Investigation of the effects of speed ratio and transversal overlapping ratio on CVD form roller dressing of corundum wheels and subsequent grinding performance

Abstract

Grinding operation performance is strongly affected by grinding wheel surface condition. Two of the main indicators of grinding behaviour are the ground part surface roughness and the consumed amount of energy, which are both affected by grinding wheel dressing operation. Researchers have deeply studied and modelled effects of dressing parameters for stationary and rotary dressers for vitreous-bonded corundum wheels, but there is still a lack of scientific knowledge on the effects of disc dressing parameters on grinding performance and on the ground part surface condition due the grater kinematical and dynamical complexity of the rotary dressing process related to the fact that both bodies are rotating. In this paper, a deep analysis of infiltrated CVD disc dressing efficiency for conventional grinding wheels will be presented, considering the influence of the combination of dressing parameters altogether. Specifically, the effects of a wide range of speed ratios (qd) and transversal overlapping ratios (Ud) will be tested, monitoring dressing and grinding indicators such as dressing forces and grinding power, as well as surface finish of the ground part. This work covers the whole range of speed ratios used in the industry, including those below −1.0 and above 1.0, an area that few researchers have dug into before. Furthermore, the impact of integer qnd ratios is explored, which is yet to be studied in the literature. Results show a high dependency of all analysed indicators on both analysed parameters (qd and Ud) and uncover the significance of taking into consideration the rotational speed ratio (qnd). Hence, findings can result in a useful tool for the selection of most suitable dressing parameters when specific surface qualities need to be achieved.