Investigating effects of adhesion wear on cutting efficiency and energy cost in dry belt finishing

Abstract

Adhesion wear, an improper wear form on abrasive belt, is often found in dry belt finishing as a common phenomenon. Therefore, its effects on this machining process are important to be investigated. This paper gives a comprehensive understanding of its effects on cutting efficiency and energy cost. First, a series of finishing tests with different applied pressures and different belt feed rates are performed. Then, the material removal rate and specific energy are obtained and analyzed through an analytical approach to dissociate costed energy on sliding and cutting. It has been demonstrated that increasing belt feed rate can give a higher material removal rate with a lower energy cost in normal finishing. The adhesion wear can significantly worsen cutting ability and waste energy in sliding. Compared with belt finishing under minimal quantity lubrication (MQL), dry belt finishing is able to improve material removal but with an uneconomic energy consumption.