Abrasive Belt Grinding Research Articles

Investigating the effects of contact pressure on rail material abrasive belt grinding performance

This paper presents an experimental investigation into the effects of various contact pressures on the abrasive belt grinding performance of rail material. The contact relations between the contact wheel covered with elastic rubber and the head surface of the rail are first analytically discussed as they relate to the pressure distribution. The contact pressure, which is proposed as the control variable in grinding experiments instead of the loaded force, apparently indicates a highly accurate contact state. Accordingly, contact pressure was chosen as a variable parameter for abrasive belt grinding experiments on an Mn-steel rail workpiece. The results of the experiment, including material removal rate, grinding ratio, surface roughness, hardness, chip size, and chip elements, are discussed in detail. Elevated contact pressure exerted a positive influence on material removal rate in the experiments, and the surface hardness of the ground rail surface increased as contact pressure increased. Conversely, grinding ratio decreased with increasing contact pressure. The size of chips also increased as contact pressure increased, as did the oxygen content in the chips—this may indicate that Fe3O4 and Fe2O3 content in the chips also increased as contact pressure increased.

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

The surface finishing and stock removal of complicated geometries is the principal objective for grinding with compliant abrasive tools. To understand and achieve optimum material removal in a tertiary finishing process such as Abrasive Belt Grinding, it is essential to look in more detail at the process parameters/variables that affect the stock removal rate. The process variables involved in a belt grinding process include the grit and abrasive type of grinding belt, belt speed, contact wheel hardness, serration, and grinding force. Changing these process variables will affect the performance of the process. The literature survey on belt grinding shows certain limited understanding of material removal on the process variables. Experimental trials were conducted based on the Taguchi Method to evaluate the influence of individual and interactive process variables. Analysis of variance (ANOVA) was employed to investigate the belt grinding characteristics on material removal. This research work describes a systematic approach to optimise process parameters to achieve the desired stock removal in a compliant Abrasive Belt Grinding process. Experimental study showed that the removed material from a surface due to the belt grinding process has a non-linear relationship with the process variables. In this paper, the Adaptive Neuro-Fuzzy Inference System (ANFIS) model is used to determine material removal. Compared with the experimental results, the model accurately predicts the stock removal. With further verification of the empirical model, a better understanding of the grinding parameters involved in material removal, particularly the influence of the individual process variables and their interaction, can be obtained.

Investigation of Diamond Elastic Belts Characteristics Effect on Rotary Belt Grinding Process Output Performance

The article is dedicated to the advantages and disadvantages of belt grinding in comparison to the abrasive wheel processing. Abrasive belt grinding has a number of significant advantages in comparison to the abrasive wheel processing. Compared to abrasive wheel grinding, belt grinding process is characterized by greater productivity and higher quality of the finished part surface. The most appropriate scheme in terms of achieving low surface roughness is the method of rotary belt envelope grinding with diamond elastic belts. The results of the experimental studies of the effect of grinding with diamond elastic belts on the surface roughness, removal of metal, and the amount of the bearing surface, are reported. Hence, the following conclusions are represented – at grinding, the diamond elastic belts provide the surface roughness of Ra 0.04 - Ra 0.008 in the processing of hard alloy metals, steels, non-ferrous metals and titanium-base alloy, with the simultaneous improvement of microgeometric characteristics and increase of bearing area.

Finite Element Simulation about Abrasive Belt Grinding Silicon Carbide

Silicon carbide, a high-strength material, has a ductile-brittle transition mechanism. In order to establish a reasonable silicon carbide abrasive belt grinding parameters to obtain high precision silicon carbide free-surface efficiently, a series of finite element simulations were conducted to comprehend the single point diamond grinding of silicon carbide using professional analysis software of nonlinear finite element in this paper. According to the differences of cutting parameter, such as cutting depth, cutting deformation of the chip and the maximum cutting force were studied. For the free-form surface with higher accuracy, the data showed that ductile machining of silicon carbide is more efficient along with the larger rake angle, the higher cutting speed and the smaller cutting depth.

