulation Study ◽  
Digital Computer ◽  
Surface Interactions ◽  
Apex Angle ◽  
Physical Significance ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Stochastic Nature ◽  
Table Speed

A model in terms of grain distributions and kinematic conditions has been recently developed [8] for a specified grinding process. Using this model, an exploratory attempt was made to study the grinding process with respect to the surface topography and nature of surface interactions by simulation on a digital computer. Fundamental grinding parameters, such as the effective grain density, grain spacings, chip depths, and chip areas, are employed to describe the grain-workpiece interactions. The grinding process is studied under a systematic variation of table speed, wheel depth of cut, and grain apex angle. The physical significance of the Z-distribution and stochastic nature of the grinding process is also discussed.

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.

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.

Grinding Process Size Effect and Kinematics Numerical Analysis

1999 ◽  
Vol 122 (1) ◽  
pp. 59-69 ◽  
Author(s):  
William L. Cooper ◽  
Adrienne S. Lavine
Keyword(s):  
Steady State ◽  
Removal Rate ◽  
Empirical Relationship ◽  
Three Dimensional ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Zone Length ◽  
Abrasive Grains ◽  
Three Dimensional Modeling ◽  
Stock Removal

The present work developed numerical codes that simulate steady-state grinding process kinematics. The three-dimensional modeling procedure entails the following: specifying the sizes, shapes, and positions of individual abrasive grains on the wheel surface; geometrically calculating the abrasive grains’ depth of cut distributions along the grinding zone as they pass through the grinding zone (neglecting wheel, abrasive grain, and workpiece deflections); using an empirical relationship to relate the abrasive grains’ geometric depths of cut to the grains’ actual depths of cut; and updating the workpiece surface to account for material removal. The resulting data include the abrasive grains’ average depth of cut distribution along the grinding zone, stock removal depth, stock removal rate, grinding zone shape, grinding zone length, percentage of grains impacting the workpiece, grain-workpiece impact frequency, etc. The calculated grinding zone lengths compare favorably with experimental data. This article examines a number of steady-state grinding processes. [S1087-1357(00)00101-5]

Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel

2021 ◽  
pp. 095440542110406
Author(s):  
Yutong Qiu ◽  
Jingfei Yin ◽  
Yang Cao ◽  
Wenfeng Ding
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Ultrasonic Vibration ◽  
Generation Mechanism ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Abrasive Wheel ◽  
Grinding Parameters ◽  
Conventional Grinding ◽  
Ultrasonic Vibration Assisted Grinding

Tangential ultrasonic vibration-assisted grinding (TUAG) has a wide prospect in machining difficult-to-machine materials. However, the surface generation mechanism in TUAG is not fully recovered. This study proposes an analytical model of the surface topography produced by TUAG. Based on the model, the surface topography and roughness are predicted and experimentally verified. In addition, the influence of the grinding parameters on the surface topography is analyzed. The predicted surface topography well coincides with experimental measurements, and the prediction error in surface roughness Ra by the proposed model is less than 5%. Compared with conventional grinding, TUAG produces a surface with more uniform scratches and surface roughness Ra was reduced by up to 27% with the proper parameters. However, the improvement of surface roughness in TUAG is weakened when grinding speed or depth of cut increases. Moreover, the influence of the ultrasonic vibration amplitude on the surface roughness is not monotonous. With the grinding parameters selected in this study, TUAG with an ultrasonic amplitude of 7.5 μm produces the minimum surface roughness.

In-Process Prediction of Surface Roughness in Grinding Process by Monitoring of Cutting Force Ratio

2014 ◽  
Vol 627 ◽  
pp. 29-34 ◽  
Author(s):  
Vichaya Thammasing ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Spindle Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Average Surface Roughness ◽  
Average Surface ◽  
Developed Surface ◽  
Force Ratio

The purpose of this research is to develop the models to predict the average surface roughness and the surface roughness during the in-process grinding by monitoring the cutting force ratio. The proposed models are developed based on the experimentally obtained results by employing the exponential function with four factors, which are the spindle speed, the feed rate, the depth of cut, and the cutting force ratio. The experimentally obtained results showed that the dimensionless cutting force ratio is usable to predict the surface roughness during the grinding process, which can be calculated and obtained by taking the ratio of the corresponding time records of the cutting force Fy in the spindle speed direction to that of the cutting force Fz in the radial wheel direction. The multiple regression analysis is utilized to calculate the regression coefficients with the use of the least square method at 95% confident level. The experimentally obtained models have been verified by the new cutting tests. It is proved that the developed surface roughness models can be used to predict the in-process surface roughness with the high accuracy of 93.9% for the average surface roughness and 92.8% for the surface roughness.

