Abrasive Technology Research Articles

Multi-objective optimization and accelerated experimental research on load distribution of planetary roller screw mechanism

Load distribution is a critical characteristic that determines the load carrying capacity of planetary roller screw mechanism (PRSM). First, a load distribution calculation model is established. Subsequently, a multi-objective optimization model to achieve uniform load distribution is constructed based on NSGA-II. Then, considering the optimization effect, machining feasibility and machining efficiency, the optimal load uniform distribution design method for linear thinning of thread thickness is determined using the analytical hierarchy process. Finally, an accelerated test method of PRSM load-bearing characteristics based on abrasive technology is proposed for the first time. The experimental results show that after optimization, the maximum contact width decreases by 12.5% and the fluctuation amplitude decreases by 74.6%, which significantly improves the uniformity of PRSM load distribution.

Special Issue on Abrasive Technology for High-Precision and High-Efficiency Machining of High-Performance Materials

The demand for high-precision and high-efficient machining of high-performance materials and components has increased in various industries such as optical, automotive, communication, life sciences, and medical sciences. Certain difficult-to-machine materials can be reliably machined using deterministic precision cutting processes. However, hard and brittle materials such as ceramics, carbides, hardened steel molds, glassy materials, or semiconductor materials, require precision abrasive technologies with super abrasives like diamond, cBN, or new tool materials for machining. However, machining high-precision components and their molds/dies using abrasive processes is considerably more difficult due to their complex and non-deterministic nature and textured surfaces. Furthermore, high-energy processes such as laser technology can assist abrasive technologies in ensuring higher precision and efficiency. Precision grinding and polishing processes are primarily used to generate high-quality and functional components, typically made of difficult-to-machine materials. Thus, the surface quality achievable by precision grinding and polishing processes becomes more important for reducing machining time and costs. This special issue features 10 papers on the most recent advances in precision abrasive technologies. These papers cover the following topics: - Ultrasonic grinding of micro holes using cemented WC tools - Drilling holes in CFRP aircraft using cBN electroplated ball end mill - In situ evaluation of drill wear using tool images - Grinding belt based on modified information entropy - Radial directional vibration-assisted grinding of Al2O3 ceramics - Chatter vibration suppression using fixed superabrasive polishing stone - Free abrasive finishing of internal channels with different cross-sectional geometries - High-quality machining of cemented carbide using PCD ball end mills - Fixed-abrasive machining with magnetic brush for Ti-6Al-4V ELI alloy - High-efficient polishing of polymer surfaces using catalyst-referred etching This issue will provide an understanding of the recent developments in abrasive technologies, leading to further research. We deeply appreciate the careful work of all the authors, and we thank the reviewers for their incisive efforts.

Abrasive Technologies with Dry Ice as a Blasting Medium—Review

The objective of this work was to present an overview of abrasive technologies with solid carbon dioxide as a blasting medium. These methods can be successfully used for the removal of a wide range of types of industrial pollution. The article covers literature reports in the field of the examined cleaning mechanisms and manufacturing process of dry ice, focusing on the structure and size of the product. Having the correct understanding of these processes is crucial for further technological development. Then various configurations of the dry-ice-blasting and snow-blasting systems are presented, including a range of typical parameters met in the literature and in industrial applications. Because the nozzle can be treated as a key part of the system, typical examples of nozzles are described. Special attention is paid to the usability of each type. This study also covers the actual scope of applications for the described systems, especially in industry and science.

Modelling Particle Motion during High-Voltage Electrostatic Abrasive Implantation Based on Multi-Physics Field Coupling

Electrostatic abrasive implantation technology is a classical process based on electrostatic field to implant abrasive particles into base material. However, there is still not a quantitative model to ensure the implantation performance due to the fact that the electrostatic abrasive implantation is a complex multi-physics coupled process. To ensure the quality of sandpaper and elucidate the complex motion mechanism of Al2O3 based abrasive particles in a high voltage electrostatic field, a multi-physical field coupling simulation model is proposed. First, the mechanical model is constructed for the complex problem of the electrostatic abrasive implantation process. Then, the field model is established for the problem that the superposition of multi-physical fields leads to complicated environmental conditions. Finally, the evaluation model is established for the problems that the abrasive planting effect is difficult to evaluate and the planting parameters are difficult to adjust. Besides, a tailored electrostatic abrasive planting testing equipment is designed for the implantation performance analysis purpose. Single-parameter electrostatic abrasive planting experiments were conducted to analyze and verify the effect of different pole plate voltage and pole plate spacing on the abrasive implantation rate. To ensure the implantation performance, the applicable pole plate spacing ranges from 30 mm to 50 mm and the suitable voltage is 20–40 kV according to the simulation result in the proposed two models. Meanwhile, the implantation rate experimentation shows the coupling field model coincides with the experiments better. The key factors affecting the electrostatic abrasive planting process are identified, and a feasible multi-physical field coupled abrasive particle motion simulation model is proposed.