Experiment and Surface Roughness Prediction Model for Ti-6Al-4V in Abrasive Belt Grinding

In abrasive belt grinding, abrasive belt granularity, abrasive belt speed,feeding speed and grinding force have a great influence on the surface roughness. In order to predicate the surface roughness of Ti-6Al-4V,a response surface methodology are used to build the model to predict surface roughness,and the influence of various parameters on surface roughness was analysed. The research shows that with the abrasive belt granularity and abrasive belt speed increasing,the work piece surface roughness decreases;with the grinding force and feeding speed increasing,the work piece surface roughness increases. Through the test,the response surface methodology with high prediction accuracy,provides a theoretical basis for the reasonable selection of abrasive belt grinding parameters.

Experiment and Surface Roughness Prediction Model for Ti-6Al-4V in Abrasive Belt Grinding

In abrasive belt grinding, abrasive belt granularity, abrasive belt speed,feeding speed and grinding force have a great influence on the surface roughness. In order to predicate the surface roughness of Ti-6Al-4V,a response surface methodology are used to build the model to predict surface roughness,and the influence of various parameters on surface roughness was analysed. The research shows that with the abrasive belt granularity and abrasive belt speed increasing,the work piece surface roughness decreases;with the grinding force and feeding speed increasing,the work piece surface roughness increases. Through the test,the response surface methodology with high prediction accuracy,provides a theoretical basis for the reasonable selection of abrasive belt grinding parameters.

Model of an abrasive belt grinding surface removal contour and its application

Belt grinding technology is used for machining the complex surface of a blade; however, it is difficult to ensure processing accuracy. To solve this problem, a surface removal contour (SRC) model for grinding the complex surface of a blade is proposed. First, this paper discusses why the normal contact pressure between the grinding wheel and workpiece surface accords with the Hertz contact theory, and further, the calculation method for the pressure distribution of the Hertz contact is given. Second, the SRC model is determined from the material removal rate (MRR) nonlinear model. To deter- mine the parameters of the MRR nonlinear and linear models, an abrasive belt grinding experiment was performed, which showed the relative error for the MRR nonlinear model was −1.1∼1.4 % and for the linear model was −12∼8 %. Third, combined with the Hertz contact theory, a SRC model based on the MRR nonlinear model was built. The SRC experiment showed the model's accumulative error was only ±1 %, but the accumulative error of the SRC model based on the MRR linearmodelwas −11∼5%.Finally,theapplicationofabrasive belt grinding on the blade showed the SRC model based on the MRR nonlinear model was better in dimensional precision and consistency of surface quality than the MRR nonlinear model. This led to more than 17.5 % surface roughness over the processing requirement and, beyond a 30 % maximum error, exceeded the standard. The residual stress on the blade surface after grinding appeared as a tensile stress.

Kinematic analysis and feedrate optimization in six-axis NC abrasive belt grinding of blades

The purpose of this paper is to propose a kinematic analysis and optimization method for a kind of six-axis numerical control (NC) belt grinding machine tools when grinding blades. Six-axis NC abrasive belt grinding machine tools have been widely used for grinding blades in the aero engine manufacturing enterprises. Kinematic analysis and feedrate optimization play an important role in efficient machining with NC machine tools. After analyzing the basic kinematic relation of the six-axis NC abrasive belt grinding machine tool, coordinate systems are established to calculate the generalized kinematics model. The formulas of the rotary angles and the motion coordinates are provided by simultaneously transforming the three vectors which control the motions of the abrasive belt contact disk. An efficient strategy for feedrate optimization is developed to meet the accuracy requirements of blade abrasive belt grinding process. Both the load capacity of process system and the servo drive capability of machine tools are considered. The validity is demonstrated with simulations and experiments on a TX6-1000HV computer numerical control (CNC) machine tool.

Belt grinding process with force control system for blade of aero-engine

In abrasive belt grinding process for surface of blade, elasticity, deformation and abrasive belt wear are major factors affecting the machining stability, efficiency and quality. In order to improve the grinding process and realize optimal grinding, a new controllable and flexible belt grinding mechanism is designed and assembled in a special computer numerical control grinding machine, accompanied with a constant grinding force control system. Based on the analysis of proportional valve and cylinder system in this grinding mechanism, a mathematic model of normal grinding force is constructed. Afterward, a fuzzy proportional–integral–derivative control strategy is proposed to deal with the uncertainty and nonlinearity of this system. A Simulink model of force control process is developed, and the good performance is achieved according to the simulation result. Finally, several grinding experiments for an aero-engine fan blade are carried out. The measurements show that the proposed grinding process with fuzzy proportional–integral–derivative force controller enhances the machining stability and efficiency considerably. What is more, the machining qualities, such as surface roughness, form accuracy and consistency, are improved significantly. And all the grinding results satisfy the machining requirements in the manufacturing process of blade.