Application of Taguchi Technique to Surface-Grinding of Mold Steel

2016 ◽  
Vol 689 ◽  
pp. 7-11 ◽  
Author(s):  
Y. Şahin ◽  
Senai Yalcinkaya
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Quality Characteristics ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Fluid Environment ◽  
Selection Of

The selection of optimum machining parameters plays a significant role for the quality characteristics of products and its costs for grinding. This study describes the optimization of the grinding process for an optimal parametric combination to yield a surface roughness using the Taguchi method. An orthogonal array and analysis of variance are employed to investigate the effects of cutting environment (A), depth of cut (B) and feed rate (C) on the surface roughness characteristics of mold steels. Confirmation experiments were conducted to verify the optimal testing parameters. The experimental results indicated that the surface finish decreased with cutting-fluid and depth of cut, but decreased with increasing feed rate. It is revealed that the cutting fluid environment had highest physical as well as statistical influence on the surface roughness (71.38%), followed by depth of cut (25.54%), but the least effect was exhibited by feed rate (1.62%).

Research on Prediction Model of Surface Roughness in Ultrasonic Polishing Nano-ZrO2 Ceramics

2009 ◽  
Vol 69-70 ◽  
pp. 128-132
Author(s):  
Ming Li Zhao ◽  
Bo Zhao ◽  
Yu Qing Wang ◽  
Guo Fu Gao
Keyword(s):  
Surface Roughness ◽  
Orthogonal Test ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
Test Results ◽  
Work Situation ◽  
Table Speed ◽  
Abrasive Size ◽  
Regressive Analysis

The orthogonal test of surface roughness in ultrasonic polishing nano-ZrO2 ceramics was carried out in the present paper. Through the test, the influence of machining parameters on the surface roughness was investigated. The test results showed that the influence of abrasive size on surface roughness is the most remarkable, and the other important factors are the depth of cut, on/off work situation of ultrasonic generator, axial feed speed, and working table speed in turns. Furthermore, through the regressive analysis of test data, an empirical formula of surface roughness was established to select reasonable polishing parameters.

Optimization of Surface Roughness in Centreless Grinding Process Based on Taguchi Method

2021 ◽  
pp. 37-47
Author(s):  
Prosun Mandal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Wheel Speed ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Signal To Noise ◽  
Grinding Parameters ◽  
Medium Level ◽  
Grinding Conditions ◽  
Valve Opening

This chapter aims to optimize centreless grinding conditions using the Taguchi method for minimizing surface roughness. The grinding operation has been performed according to the L9 orthogonal array in a centreless grinding process. The centreless grinding experiments are carried out on the crane-hook pin of C40 steel. The analysis of variance (ANOVA) and computation of signal to noise (S/N) ratio are adopted to determine the influence of grinding parameters (depth of cut [µm], regulating wheel speed [rpm], and coolant valve opening) on surface roughness. The depth of cut (µm) is found to be the most significant among the grinding parameters on the surface roughness. The signal to noise (S/N) ratio was calculated based on smaller the best criteria. The lower level of depth of cut, medium level of regulating wheel speed, and higher-level coolant valve opening is found to be optimal grinding condition according to the mean response and signal to noise (S/N) ratio.

scholarly journals Modeling of Vibration Condition in Flat Surface Grinding Process

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Process Model ◽  
Flat Surface ◽  
Normal Component ◽  
Cutting Speed ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Forces ◽  
Vibration Condition

This article presents a new model of the flat surface grinding process vibration conditions. The study establishes a particular analysis and comparison between the influence of the normal and tangential components of grinding forces on the vibration conditions of the process. The bifurcation diagrams are used to examine the process vibration conditions for the depth of cut and the cutting speed as the bifurcation parameters. The workpiece is considered to be rigid and the grinding wheel is modeled as a nonlinear two-degrees-of-freedom mass-spring-damper oscillator. To verify the model, experiments are carried out to analyze in the frequency domain the normal and tangential dynamic grinding forces. The results of the process model simulation show that the vibration condition is more affected by the normal component than the tangential component of the grinding forces. The results of the tested experimental conditions indicate that the cutting speed of 30 m/s can permit grinding at the depth of cut up to 0.02 mm without sacrificing the process of vibration behavior.

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