Abstract
High efficiency deep grinding (HEDG) of a low alloy steel (51CrV4) has been carried out on an Edgetek 5-axis CNC grinding machine, using electroplated CBN wheels. The initial tests were conducted in a surface grinding mode over a wide range of grinding conditions, to evaluate the levels of specific grinding energy, workpiece surface integrity and wheel wear. The burn threshold conditions for the ground workpiece surface have been proposed in terms of a critical heat flux which is shown to vary with material removal rate. Cylindrical grinding in HEDG mode has also been carried out based on the knowledge obtained from the surface grinding. It has shown that the HEDG technology can be transferred successfully to the field of cylindrical grinding to achieve very high specific material removal rates in excess of 400mm 3/mm.s. The successful application of HEDG to cylindrical components depends on the appropriate selection of grinding parameters and also the grinding fluid supply strategy. Thermal modelling of the HEDG process combined with surface integrity studies, has shown that under cylindrical grinding conditions a significant reduction in grinding fluid supply is possible even when operating within the HEDG regime.
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