Application model of surface removal contour to blade abrasive belt grinding

In order to improve dimensional accuracy of aero-engine blade edges, surface removal contour (SRC) model is applied to the engine blade grinding in this study. Firstly, according to variable curvature of characteristics the engine blades, this paper adopts the semi-Hertz contact theory to simulate grinding contact state. Secondly, surface removal contour model was deduced from the material removal rate (MRR) nonlinear model, and the model of the final grinding depth is proposed, and the model consider the influence of path interval. Thirdly, for determining the parameters of MRR nonlinear and linear model, abrasive belt grinding experiment is carried out, which shows the relative error of MRR nonlinear model to be -1.1↓~1.4↓. The application of abrasive belt grinding on the blade showed the maximum error of the processing is within 0.05 mm and the abrasive belt grinding process system is stable.

Interference analysis and simulation of abrasive belt grinding and polishing of blisk

Blisk is a difficult processing part with complex structure. The polishing quality and accuracy of the blade surface will significantly affect its performance and life. A new abrasive belt system is developed to grind and polish the blade on the blisk. In view of the problem that the abrasive belt is easy to interfere with the adjacent blades in the grinding and polishing process, an algorithm for judging the critical interference state is proposed based on the structural characteristics of the abrasive belt tool system and the actual grinding and polishing process of the blades. On the basis of above, a new algorithm is developed to calculate the range of interference-free wrap angle of the abrasive belt tool system. This paper established a simulation model based on VERICUT software and simulated the process of the blisk polishing. The simulation and experiment results verifies the effectiveness of the algorithm.

Experiment Research on ZrO2 Engineering Ceramics with Abrasive Belt Grinding

Abrasive belt grinding experiments of ZrO2Engineering Ceramics are carried out by using 4 different abrasive belts. The orthogonal test with zirconia-corundum belt was to get the best grinding parameter, the amount of material removal workpiece surface roughness and belt wear were measured to get the best grinding parameter.In this paper,the influence of abrasive belt granularity and different grinding parameters to grinding efficiency and workpiece surface quality throughout the process of grinding ZrO2Engineering Ceramics was analyzed. Analysis wear mechanism of engineering ceramics based on the Abrasive cutting model by observing the surface morphology. The results show that increasing the grinding force or the abrasive belt granularity can decrease the workpiece surface roughness;With the abrasive belt speed or grinding force increasing,the material removal rate and the wear ratio to some extent, but brittle fracture is occued easily on its surface when exceeds the critical value; When the abrasive belt speed is 19m/s,the grinding force is 15N and the abrasive belt granularity is 120#, ZrO2Engineering Ceramics grinding effects reach the best.

Investigations on Belt Grinding of GH4169 Nickel-Based Superalloy

The majority of aero-engine components are designed and manufactured with nickel-based superalloy GH4169 in mind. There is little information available in the literature related to belt grinding processes of aero-engine components. Up to now, limited research has been reported in the use of belt for grinding aero-engine components made of nickel-based superalloy GH4169. A case study of an abrasive belt grinding performance applied on nickel-based superalloy GH4169 in manufacturing processes is presented, aiming to investigate the possibility of using belt grinding as a operation for components made of nickel-based superalloy GH4169. For the ‘optimised’ grinding conditions, the belt service life is evaluated by changing grinding parameters (grinding speed, contact force and oscillation frequency), and the following output measures are obtained: material removal, belt wear and grinding ratio. As a result, the maximum grinding ratio of G is 8.8, it could be concluded that belt grinding might be considered as a viable process for grinding aero-engine components.

Workpiece Surface Integrity of GH4169 Nickel-Based Superalloy when Employing Abrasive Belt Grinding Method

The use of GH4169 nickel-based superalloy for the manufacture of gas turbine engines components for aerospace/energy applications has become a routine exercise. However, components with complex designs specifications might pose manufacturing challenges especially when grinding processes are needed to enable their compliance with tight industrial standards for workpiece surface integrity. Information on grinding processes for such sensitive industrial applications is scarce. The paper reports on the influence of grinding methods/strategies on the quality and integrity of workpiece surfaces obtained after abrasive belt grinding methods on GH4169 nickel-based superalloy. The influences of grinding speed, contact pressure and oscillation frequency on surface roughness were discussed. The performance of the abrasive belt and surface topography were discussed. As a result, the maximum surface roughness of Ra is 0.072μm, and have a good performance of the abrasive belt, it could be concluded that abrasive belt grinding might be considered as a viable process for grinding aero-engine components.

