Abstract
Grinding efficiency is one of the most important considerations in the selection of grinding operation conditions because it has a significant impact on the productivity, quality, energy consumption and cost. Focusing on the core issues of grinding process, the paper presents some fundamental research findings in relation to grinding material removal mechanisms. The grinding efficiency is analysed by considering the rubbing, ploughing and cutting of a single-grit grinding. By analysing the features of acoustic emission in single-grit grinding tests, an evidence-based scientific foundation has been established for monitoring grinding efficiency using acoustic emission. Following the discussion of the energy consumption, temperature elevation and thermal stresses in grinding, the paper provides a logical depiction that explains why acoustic emission can be used for grinding thermal performance monitoring. As a result, a novel acoustic emission monitoring method is to monitor grinding temperature and grinding wheel wear status.
Highlights
Grinding operation is commonly applied to material removal in order to achieve required size and form accuracy with specified surface finish
Following the discussion of the energy consumption, temperature elevation and thermal stresses in grinding, the paper provides a logical depiction that explains why acoustic emission can be used for grinding thermal performance monitoring
This paper focuses on the fundamentals of material removal in grinding and associated acoustic emission (AE) phenomenon to illustrate some interesting relationships between grinding AE features and the grinding mechanical and thermal performance
Summary
Grinding operation is commonly applied to material removal in order to achieve required size and form accuracy with specified surface finish. With a simple test rig set-up on a Nanoform 250 machine as shown, the material removal can be investigated by using a cubic boron nitride (CBN) grit to scratch workpiece as it acts in a grinding process. It is interesting to identify the features of grinding acoustic emission in relation to the rubbing, ploughing and cutting actions in single-grit grinding.
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