Abstract
The paper presents the results obtained for abrasive electro-discharge grinding (AEDG) of Ti6Al4V titanium alloy with the use of super hard grinding wheels of cubic boron nitride with a metal bond. The experimental investigations were focused on process monitoring for sharp and worn grinding wheels. For the evaluation of the grinding process, the grinding force amplitude and a few descriptors of the high-frequency stress waves were investigated in both time and frequency domains. The results show that during the AEDG, specific elastic waves are generated. Since these waves have characteristic amplitudes, frequencies, and other different descriptors dependent on the current grinding wheel cutting ability and discharge parameters, they can be applied to estimate a statistically significant regression function. For each measurement signal, a few statistical features are calculated and used as input for data selection and classification procedures. Registration and classification of forces and acoustic emission signals can be used to analyse the abrasive electro-discharge grinding process and allow for the determination of the machining results and the lifespan of super hard grinding wheels.
Highlights
Performance and efficiency of grinding is affected by the selected conditions, processing parameters, and the condition of the active surface of the grinding wheel, which determines the ability to remove the machining allowance.Grinding wheel wear is an important factor having effect on grinding in the manufacturing process of engineered parts and tools
Titanium alloys present low grindability due to low thermal conductivity, high chemical reactivity, low elastic modulus, high hardness and strength at elevated temperatures and peculiar work hardening features
This section is divided into parts connected with the main goals of experimental studies related to the following topics: geometrical structure of the surface of titanium alloy workpieces after grinding in different process conditions; the changes in the acoustic emission and force values during grinding and the correlation of output signals with the surface quality and grinding wheel wear, possibility of predicting tool wear and classifying the abrasive electro-discharge grinding (AEDG) process by output signals
Summary
Performance and efficiency of grinding is affected by the selected conditions, processing parameters, and the condition of the active surface of the grinding wheel, which determines the ability to remove the machining allowance.Grinding wheel wear is an important factor having effect on grinding in the manufacturing process of engineered parts and tools. The lifespan of the grinding wheel and final surface properties of the workpiece are directly affected by grinding forces and the operating cutting temperature (i.e. in [1, 2]). Another problem is the properties of materials and their machinability, especially in the case of difficult-to-machine materials like titanium, nickel alloys or ceramics. When the SiC (GC) wheel is dull, the normal force increases sharply while the tangential grinding force increases
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