Parameter Optimization of the Steel Grinding Process

1976 ◽  
Vol 98 (3) ◽  
pp. 1048-1052 ◽  
Author(s):  
R. W. Mayne ◽  
S. Malkin
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Metal Removal Rate ◽  
Wheel Wear ◽  
Trade Off ◽  
Grinding Wheel Wear ◽  
Grinding Performance ◽  
Nonlinear Programming Methods

This paper is concerned with the application of nonlinear programming methods to the surface grinding of steels and considers the specific case of plunge grinding. Performance equations based on a model of the process are presented and then optimized. Trade-off curves are established showing the best metal removal rate possible for given constraints on surface quality and at specified conditions of grinding wheel wear. Optimum values for the various parameters in the grinding process are also included. In addition, the sensitivity of steel grinding performance to nonoptimum choices of grinding wheel velocity and diameter is considered.

Factors Influencing the Performance of Grinding Wheels

1959 ◽  
Vol 81 (3) ◽  
pp. 187-199 ◽  
Author(s):  
E. J. Krabacher
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Grinding Wheel ◽  
Metal Removal Rate ◽  
Grinding Wheels ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Grinding Ratio ◽  
Material Hardness ◽  
Chip Load

Optimum utilization of grinding wheels can best be achieved if the nature of their performance and wear characteristics, and the factors that affect these characteristics, are understood and applied. As reported in this paper, a comprehensive, continuing, grinding-research program has contributed to such an understanding. A study of the nature of grinding-wheel wear indicates that the grinding-wheel wear curve is similar to those of other cutting tools. It demonstrates further that the type of grinding operation significantly affects the nature of wheel wear. A unique technique has been developed for very accurately measuring grinding-wheel wear. This measured wear may be translated into terms of “grinding ratio,” which is the generally accepted parameter for measuring wheel wear. It is the ratio of the volume of metal removed per unit volume of wheel worn away. Extensive studies have been carried out to determine the effect of mechanical variables on grinding ratio, power required in metal removal, and on surface finish. Experimental findings indicate that grinding ratio decreases with increased metal-removal rate and increases with workpiece diameter, decreased chip load, and increased concentration of grinding fluid. Power is found to increase with both the metal-removal rate and the amount of metal removed. It increases slightly with workpiece diameter and is affected little by work-material hardness. Surface finish is found to improve with decreased metal-removal rate and decreased chip load. It also is affected little by work diameter or work-material hardness. Fundamental research in the mechanics of wheel wear is supplying much additional information in the study of grinding-wheel wear. The measurement of grinding forces employing a cylindrical grinding dynamometer provides the opportunity for relating the wear of grinding wheels to the basic mechanics of the process through such fundamental quantities as grinding forces, specific energy, and grinding friction. Two additional experimental techniques for the study of chip formation in grinding have also proved to be most useful research tools. A “quick-stop” apparatus is used to freeze the grinding action by accelerating a tiny workpiece almost instantaneously to grinding-wheel speed. Another technique permits the comparison of the shape of the grinding grit and that of the contour of its path through the workpiece by a unique replicating method.

Analysis of the Tribological Conditions in Grinding of Polycrystalline Diamond Based on Single Grain Friction Tests Using the Pin-Disk Principle

2018 ◽  
Vol 767 ◽  
pp. 259-267 ◽  
Author(s):  
Frederik Vits ◽  
Daniel Trauth ◽  
Patrick Mattfeld ◽  
Rudolf Vits ◽  
Fritz Klocke
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Polycrystalline Diamond ◽  
Grinding Wheel ◽  
Grinding Process ◽  
State Variables ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Single Grain ◽  
Zone Temperature

Cutting tools made of polycrystalline diamond (PCD) are used for machining of aluminum alloys, fiber-reinforced plastic composites and wood. Compared to cemented carbide tools with geometrically defined cutting edges, PCD tools offer significant advantages with respect to tool life. High demands regarding the cutting edge roughness and the quality of the rake and the flank face usually require a grinding process with diamond grinding wheels. The PCD grinding process, however, is characterized by low material removal rates and high grinding wheel wear. The material removal rate and the grinding wheel wear, in turn, highly depend on the process state variables process force and process temperature. However, the relationship between these process state variables and the process input variables is largely unknown. This work provides a contribution to the closure of this knowledge gap by means of an adapted friction law. A single grain friction test stand using the pin-disk principle was developed, which enables a measurement of the friction force and the contact zone temperature for normal forces and relative speeds that are common in PCD grinding. During the experiments, the specification of the PCD disc, the cross-sectional area of the friction sample made of monocrystalline diamond as well as the process parameters normal force and relative speed were varied. In addition, the tests were carried out without lubrication as well as with a minimum lubrication. A high correlation between the contact force and the coefficient of friction was determined. This relationship was mathematically formulated in a friction law. In addition, a direct influence of the contact force and the relative velocity on the contact zone temperature was identified. The knowledge gained leads to an improved understanding of the PCD grinding process and thus enables a more efficient grinding process design.