Special Issue on High Performance Abrasive Technologies

Demand for the high-precision and high-efficiency machining of hard ceramics, such as silicon carbide for semiconductors and hardened steel for molding dies, has significantly increased for optical and medical devices as well as for powered devices in automobiles. Certain types of hard metals can be machined by deterministic precision-cutting processes. However, hard and brittle ceramics, hardened steel for molds, and semiconductor materials have to be machined using precision abrasive technologies, such as grinding, polishing, and ultrasonic vibration technologies that use diamond super abrasives. The machining of high-precision components and their molds/dies using abrasive processes is very difficult due to their complex and nondeterministic natures as well as their complex textured surfaces. Furthermore, the development of new cutting-edge tools or machining methods and the active use of physicochemical phenomena are key to the development of high-precision and high-efficiency machining. This special issue features 11 research papers on the most recent advances in precision abrasive technologies. These papers cover the following topics: - Characteristics of abrasive grains in creep-feed grinding - Quantitative evaluation of the surface profiles of grinding wheels - ELID grinding using elastic wheels - Nano-topographies of ground surfaces - Novel grinding wheels - Grinding characteristics of turbine blade materials - Polishing mechanisms - Polishing technologies using magnetic fluid slurries - Application of ultrasonic vibration machining - Turning and rotary cutting technologies This issue is expected to help its readers to understand recent developments in abrasive technologies and to lead to further research. We deeply appreciate the careful work of all the authors, and we thank the reviewers for their incisive efforts.

An investigation into the cutting efficiency of a novel degradable glass as an alternative to alumina powder in air abrasion cutting of enamel

ObjectivesTo develop and test the cutting efficiency of a novel degradable glass as an alternative media to alumina powder for air abrasion.Materials and methodsA zinc-based glass (QMZK2) was designed, produced, and evaluated with a multi-modality imaging analysis. The glass dissolution study was carried out in three acids, using ICP-OES (inductively coupled plasma optical emission spectroscopy) at 5 different time points: 2.5, 5, 10, 60, and 240 min. The cutting efficiency of both materials was tested under the same parameters on slabs of elephant enamel. A stained fissure of a molar tooth was air abraded with the glass and evaluated with X-ray micro-tomography before and after air abrasion.ResultsThe particle size distribution of the glass was similar to that of alumina 53 µm but with a slightly greater dispersion of particle size. The shape of the particles was angular, appropriate for cutting purposes. The dissolution study showed that the glass dissolved rapidly in acidic conditions at all time points. Between the two variables, pressure and powder flow, pressure was found to influence the cutting speed to a greater extent than powder flow.ConclusionsAlumina powder was found to perform significantly better in 4 of the 9 conditions tested on elephant enamel, QMZK2 in one, and no significant differences were found for the rest of the 4 conditions. The QMZK2 seems to offer promising results as an alternative material to alumina.Clinical relevance.QMZK2 glass has the potential for replacing aluminum oxide as a degradable material in air abrasion technology.

Optimal Selection of Backside Roughing Parameters of High-Value Components Using Abrasive Jet Processing

This paper mainly presents a set of new Sapphire Backside Roughing technology. Presently, the associated Sapphire Backside Roughing technology is still concentrated on chemical etching, as its yield rate and efficiency are often limited by lattice structures, and the derived chemical waste fluid after etching is most likely to cause ecological contamination. In this research, refined abrasive jet processing technology is adopted, and in the meantime, the Taguchi experiment design method is taken for detailed experimental planning. Through processing parameter conditions and abrasive selection and development, proper surface roughing and processing uniformity are obtained so as to improve the various weak points of the abovementioned traditional etching effectively. It is discovered that abrasive blasting processing technology is, respectively, combined with wax-coated #1000 SiC particles and wax-coated #800 Zirconium particles to process the sapphire substrate with initial surface roughness 0.8–0.9 μmRa from the experiment. A 1.1–1.2 μmRa surface roughness effect can be achieved about two minutes later. The experimental results show that the actual degree of sapphire substrate surface roughing obtained in the AJM process depends on the gas pressure, impact angle, wax-coated abrasives, and additives. The new Sapphire Backside Roughing technology has high flexibility, which not only meets the requirements for sapphire surface roughing specification but can also effectively reduce the sapphire substrate roughing time and related cost.

