Grinding Performance Of Wheel Research Articles

Phenomenon of Lagging in the Values of Grinding Wheel Performance Characteristics Due to the Radial Transformation of the Cutting Surface of a Wheel under Abrasive Diamond Treatment

Phenomenon of Lagging in the Values of Grinding Wheel Performance Characteristics Due to the Radial Transformation of the Cutting Surface of a Wheel under Abrasive Diamond Treatment

Improved grinding performance of SiC using an innovative bionic vein-like structured grinding wheel optimized by hydrodynamics

Diamond grinding wheel grinding has gradually become the main method for processing hard and brittle materials such as silicon carbide. Surface-structured grinding wheel prepared by laser ablation is a key technology to enhance grinding performance. A novel laser ablation vein-like structured grinding wheel (VLSGW) is suggested in this paper. The vein structure can effectively reduce the flow resistance. Four kinds of bionic vein structure flow channels were ablated on grinding wheels by picosecond pulse laser. The influence of the VLSGW on the air backflow and air pressure on the workpiece surface was analyzed by simulation. The grinding performance of VLSGW and unstructured grinding wheel (USGW) grinding SiC were compared. Compared with USGW, VLSGW can reduce normal and tangential grinding forces by up to 47.37 % and 41.06 %. At the same time VLSGW has a better workpiece surface topology and wear resistance than USGW.

Grain wear properties and grinding performance of porous diamond grinding wheels

Conventional diamond grinding wheels present challenges such as poor self-sharpening and difficulties in achieving ductile domain machining when processing hard and brittle materials, reducing machining quality and efficiency. This paper introduces a novel grinding wheel composed of porous diamond abrasive grains for better ultra-precision machining. Thermochemical etching is used to produce porous diamond grains of varying corrosion levels, and the cutting and wear mechanisms of these grains are investigated through molecular dynamics simulations and single-grain scratch tests. Compared to conventional diamond grains, the increased "micro-edge" and "multi-edge" features of porous diamond grains effectively reduce cutting force and heat. Notably, corrosion pore sizes ranging from 2 μm to 5 μm reduce cutting damage. Conventional diamond abrasive grains primarily incur damage through crystal surface dissociation and block crushing, whereas porous diamond abrasive grains experience damage mainly due to micro-crushing and micro-fracture. Ultra-precision grinding tests on 4H–SiC revealed that conventional abrasives produced cracks and pits on the grinding surface. In contrast, abrasives with a 2 μm eroded aperture exhibited predominantly ductile removal with minimal cracks and pits present. Abrasives with a 5 μm eroded aperture displayed desirable characteristics. This research offers valuable technical insights for enhancing the grinding performance of diamond wheels.

Progress in grinding performance by additive manufacturing of grinding wheels integrated with internal venturi cooling channels and surface slots

Among the most promising features of additive manufacturing are tool or form-free manufacturing and the ability to create intricate geometries that are difficult or even impossible to fabricate with traditional methods. These advantages can be employed to produce enhanced grinding tools. Efficient coolant fluid delivery into the cutting zone of the grinding operation has been a challenging problem since high frictional contact in the arc zone deteriorates the resin bond and lessens the grinding performance. This research study was dedicated to assessing the influence of internal cooling along with surface structures on the grinding performance of resin-bonded grinding wheels fabricated via additive manufacturing. This research introduced a novel structure that benefits from internal venturi shape cooling channels to provide exceptional fluid velocity in the tool and workpiece interaction zone. The grinding wheels have been produced employing vat photopolymerization. Grinding experiments with and without internal cooling were conducted on an aluminium plate to study the impact of introduced structures on the main aspects of grinding performance, such as cutting forces, surface roughness, tool wear, and dimensional accuracy. Two different grinding scenarios comprising shallow (10 μm depth of cut) and deep grinding (100 μm depth of cut) were carried out to reveal the influence of the material removal rate on the grinding experiments. The measured grinding forces revealed that integrating internal cooling channels and surface slots in a grinding tool could significantly reduce the grinding forces, which was more pronounced in the case of using venturi channels. Measured tool wear and dimensional accuracy together with calculated grinding ratio revealed that using cooling channels could participate in a notable increase in tool life and material removal ability, especially for venturi channels, due to improved cutting conditions, by which higher dimensional accuracy was obtained as well for the ground parts. Besides, it was discovered that the cooling channels could improve the surface quality of the ground part, which was less noticeable with the venturi channel grinding wheel. Furthermore, the optical and confocal microscopy detection confirmed that internal cooling channels could reduce chip loading on the grinding wheel surface, decrease the required number of dressing intervals, and cause effective promotion of tool life.