The Adaptive Control of Grinding Force of CNC Cam Grinder Based on Neural Network

2012 ◽  
Vol 217-219 ◽  
pp. 2051-2055
Author(s):  
Ming Li Xie ◽  
Ling Lu
Keyword(s):  
Neural Network ◽  
Adaptive Control ◽  
Control Method ◽  
Metal Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Control Measures ◽  
Numerical Control ◽  
Grinding Wheel ◽  
Grinding Process

In the process of cam grinding, the fluctuation of grinding force can lead to the abnormal wear of the grinding wheel, the decrease of the grinding surface quality and even the damage of the grinding process system. The paper took the grinding process of numerical control cam grinding machine as research subject, the grinding force mathematical model was built, the indirect test and control measures were researched and an adaptive control method based on neural network was proposed and applied to the grinding force control of the cam grinding process. At last, the controller was designed and the grinding simulation was performed with MATLAB, which proved that the system could solve the fluctuation of grinding force during the process of cam grinding and the controller was equipped with good dynamic characteristic. The results indicate that the method can realize the purpose of optimal metal removal rate and enhance the grinding quality of cams.

Effects of Impregnation of Grinding Wheel on Grinding Hardened Tool Steel

1985 ◽  
Vol 9 (1) ◽  
pp. 39-44 ◽  
Author(s):  
M.A. Younis ◽  
H. Alawi
Keyword(s):  
Structural Changes ◽  
Metal Removal ◽  
Removal Rate ◽  
Ground Surface ◽  
High Hardness ◽  
Grinding Wheel ◽  
Tool Steels ◽  
Wheel Wear ◽  
Beneficial Effects ◽  
Hardened Tool Steel

The high hardness and chemical effects of tool steels M2 and T15 cause a rapid grinding wheel wear and micro structural changes in the ground surface. The performance of sulphur-, wax-, and varnish-impregnated grinding wheels in grinding hardened tool steels M2 and T15 is investigated and compared with the performance of conventional alumina wheels. Impregnation with sulphur had in all cases beneficial effects by decreasing the grinding forces, increasing the maximum metal removal rate, improving surface integrity, and increasing considerably the grinding ratio. It also gave cost saving compared to the plain grinding wheel. The improvement was a result of the sulphur being more efficiently supplied into the chip formation process as compared to using grinding coolant only.

On the Mechanics of the Grinding Process Under Plunge Cut Conditions

1966 ◽  
Vol 88 (1) ◽  
pp. 72-79 ◽  
Author(s):  
R. S. Hahn
Keyword(s):  
Normal Force ◽  
Metal Removal ◽  
Removal Rate ◽  
The Other ◽  
Velocity Versus ◽  
Grinding Process ◽  
Metal Removal Rate ◽  
Intensity Curve ◽  
Straight Line ◽  
Force Intensity

Two broad categories of grinding action are recognized; one where negligible ploughing and rubbing take place and where the plunge velocity versus normal force intensity curve is a straight line through the origin, the other where ploughing and rubbing predominate and the plunge velocity versus normal force intensity curve is concave upward. The effects of wheelspeed, workspeed and conformity are found to differ depending upon which category the grinding action falls under. A theory relating the metal removal rate to the force intensity is presented which applies only to grinding with negligible rubbing and ploughing.

