Mathematical Model of the Grinding Force With Account for Blunting of Abrasive Grains of the Grinding Wheel

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Dmitrii V. Ardashev ◽  
Aleksandr A. Dyakonov
Keyword(s):  
Forecast Model ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Force Model ◽  
Cyclic Loads ◽  
Workpiece Material ◽  
Stochastic Nature ◽  
Abrasive Grains ◽  
Working Surface ◽  
Abrasive Grain

The paper offers a simulation model of the grinding force with account for the current condition of the grinding wheel's working surface—the value of the abrasive grain blunting area. The model of blunting area takes into account various wear mechanisms for abrasive grains: the mechanical wear is realized on the provisions of the kinetic theory of the strength of a solid subjected to cyclic loads, and the physicochemical wear is based on the intensity of interaction between the abrasive and the treated material at grinding temperatures. The offered model of the grinding force takes into account the unsteady stochastic nature of the interaction between abrasive grains of the grinding wheel and the working surface and the intensity of workpiece material deformation resistance. The model is multifactorial and complex and can be realized by supercomputer modeling. The numerical implementation of the model was performed with application of supercomputer devices engaging parallel calculations. The performed experiments on measurement of the grinding force during circular grinding have shown a 10% convergence with the calculated values. The developed grinding force model can be used as a forecast model to determine the operational functionality of grinding wheel when used in varying technological conditions.

Theory and Experiment Study on the Grinding Force

2007 ◽  
Vol 24-25 ◽  
pp. 217-222
Author(s):  
Jian Hua Zhang ◽  
Pei Qi Ge ◽  
L. Zhang
Keyword(s):  
Grinding Force ◽  
Probability Method ◽  
Force Model ◽  
Force Analysis ◽  
Experiment Study ◽  
Statistical Probability ◽  
Abrasive Grains ◽  
Abrasive Grain ◽  
Grinding Force Model ◽  
Theory And Experiment

The grinding force was one of the most important parameters, almost related with all the parameters in grinding. In this paper, the grinding force model was established by a new method. The abrasive grains were analyzed using the statistical probability method. The abrasive grains were divided into two types, one was the cutting abrasive grain, and the other was contacting abrasive grain. The force analysis of a single abrasive grain was done. The grinding force model was established on the basis of the statistical probability method and the force analysis of a single abrasive grain. Theoretical analysis was verified by the experiment. The results indicated, the experimental results agree well with the theoretical prediction. The model can accurately predict the grinding force.

Influence of AA7075 crystallographic orientation on micro-grinding force

2018 ◽  
Vol 233 (8) ◽  
pp. 1831-1843 ◽  
Author(s):  
Man Zhao ◽  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Flow Stress ◽  
Crystallographic Orientation ◽  
Factor Model ◽  
Grinding Force ◽  
Taylor Factor ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Force Model ◽  
Workpiece Material ◽  
Flow Stress Model

In micro-grinding, the depth of cut is smaller than the grain size of workpiece material. Since the micro-grinding wheel cuts through the grain boundaries, the crystallographic effects become more significant in the micro-grinding than that in macro-machining. To quantify the effect of crystallographic orientation on the flow stress of polycrystalline material, the Taylor factor model is developed by examining the number and type of the activated slip systems. Then, the shear force model is developed based on the flow stress model considering the effect of crystallographic orientation. Moreover, the plowing force is predicted based on the Vickers hardness of workpiece material and the plowing friction coefficient. A comprehensive model is then proposed to predict micro-grinding force by consolidating the mechanical, thermal, crystallographic, and size effect. Micro-grinding experiments adopting Taguchi’s method were conducted to verify the model, and the results indicated that the predictions agree well with the experimental data. Besides, single-factorial experiments were conducted with the only variable being Taylor factor and the results suggest that the Taylor factor model is capable of capturing the effect of crystallographic orientation on grinding force.

scholarly journals The enhancement of cutting capacity of a grinding wheel when processing ductile steel blank parts by ultrasonic activation

2021 ◽  
pp. 55-62
Author(s):  
A. V. Khazov ◽  
◽  
A. N. Unyanin ◽  
Keyword(s):  
Numerical Simulation ◽  
Grinding Wheel ◽  
Ultrasonic Vibrations ◽  
Ultrasonic Activation ◽  
Workpiece Material ◽  
Steel Blank ◽  
Micro Cutting ◽  
Abrasive Grains ◽  
Junction Points ◽  
Cutting Capacity