Research on Path of Contact Wheel for Ruled Blade Grinding

Blade is one of the important components in aero-engine, turbine, and wind generators. The quality of the blades has big influence on the performance of the machine. So high profile accuracy and low surface roughness were put forward. Ruled blade is just one of the blades of aero-engine, which has simple profile and little distort. This blade was grinded by two sides together in the paper. Therefore, in this thesis, the main objects are as fallow: firstly, according to the characteristics of the abrasive belt grinding, analysis the selection of grinding distance for the blade. Secondly, established the model of contact wheel compare grinding system, derived the range of wrap angle of contact wheel, and then two region were make out, one is the region can be directly grinding, and another region which may lead to wheel interference. At last the grinding path of the center of the contact wheel was obtained by calculated the blade model.

Kinematics Analysis of Abrasive Belt Grinding Robot for Aero-Engine Blade and its Simulation

This paper presents an abrasive belt grinding robotic system solution for traditional aero-engine blade manual grinding situation. In order to overcome the limitation of traditional polishing robot teaching programming way and improve the efficiency of the robot offline programming and simulation of interactive, based on OpenGL robot programming and motion simulation platform with interactive features is constructed with VC++6.0. The result shows that the system is able to realistically simulate the movement of industrial robots grinding and polishing process, and it provides a reference for the other abrasive belt grinding and polishing robot off-programming and kinematics simulation development technology.

Research on the Technology of Nc Abrasive Belt Grinding for the Leading and Trailing Edges of Aero-Engine Blades

This paper provides an analysis of the processing status and the existing problems of leading and trailing edges, and proposes a new seven-axis linkage CNC grinding method. Whats more, the paper carries out the forging blade edge abrasive belt grinding experiment. Finally, on the basis of experimental result, grinding process parameters are optimized, and the improved scheme is put forward. Through the experiment, the feasibility of the seven-axis CNC abrasive belt grinding method is verified.

Optimization Design for Gun-Receiver Materials Belt Grinding Based on Orthogonal Experimental Method and Grey Relational Analysis

In order to change the current situation of gun-receiver manual polishing, the paper presents a new process for abrasive belt grinding of gun-receiver material (C50 steel). Orthogonal test were conducted with abrasive belt grinding of C50 steel to do research on material removal rate and surface roughness. The best parameter combination to the optimization design which can guarantee high material removal rate and low surface roughness was obtained by using grey relational analysis method and verified by experiments. The above mentioned research not only can improve the removal rate of C50 steel, but also do help to prolong the service life of the belt. Whats more, it can guide a theoretical significance and practical value to the production practice.

Experimental Research on the Predictive Model for Surface Roughness of Titanium Alloy in Abrasive Belt Grinding

Titanium alloys have been applied to aerospacemedical and other fields. The surface roughness of titanium alloy about these areas is very high. Based on the results of orthogonal test, belt grinding surface roughness prediction model of TC4 Titanium alloy is established using linear regression method. The significant tests of regression equation are conducted and proved that the prediction model has a significant. The results indicate that the model has reliability on the prediction of surface roughness, abrasive belt grinding pressure has certain influence on the surface roughness, and grain size of belt and the belt linear speed have high significant influence on surface roughness and the influence coefficient are-0.9378 and-0.2317. While the contact wheel hardness and workpiece axial feeding speed have no significant influence on surface roughness.

Experimental Investigation on the Surface Integrity of Titanium Alloy TC4 in Abrasive Belt Grinding

This paper aimed at that titanium alloy grinding is easy to appear surface burn, crack, then carry out the titanium alloy TC4 abrasive belt grinding experiment, focus on the effect of grinding parameters on the titanium alloy TC4 surface integrity (surface roughness, microstructure and surface residual stress) . The results of the study show that the use of zircon corundum belt and cutting speed velocity range from 18 to 26 meter per second, the surface integrity of titanium alloy TC4 is better.