Modeling of Specific Grinding Energy Based on Wheel Topography

2011 ◽  
Vol 325 ◽  
pp. 72-78 ◽  
Author(s):  
Abdolhamid Azizi ◽  
Hamed Adibi ◽  
Seyed Mehdi Rezaei ◽  
Hamid Baseri
Keyword(s):  
Metal Removal ◽  
Unit Area ◽  
Experimental Results ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Removal Mechanism ◽  
Specific Grinding Energy ◽  
Grinding Performance ◽  
Wheel Topography ◽  
Workpiece Interaction

Grinding performance is evaluated mainly in terms of specific grinding energy. The number of active grits per unit area and their slope is considered as the two grinding wheel topographical key parameters for studying grinding performance. To provide a view on how various parameters influence specific energy and the importance of wheel topography and grit workpiece interaction, a specific grinding energy model is developed. Inputs to this model are workpiece parameters, grinding process parameters, and, in particular, the grinding wheel topographical parameters. This model has been validated by experimental results. The theoretical values considering the complexity of the grinding process reasonably compare with the experimental results. The effect of number of active grits per unit area and their slope on specific grinding energy and then metal removal mechanism is investigated. The results revealed that the number of active grits per unit area has less effect on specific grinding energy than grits slope.

A compensation algorithm of tool path for grinding wheel wear in solid cutting tool flank grinding

2021 ◽  
pp. 095440542110288
Author(s):  
Yuhao Ma ◽  
Yong Li ◽  
Lei Jiang ◽  
Guofu Ding
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Calculation Model ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Compensation Algorithm ◽  
Quality Stability ◽  
Comparison Of The Results

In finishing machining, the quality of workpiece is significantly influenced by the performance of solid cutting tool. Solid cutting tool flank is ground by CNC tool grinder in accordance with the tool path of grinding wheel. In actual grinding process, the grinding area of wheel will be gradually worn down, resulting in the decrease of geometric accuracy of flank and even wrong profile. In order to compensate the error, a compensation algorithm of tool path for solid cutting tool flank based on grinding wheel wear is proposed. Firstly, the coordinate systems are defined for the grinding process of flank, and the orientation and location calculation model of ideal wheel with the grinding process parameters is derived. Secondly, based on the profile description of wheel wear, flank errors are analyzed. Then, the compensation algorithm for anastomosis of cutting edge and relief angle is proposed. Finally, series of experiments of simulation and actual grinding are carried out. The comparison of the results shows that the algorithm can reduce the influence of wheel wear effectively, which can also improve the grinding quality stability and prolong the service life of grinding wheel.

The Effect of Porosity of CBN Grinding Tools on Grinding Properties

2012 ◽  
Vol 724 ◽  
pp. 363-366
Author(s):  
Xing Hua Yang ◽  
Jian Feng Yang ◽  
Jian Guang Bai ◽  
Sao Chun Xu
Keyword(s):  
Surface Roughness ◽  
Laser Scanning ◽  
Metal Removal ◽  
Removal Rate ◽  
Bearing Steel ◽  
Grinding Wheel ◽  
Metal Removal Rate ◽  
Conventional Sintering ◽  
The Difference ◽  
Cbn Grinding Wheel

The CBN grinding wheels with different porosity, which used 100/120 CBN grind grain and 15μm glass powder as main starting materials, pore creating material as auxiliary material, were prepared by conventional sintering technology; Used GCr15 bearing steel which quenching hardness was 60HRC as ground materials, investigated the effect of porosity of CBN wheel on its cutting ability. In this paper , the metal removal rate was measured by electronic analytical balance, surface roughness of GCr15 was analyzed used LEXT laser scanning confocal microscope and the surface topography of grinding face was observed used scanning electron microscope. The investigated results showed that the metal removal rate acutely increasing with the porosity of wheels increasing in same loading weight, it reached 0.445g/min with 41% porosity in 3500g loading weight, at the same time, the difference of surface roughness caused by variation of porosity of CBN grinding wheel was slight, it did not severely lower machining precision of workpiece.

Experimental Studies on Grinding of Titanium Alloy with SG Wheels

2007 ◽  
Vol 329 ◽  
pp. 75-80 ◽  
Author(s):  
H.X. Zhang ◽  
Wu Yi Chen ◽  
Z.T. Chen
Keyword(s):  
Titanium Alloy ◽  
Experimental Studies ◽  
Dimensional Accuracy ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Grinding Wheel Wear ◽  
Conventional Grinding ◽  
Abrasive Tools

The grinding process has been investigated in the machining of titanium alloy with conventional grinding wheel and SG grinding wheel respectively. The machinability discussed here includes grinding force, surface roughness, dimensional accuracy, grinding ratio, grinding-wheel wear and grinding-wheel life. The SG grinding wheel is found to possess particularly good grinding properties and is more suitable for grinding titanium alloy when compared with conventional abrasive tools.

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