The study aimed to identify the relations between the sticking intensity and ultrasonic vibrations (UV) used for processing and evaluate the wheels’ performance when grinding ductile materials blank parts. The authors carried out the numerical simulation of local temperatures and the 3H3M3F steel workpiece temperature when grinding by ultrasonic activation. The study determined that the application of ultrasonic vibrations with the amplitude of 3 µm causes the decrease in local temperatures by 13…40 %, and in blank part temperature – up to 20 %. The calculation identified that the activation of ultrasonic vibrations with the amplitude of 3 µm causes the decrease in the glazing coefficient by 33 % for cutting grain and by 7 % for deforming grain. When increasing the longitudinal feed rate or the grinding depth, the glazing coefficient increases to a lesser degree when using the ultrasonic vibration than in the case without ultrasonic activation. The authors carried out the numerical simulation of local temperatures when scratching the 3H3M3F steel specimens by single abrasive grains with ultrasonic activation. The sticking deformation and the stresses resulted from this deformation and affecting the junction points of sticking with grains with and without ultrasonic vibrations application are calculated. The experimental research included the micro-cutting of specimens with single abrasive grains. The experiments identified that the abrasive grains wear out and glaze to a lesser degree when micro-cutting a workpiece with ultrasonic vibrations activation. The lowering of the intensity of sticking of the workpiece material particles to the abrasive grains due to the adhesion causes the decrease in the glazing coefficient when using ultrasonic activation. The study considered the possibility to enhance the efficiency of flat grinding through the use of the energy of ultrasonic vibrations applied to a blank part in the direction with the grinding wheel axis. A workpiece fixed in the device between the vibration transducer and the support is one of the components of a vibration system. The authors performed the experiment when grinding 3H3M3F and 12H18N10T steel workpieces with the wheel face. When grinding with ultrasonic vibrations, the grinding coefficient increases up to 70 %, and the redress life increases twice or thrice.

A Coupled Thermomechanical Modeling Method for Predicting Grinding Residual Stress Based on Randomly Distributed Abrasive Grains

2019 ◽  
Vol 141 (8) ◽  
Author(s):  
Zhenguo Nie ◽  
Gang Wang ◽  
Liping Wang ◽  
Yiming (Kevin) Rong
Keyword(s):  
Residual Stress ◽  
Coupled Model ◽  
Grinding Force ◽  
Modeling Method ◽  
Temperature Fields ◽  
Force Model ◽  
Thermomechanical Model ◽  
Abrasive Wheel ◽  
Abrasive Grains ◽  
Thermomechanical Modeling

Abstract In this research, we propose a coupled thermomechanical modeling method for predicting grinding residual stress based on randomly distributed grains. In order to deal with the problem that the nominal grinding force is too small to generate the plastic deformation, we hold the opinion that grinding residual stress is totally derived from three factors: thermal stress, the nominal grinding force (pressure) over the entire grinding zone, and the equivalent plowing force just under the bottom of the abrasive wheel. Finite element model (FEM) simulation of the single-grain grinding (SGG) is conducted to obtain the critical plowing depth and the SGG force at an arbitrary cutting depth. Based on the randomly distributed abrasive grains, the equivalent grinding heat source model, the equivalent SGG plowing force model, and the equivalent nominal pressure model are all established. A 2D coupled thermomechanical model is established to simulate the grinding process for temperature fields and grinding residual stress fields. In addition, verification tests are conducted to validate the model. It turns out that the coupled model can accurately predict the multiphysical fields on both temperature and residual stress. Based on the simulation results of the model, the generation mechanism of grinding residual stress is quantitatively studied. This research provides a promising pathway to residual stress control of grinding.

Design and Fabrication of the Superabrasive Grinding Wheel with Phyllotactic Pattern

2012 ◽  
Vol 472-475 ◽  
pp. 2354-2360 ◽  
Author(s):  
Yu Shan Lu ◽  
Cheng Yi Zhao ◽  
Jun Wang ◽  
Yan He ◽  
Zhi Hui Kou
Keyword(s):  
Experimental Results ◽  
Grinding Wheel ◽  
Wheel Surface ◽  
Work Surface ◽  
Phyllotactic Pattern ◽  
Uv Lithography ◽  
Working Surface ◽  
Abrasive Grain ◽  
Grinding Performance ◽  
Cluster Pattern

In order to achieve the controllability of the abrasive arrangement on the working surface of grinding wheel,a new kind of the superabrasive grinding wheel, which has defined abrasive grain cluster pattern, has been designed based on the phyllotaxis theory of biology, and fabricated with UV lithography method and electroplating technology. The analytical results indicate that the phyllotactic parameters influence on the abrasive arrangement configuration on the work surface of the superabrasive grinding wheel, so as to improve grinding performance of the grinding wheel, increasing the diameter of phyllotactic abrasive grain cluster and decreasing phyllotactic coefficient can increases the abrasive grain density of the surperabrasive grinding wheel surface. Electroplating experimental results show that the reasonable electroplating processes can reduce the faults of defined abrasive arrangement on the superabrasive grinding wheel surface.

scholarly journals An Improved Cutting Force Model for Ultrasonically Assisted Grinding of Hard and Brittle Materials