Electrochemical and X-ray Examinations of Erosion Products during Dressing of Superhard Grinding Wheels Using Alternating Current and Ecological Electrolytes of Low Concentration of Chemical Compounds.

This article introduces significant cognitive and usable values in the field of abrasive technology especially in the development of new methods of the electrochemical dressing of superhard grinding wheels with metal bonds. Cognitive values mainly concern the elaboration of the theoretical backgrounds of the electrochemical digestion of compounds of grinding wheel metal bond and gumming up products of the cutting surface of grinding wheel (CSGW). Cognitive values also deal with determining the mathematical relationships describing the influence of technological conditions of dressing on shaping of cutting abilities of superhard grinding wheels. On the other hand, the useful values refer to the industry implementation of the elaborated method and equipment for the electrochemical dressing of suparhard grinding wheels using alternating current (ECDGW-AC). The cost of the device for the realization of this process is low and can be applied in the production conditions. The novel achievements presented in the article are: the elaboration of a new method and equipment for electrochemical dressing of superhard grinding wheels (ECDGW-AC), the selection of electrolytes of low concentration of chemical compounds, tests concerning the digestion of grinding wheel metal bond compounds and gumming up products of CSGW using X-ray analysis, as well as the determination of chemical reactions taking place during elaborated new dressing process, the elaboration of mathematical relationships describing influence of technological conditions of this process on dressing speed and shaping of cutting abilities of superhard grinding wheels, and the performance of technological tests of dressing of superhard grinding wheels using ECDGW-AC method. The elaborated method can be used in ambient temperature and does not cause thermal damages of abrasive grains of cutting surface of grinding wheel and is useful not only for dressing super hard grinding wheels but also for correcting their geometrical deviations.

Special Issue on Advances in Abrasive Technology

As abrasive technologies are currently indispensable for production processes in the automotive, aerospace, optics, telecommunications, and healthcare industries, among others, it is essential that the application of abrasive processing to production be optimized and improved. To those ends, it is necessary to understand how to approach the task, as there are many processing factors to consider. However, priority is given to understanding the abrasive processing mechanism that determine finishing results, as well as the relationship between the processing factors and individual conditions. Measurement, analysis, and evaluation technologies are also important. Furthermore, the development of new abrasive tools or machining fluids and the active use of physicochemical phenomena are key to the development of advanced abrasive technologies. Cutting-edge studies focusing on advanced abrasive technologies were collected for this special issue, which includes 12 papers covering the following topics: - Quantitative evaluation of surface profile of grinding wheel - Elucidation of grinding mechanism, based on grinding force - Novel grinding wheel - High-efficiency and high-accuracy grinding of difficult-to-cut materials - Polishing technology using magnetic fluid slurry - Application of ultrasonic waves or ultra-fine bubbles to coolants, and their effects on them - Planarization technology for single-crystal silicon carbide This issue is expected to help its readers to understand recent developments in abrasive technologies and to lead to further research. We deeply appreciate the contributions of all authors and thank the reviewers for their incisive efforts.

Elbow precision machining technology by abrasive flow based on direct Monte Carlo method

The investigation was carried out on the technical problems of finishing the inner surface of elbow parts and the action mechanism of particles in elbow precision machining by abrasive flow. This work was analyzed and researched by combining theory, numerical and experimental methods. The direct simulation Monte Carlo (DSMC) method and the finite element analysis method were combined to reveal the random collision of particles during the precision machining of abrasive flow. Under different inlet velocity, volume fraction and abrasive particle size, the dynamic pressure and turbulence flow energy of abrasive flow in elbow were analyzed, and the machining mechanism of particles on the wall and the influence of different machining parameters on the precision machining quality of abrasive flow were obtained. The test results show the order of the influence of different parameters on the quality of abrasive flow precision machining and establish the optimal process parameters. The results of the surface morphology before and after the precision machining of the inner surface of the elbow are discussed, and the surface roughness Ra value is reduced from 1.125 µm to 0.295 µm after the precision machining of the abrasive flow. The application of DSMC method provides special insights for the development of abrasive flow technology.

