Evaluating the performance of “seeded gel” grinding wheels

Abstract

This investigation was undertaken to compare the performance of grinding wheels containing newly developed “seeded gel” aluminum oxide abrasive with wheels containing conventional monocrystalline aluminum oxide. Experiments were conducted on a computer-controlled instrumented internal grinder over a wide range of removal rates with two dressing conditions on hardened bearing-steel specimens. It was found that wheels containing “seeded gel” abrasive required less grinding power and gave higher grinding ratios than monocrystalline abrasive wheels of the same grade with no significant difference in surface roughness. The potential improvement in productivity using “seeded gel” abrasive wheels was estimated using an optimization program which predicts the maximum possible removal rate subject to constraints on workpiece burn and surface roughness. As compared with monocrystalline abrasive wheels of the same grade, estimated optimal removal rates for “seeded gel” wheels were 15–30% higher while also providing 40–80% higher grinding ratios. With harder grade monocrystalline wheels to obtain comparable grinding ratios, estimated optimal removal rates with “seeded gel” were 40–60% higher. For comparable optimal removal rates obtained by using softer monocrystalline wheels, estimated grinding ratios with “seeded gel” wheels were as much as four times higher.