2021 ◽  
Vol 11 (9) ◽  
pp. 3888
Author(s):  
Renke Kang ◽  
Jinting Liu ◽  
Zhigang Dong ◽  
Feifei Zheng ◽  
Yan Bao ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Experimental Studies ◽  
Brittle Materials ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Force Model ◽  
Cutting Force Model ◽  
Fillet Radius ◽  
Hard And Brittle Materials

Cutting force is one of the most important factors in the ultrasonically assisted grinding (UAG) of hard and brittle materials. Many theoretical and experimental studies show that UAG can effectively reduce cutting forces. The existing models for UAG mostly assume an ideal grinding wheel with abrasives in both the end and lateral faces to accomplish material removal, whereas the important role of the transition fillet surface is ignored. In this study, a theoretical cutting force model is presented to predict cutting forces with the consideration of the diamond abrasives in the end face, the lateral face, and the transition fillet surface of the grinding tool. This study analyzed and calculated the vibration amplitudes and the cutting forces in both the normal and tangential directions. It discusses the influences of the input parameters (rotation speed, feed rate, amplitude, depth and radius of transition fillet) on cutting forces. The study demonstrates that the fillet radius is an important factor affecting the grinding force. With an increase in fillet radius from 0.2 to 1.2 mm, the grinding force increases by 139.6% in the axial direction and decreases by 70% in the feed direction. The error of the proposed cutting force model is 10.3%, and the experimental results verify the correctness of the force model.

Contact Stiffness of Grinding Wheels due to the Difference of Table Feed Rate

2009 ◽  
Vol 76-78 ◽  
pp. 137-142 ◽  
Author(s):  
Takazo Yamada ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Stationary State ◽  
Feed Rate ◽  
Contact Stiffness ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Abrasive Grain ◽  
Residual Stock ◽  
The Difference ◽  
Stock Removal

Usually, the contact stiffness between a grinding wheel and a workpiece has been measured in a stationary state. So, in this study, the contact stiffness under the grinding operation is measured under different table feed rate of the workpiece. From this result, it is known that, while the contact stiffness in the stationary state increases with the increase of the contact force, the contact stiffness under the grinding operation decreases with the increase of the normal grinding force relating the table feed rate. In this paper, since the number of contacting abrasive grain with workpiece is constant irrespective of the table feed rate, and the residual stock removal of workpiece is varied by the table feed rate, it is clarified that the contact stiffness under the grinding operation differs from the contact stiffness measured by the stationary state.

Research on the Grinding Force of the Basin-Like Grinding Wheel in Grinding Elliptical Grooves of Outer Race

2013 ◽  
Vol 823 ◽  
pp. 143-148
Author(s):  
Xiao Xue Li ◽  
Jun Ming Wang ◽  
Yu Qin Sun ◽  
Zhen Gang Gao
Keyword(s):  
High Speed ◽  
Grinding Force ◽  
The Other ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Feed Velocity ◽  
Outer Race ◽  
Abrasive Grains ◽  
Other Hand

In order to calculate the grinding force of the basin-like grinding wheel in grinding outer race elliptical grooves, the thesis simplifies the grinding process as follow: the evenly distributed abrasive grains move around grinding wheel axis along an imaginary ellipse at high speed, while the imaginary ellipse moves along the trace deflected from the grinding wheel axis simultaneously. The analysis of grinding force in CVJ outer race elliptical groove grinding with basin-like grinding wheel reveals that, the grinding force will be decreased, if wheel velocity increased and feed velocity decreased. On the other hand, with the decrease of inter-grain spacing, the grinding force of basin-like grinding wheel will be increased, but the grinding force of abrasive grit will be decreased.

scholarly journals On the Grinding Performance of Alumina Wheels in Ultrasonic Vibration-Assisted Grinding of Hardened GCr15 Steel

2021 ◽  
Author(s):  
Yutong Qiu ◽  
Biao Zhao ◽  
Yang Cao ◽  
Wenfeng Ding ◽  
Yucan Fu ◽  
...  
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Wear Property ◽  
Wheel Wear ◽  
Machined Surface ◽  
Gcr15 Steel ◽  
Abrasive Grains ◽  
Ultrasonic Vibration Assisted Grinding

Abstract Composite manufacturing with multiple energy fields is an important source of processing technology innovation. In this work, comparative experiments on the conventional grinding (CG) and ultrasonic vibration-assisted grinding (UVAG) of hardened GCr15 steel were conducted with WA wheel. The grinding wheel wear patterns and chips were characterized. In addition, grinding force, force ratio, and ground surface quality were investigated to evaluate wheel performance. Results illustrate that the interaction between abrasive grains and workpiece in UVAG process has the characteristics of high frequency and discontinuity. The wear property of abrasive grains is changed and the grinding force is decreased because the generation of micro-fracture in abrasive grains improves the grinding wheel self-sharpening. Better surface quality is obtained, the surface roughness is reduced by up to 18.96%, and the number of defects on the machined surface is reduced through the superior reciprocating ironing of UVAG. Accordingly, WA wheel performance is improved by UVAG.

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