Researh of Influence of Technological Factors of Formation of Plasma Coatings on their Thermal Technical Properties

The article considers issues related to the choice of abrasive material and technology of its use for the formation of necessary roughness on the base material and necessary heat resistance of the heat-protective coating during plasma spraying. The influence of the shape and size of the abrasive on final roughness of the treated surface was studied at various angles of contact between the sprayed abrasive and the surface (angle of attack). From the condition of maximum heat resistance, the composition of the heat-resistant composite coating of the spinel type was determined, which consists of 3 layers: the 1st layer (sublayer) material is a chromium-aluminum composite and the 2nd layer of a transitional spinel-based aluminum and chromium oxide + chromium-aluminum composite and the 3rd a layer of spinel based on aluminum and chromium oxides.

Comparison of abrasive water jet technologies in terms of performance and kerf geometry accuracy for cutting ceramics

Comparison of abrasive water jet technologies in terms of performance and kerf geometry accuracy for cutting ceramics

Comparison of abrasive water jet technologies in terms of performance and kerf geometry accuracy for cutting ceramics

Hard machining of brittle materials such as ceramics is a process-oriented challenge. For the machining of such materials, abrasive water jet cutting is an appropriate alternative to the commonly used diamond grinding and laser cutting processes. In abrasive water jet machining the injection technology is currently used almost exclusively. Due to the realisation of the suspension jet technology a higher cutting performance can be achieved. In this article, the known injection technology and the suspension technology are compared. To do so, the influences on the quality were examined for trimming technical ceramics. The investigation illustrates that suspension technology trims with a higher accuracy than injection technology in matters of kerf geometry but with a lower material removal rate.

Special Issue on Advanced Abrasive Process Technologies

The demand for high-precision and high-efficiency machining of hard ceramics such as silicon carbide (SiC) for semiconductors and hardened steel for molding dies has significantly increased for power devices in automobiles, optical devices, and medical devices. Certain types of hard metals can be machined by deterministic precision-cutting processes. However, hard and brittle ceramics, hardened steel for molds, or semiconductor materials have to be machined by precision abrasive technologies such as grinding, polishing, and ultrasonic vibration technologies with diamond super abrasives. The machining of high-precision components and their molds/dies by abrasive processes is much more difficult owing to their complex and nondeterministic nature as well as their complex textured surface. Furthermore, high-energy processes with UV lasers and IR lasers, and ultrasonic vibration can be used to assist abrasive technologies for greater precision and efficiency. In this sense, precision grinding and polishing processes are primarily used to generate high-quality and functional components usually made of hard and brittle materials. The surface quality achieved by precision grinding and polishing processes becomes more important to reduce processing time and costs. This special issue features seven research papers on the most recent advances in precision abrasive technologies for hard materials. These papers cover various abrasive machining processes such as grinding, polishing, ultrasonic-assisted grinding, and laser-assisted technologies. We deeply appreciate the careful work of all the authors and thank the reviewers for their incisive efforts. We also hope that this special issue will encourage further research on abrasive technologies.

Fujimi’s New SiC CMP Slurry Development

Introduction Since silicon carbide (SiC) is a very hard substrate and is stable both chemically and physically, wafer processing is costly and takes a lot of time. Particularly, in the chemical mechanical polishing (CMP) process, which is the final wafering process, significant improvement in performance such as surface quality and productivity is required for high volume commercial production. At Fujimi, we have developed a high removal rate slurry of over 1.5 μm per hour on the Si-face under neutral pH and conventional CMP processing conditions. We have also proven that the slurry had a nice behavior in removal rate performance based on Prenston equation, that is, removal rate was proportional to the pressure and velocity of substrate. Furthermore, our testing result has shown great surface morphology such as no scratches and no latent scratches beneath the surface. Low surface roughness was achieved under 0.1nm of RMS at 10x10μm area. Fujimi has introduced this new SiC slurry at the Advanced Industrial Science and Technology (AIST) as a suitable stock polishing slurry to remove surface damage coming from previous grinding or lapping steps. We have demonstrated the benefit of a two-step CMP process which applies a stock step using the higher removal rate slurry followed by a fine step using our Colloidal silica type slurry. As a result, the combination process could realize to produce the SiC epi-ready wafer with fine quality surface in shorter process time than conventional process [1]. Results and DiscussionIn this study, we will discuss our SiC slurry development technologies. At Fujimi, we can control the size and shape of the abrasive grains. Utilizing our expertise in chemical and additive formulation, we can modify our slurries to meet our customers’ various performance criteria. In Figure 1, it shows a test result example in which the removal rate of the Si-Face was improved. These improved performances depended on the type of additive used in the slurry. Test was performed using substrates of 4-inch 4H-N SiC (4°off) Si-face substrates with exactly the same polishing process and pad condition for all slurries. Slurry A was a result of high speed conventional slurry used by AIST [1] as a reference slurry. Slurry B was a newly developed slurry with improved abrasive grains dispersion. Slurry C was also a newly developed slurry focusing on the improvement of oxidation efficiency. As a result, it was possible to achieve a polishing removal rate over 2 um / hour as well as maintain low surface roughness at the same time. [1] S. Hirano et al., Journal of the Japan Society for Abrasive Technology, 60, (2016)353 Figure 1

