Experimental Investigation of Burr Formation in the Surface Grinding of Tool Steel

Abstract

Increasing industrial requirements concerning the precision of edge geometry lead to the investigation of burr formation, particularly in finishing operations such as grinding. In the present paper, a fundamental investigation of burr formation in the flat surface grinding of tempered tool steel (90MnCrV8) is presented. Conventional and superabrasive grinding wheels with different grain sizes and materials are used under varying cutting conditions. In addition, a ‘hybrid grinding wheel’, which essentially is the wheel hub of a superabrasive wheel with an aluminium oxide abrasive layer, is used in order to isolate the influence of the abrasive material. The geometry of the generated exit burrs at the workpiece edge is investigated. The geometrical burr parameters are measured using optical microscopy. Furthermore, measured grinding forces and temperatures are correlated with the burr parameters. In addition, the microstructure of the burr material is analysed by metallographic sections. As a result of the experimental investigations, an approach to describing burr formation mechanisms in grinding as well as the influences of grinding wheel and cutting parameters on burr shape and size is obtained.