Abstract
The article presents the results of experimental investigations to determine the effect of wear phenomena of grinding wheels with sol-gel alumina abrasive grains on chip formation during internal cylindrical plunge grinding of 100Cr6 steel. Basic wear phenomena conducted during the grinding process using microcrystalline sintered corundum abrasives are described. In order to expand our knowledge of this phenomena, experimental tests were conducted in two stages. In stage 1, only one opening was machined, which corresponded to the removal of 464 mm3 of workpiece material. In the second stage, the process was carried to machine 100 subsequent openings (material removal V w = 46,400 mm3). Such methodology allowed one to observe changes in the form of chips resulting from the progressive wear of the grinding wheel components. The form and size of the chips were identified by recording and analyzing the SEM micrographs of the chips for both grinding stages, respectively. Conducted studies have shown that the dominant type of chips, shaped in the initial period of the grinding wheel’s life, are large (several hundred μm in length) flowing-type chips resulting from material removal by sharp cutting edges of abrasive grain active vertices. At the end of the grinding wheel’s life, when active vertices of abrasive grains have clear signs of large fatigue and thermo-fatigue wear, only in the near-edge zones of the wheel can flowing-type and shearing-type chips (usually less than 100 μm in length) be observed, while knife-type and slice-type microchips were predominately registered on the whole grinding wheel surface.
Highlights
For many years, the form of chips generated in machining processes was the source of information on the process conditions, allowing one to define the basic phenomena related to material removal, as well as predicting and evaluating the process quantities
The wide range of analysis of chip morphology presented in this text, as well as of the grinding wheel active surface condition, allows one to formulate credible conclusions regarding the effect of wear phenomena on grinding wheels with sol-gel alumina abrasive grains on chip formation during internal cylindrical plunge grinding of 100Cr6 steel
– The dominant type of chips, shaped in the initial period of the grinding wheel’s life, are large flowing-type chips resulting from material removal by the sharp cutting edges of abrasive grain active vertices
Summary
The form of chips generated in machining processes was the source of information on the process conditions, allowing one to define the basic phenomena related to material removal, as well as predicting and evaluating the process quantities. Information from the analysis of the form of such chips is important in investigations of new varieties of the abrasive processes or by determining the effect of process modernization on its course Initial work in this area was related with a better understanding and classification of the forms of chips generated in various grinding processes and seeking a relationship between the form of chips and process parameters. Wong and Doyle [6] drew attention to the form of chips throughout the sample issue of the impact of a fragmented zone on an increase in metal removal in the form of thin delaminated wear platelets The authors demonstrated this effect by observing the forms of chips generated in the examined process, stating that thin delaminated wear platelets are evident when grinding in an inert atmosphere and take the form of oxide hollow spheres (spherical chips, melted globule) when grinding in air. The obtained results of such a comparison gives one an estimate of the temperature that the chip would have undergone during the grinding process
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