Ultra-precision finishing of low expansion ceramics by compliant abrasive technologies: A comparative study

Advanced ceramics have many attractive features such as high stability and wear resistance that find broad applications in various fields, e.g. optics, aerospace, etc. However, the accompanying difficult-to-machine property with complex geometry brings great challenges to the commonly used laser machining and rigid wheel based grinding in industry. To achieve optical surface quality with surface roughness below 10 nm Ra, three promising ultra-precision compliant machining technologies using adaptive elastic tools are presented in this paper, including bonnet polishing, compliant pitch polishing and shape adaptive grinding with fine grain size. A comparative study was conducted by machining three different low thermal expansion ceramics while continuously increasing attack angle, spindle speed and tool offset across rectangular regions. Material removal rate (MRR) and surface roughness (Ra) with respect to different process conditions are compared. With sufficient data, the processing ability using above three compliant machining technologies is summarized based on the MRR-Ra plots for different ceramics. In addition, microscopic observation and X-ray diffraction analysis are conducted to characterize differences in material behavior.

Cutting Capability of Microdrills in Nonstep Drilling

There is a high demand for microdrilling processes to drill microholes with diameters equal to or less than 0.2 mm for use in fuel injection nozzles. In this study, nonstep drilling methods are developed for high-efficiency processing. Herein, the effects of the cutting oil supply method and the drill’s feed rate on the developed thrust force and torque during drilling are investigated. Accordingly, it is shown that drop supply of the cutting oil is the optimal method for nonstep drilling because the oil is sucked into the microhole. Furthermore, a high-feed rate is preferred because it produces continuous chips.**This paper is a translation with revision of the paper: M. Uchiyama and N. Sakata, “Cutting capability of micro drills in non-step drilling 1st report: Optimization of cutting oil supply and drill feed,” J. of the Japan Society for Abrasive Technology, Vol.59, Issue 1, pp. 27-31, doi: 10.11420/jsat.59.27, 2015 (in Japanese).

A Novel Process Model of Ship Rust Removal by Premixed Abrasive Jet based on Neural Network

In view of the technological requirements of the development of green shipbuilding technology on the effect of ship surface rust removal, the premixed abrasive jet technology is used to remove rust. Because the rust removal of ships with premixed abrasive jet is influenced by multiple parameters and has a high nonlinear relationship between various parameters, the accurate process model of it is difficult to establish. On the basis of artificial neural network modelling technology, the model of ship rust removal with premixed abrasive jet is built. The model takes the system pressure, the target distance, the moving speed of the spray gun and the particle size of the abrasive as input parameters, and the score which can most reflect the effect of the rust removal as output parameter. The test results show that the prediction error of the model is small, and it can better reflect the process rule between the effect of the premixed abrasive jet and the process parameters. We can guide the selection of process parameters according to the model.

Development of high productivity process beginning with electric field abrasive particle Control technology

Development of high productivity process beginning with electric field abrasive particle Control technology

Experimental study on abrasive water-jet polishing of cemented carbide and polycrystalline diamond tools

This research paper studies the material removal mechanism, influence of water jet pressure and jet impact angle on the polishing effect of super-hard tools surfaces and edges experimentally. The results showed that the water jet pressure and jet impact angle have great influence on the materials removal efficiency. The jet angle of 15° and pressure of 10 MPa resulted in better-polished surface of the cemented carbide tools. The rake face of polycrystalline diamond cutting tools experienced no significant change under low pressure of 5 Mpa. Nevertheless, at a jet impact angle of 75° and a pressure of 20 MPa, the edge of the polished polycrystalline diamond cutting tool was bright, smooth, and rounded with 'ductile erosion micro material removal mechanism' without any fracture. The results demonstrated that the built abrasive water jet polishing technology system can be used in the super-hard tools industry to improve on the tool's services life.