Abstract
This paper considers heavy duty grinding with resin bonded corundum grinding wheels and without lubrication and cooling. A vertical turning machine redesigned to a grinding machine test bench with a power controlled grinding spindle is used in all of the experiments, allowing high tangential table feed rates up to 480 m/min. This special test-rig emulates the railway grinding usually done by a railway grinding train. The main test-rig components are presented and the resulting kinematics of the experimental set-up is described. A stochastic kinematic grinding model is presented. A wear model that is based on the kinematic description of the grinding process is set up. Grain breakage is identified as the main wear phenomenon, initiated by grain flattening and micro-splintering. The wear model is implemented into the stochastic kinematic modelling. The workpiece material side flow and spring back are considered. The simulation results are validated experimentally. The workpiece surface roughness is compared and a good agreement between simulation and experiment can be found, where the deviation between the experiment and the simulation is less than 15% for single-sided contact between the grinding wheel and the workpiece. Higher deviations between simulation and experiment, up to 24%, for double-sided contact is observed.
Highlights
Three important global trends of manufacturing technology in recent years were observed: moving towards increasing performance in material removal rate, higher resulting surface quality, and the reduction of coolant consumption
The implementation of high performance machining processes in general have become increasingly significant among cutting processes and could already modify many industrial manufacturing process chains by substituting one or more machining steps, and save cost
The marked tilt angle is adjusted with a hydraulic cylinder and can be positioned in a positive and negative direction within ±15◦
Summary
Three important global trends of manufacturing technology in recent years were observed: moving towards increasing performance in material removal rate, higher resulting surface quality, and the reduction of coolant consumption. Grinding is often used for finishing applications to generate smooth surfaces with high integrity and low form deviations, but grinding is yet increasingly challenging other manufacturing technologies such as high-speed or high-performance milling and turning. The implementation of high performance machining processes in general have become increasingly significant among cutting processes and could already modify many industrial manufacturing process chains by substituting one or more machining steps, and save cost. As stated by Bhaduri and Chattopadhyay [1], and by Kopac and Krajnik [2], high quality parts require high-performance grinding technologies when considering superior surface finish and high removal rate. The literature classifies high performance grinding not clearly distinguishable from conventional grinding and covers different grinding techniques such as: High Speed Grinding (HSG), High Efficiency Deep Grinding (HEDG), Speed-Stroke Grinding, High-Performance Surface Peel
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