Technological support of tool wear resistant qualities and cost saving of process of planetary grinding of flat parts

Abstract

A lot of factors varied in time lead to instability of the grinding process. Besides, the method of grinding influences significantly the productivity and quality of processing. In this regard a creation of processes of intensive defect-free grinding on the basis of new constructive and technology solutions represents the scientific problem which is of great importance. One of such solutions is application of planetary face grinding which allows simultaneously changing the kinematics of movement, implementing discontinuous grinding. The distinctive features of such grinding are decreasing the heat release rate in a contact zone; ensuring intermittence of the process with a solid grinding wheel; reverse grinding; cutting by different edges of an abrasive grain; stabilization of working parameters of a grinding wheel; ensuring work of a grinding wheel in a self-sharpening mode. The design of the planetary grinding tool was developed for plane surface processing for implementation of the specified distinctive features of planetary grinding. The kinematics of shaping a surface by flat face diamond grinding has been investigated; manufacturing capabilities of planetary face grinding have been revealed, and ways of improvement of quality and productivity have been offered. The algorithm and the program to define the motion path of a grain depending on the given set of grinding factors were received. Optimization of the process of face diamond grinding using the planetary grinding device has been confirmed with the developed program and techniques to choose cutting conditions of planetary grinding and characteristics of grinding wheels for processing different materials. While studying the process of planetary grinding, special attention was paid to the research how processing conditions influence microgeometry of the processed surface made of steel 4X5M (Russian State Standard (GOST)). As a result of the executed research, it was established that surface roughness parameter Ra during the processing using the planetary grinding device is 35 - 40% less than when using the tool with the solid cutting surface. This phenomenon can be accounted for more uniform work of the cutting grains of the planetary grinding tool as the number of meetings of diamond grains with the surface being processed increases. At the same time, it should be noted that during the planetary grinding more intensive smoothing of tops of microroughnesses is observed that provides the creation of steadier cutting shape. The given method of calculation of cost value of grinding operation allows solving various manufacturing problems: to compare cost value of grinding different materials, grinding wheels of different parameters; to define the optimum grinding conditions.