Permeability design and assessment of the additively manufactured metal-bonded diamond grinding wheel based on TPMS structures

The development of porous metal-bonded diamond grinding wheel with excellent permeability and satisfying mechanical properties is a huge challenge for traditional manufacturing process. In this paper, a novel design and fabrication method of metal-bonded diamond grinding wheel with human-designed open porous structure is proposed based on triply periodic minimal surfaces (TPMS) and additive manufacturing (AM) process. Darcy’ law and Kozeny-Carman equation are used to calculate the permeability coefficient for the porous grinding wheel. The optimal design method of grinding wheel porous structure is proposed comprehensively considering the geometric characteristic, permeability and mechanical properties. The grinding performance of AM porous grinding wheel is evaluated by BK7 glass grinding experiment. The permeability test result proves the effectiveness of permeability design method for the novel diamond grinding wheel. The grinding test result proves the advantages of the novel diamond grinding wheel.

Study on the Preparation and Performance of Silicone-Modified Phenolic Resin Binder for Rail Grinding Wheels.

A scheme for manufacturing heavy-duty rail grinding wheels with silicone-modified phenolic resin (SMPR) as a binder in the field of rail grinding is presented to improve the performance of grinding wheels. To optimize the heat resistance and mechanical performance of rail grinding wheels, an SMPR for industrial production of rail grinding wheels was prepared in a two-step reaction using methyl-trimethoxy-silane (MTMS) as the organosilicon modifier by guiding the occurrence of the transesterification and addition polymerization reactions. The effect of MTMS concentration on the performance of silicone-modified phenolic resin for application in rail grinding wheels was investigated. The molecular structure, thermal stability, bending strength, and impact strength values of the SMPR were characterized by Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and mechanical property testing, and the effect of MTMS content on the resin properties was investigated. The results indicated that MTMS successfully improved the performance of the phenolic resin. The thermogravimetric weight loss temperature of the SMPR modified by MTMS with 40% phenol mass at 30% weight loss is 66% higher than that of common phenolic resin (UMPR), exhibiting the best thermal stability; in addition, its bending strength and impact strength were enhanced by approximately 14% and 6%, respectively, compared with those of common UMPR. This study utilized an innovative Bronsted acid as a catalyst and simplified several intermediate reactions in the conventional silicone-modified phenolic resin technology. This new investigation of the synthesis process decreases the manufacturing cost of the SMPR, liberates it from the restrictions of grinding applications, and enables the SMPR to maximize its performance in the rail grinding industry. This study serves as a reference for future work on resin binders for grinding wheels and the development of rail grinding wheel manufacturing technology.

Research on Online Monitoring Model of Grinding Performance of Different Grinding Wheels in Internal Plunge Grinding

Research on Online Monitoring Model of Grinding Performance of Different Grinding Wheels in Internal Plunge Grinding

Study on the preparation of Ni Al intermetallic-bonded diamond grinding block and grinding performance for sapphire

At present, high-quality thinning processing of sapphire puts forward higher requirements on the sharpness and shape retention of diamond grinding wheels. There is thereby an urgent need to find a kind of bond material with moderate holding force on diamond to promote the performance of diamond grinding wheels. In this study, a novel NiAl intermetallic-bonded diamond grinding block is developed. NiAl gas-atomized pre-alloyed powders are used as bonds to endow materials with lower oxygen content and great flexural strength. Moreover, Cu3Sn with low melting point is introduced in the diamond grinding block to reduce sintering temperature and thermal damage of diamond. The NiAl intermetallic-bonded diamond grinding block containing 5 wt% Cu3Sn with flexural strength of 89 MPa and porosity of 0.67 % presents the best grinding performance for sapphire. After grinding, the wear rate, wear ratio and surface roughness of the sapphire are 319.93 mm3/min, 36.9 and 1.09 μm, respectively. The proper holding force of bonds on the diamond ensures that diamonds could fall off when the edges become slightly blunt, which contributes to the great sharpness and shape retention of grinding blocks.

Research on laser preparation and grinding performance of hydrophilic structured grinding wheels

In order to solve the problems of workpiece damage and grinding wheel clogging when grinding difficult-to-cut materials such as alumina ceramics, organisms with regular hexagonal structures distributed on the body surface and with strong hydrophilicity and high anti-wear functions were used as biomimetic objects for the first time, and the preparation process optimization, structure size design and grinding performance evaluation of hydrophilic structured bronze-bonded diamond grinding wheels were explored in this paper. The influence of the preparation process parameters on the micro-topography and the dimensional accuracy of the structure on the surface of the grinding wheel was revealed, and a new laser structuring process based on the coordinated control of focus position and scanning times was proposed, which could efficiently prepare regular hexagonal structures with a small wall inclination angle and a depth of several millimeters on the surface of the grinding wheel. It was the first to clarify the influence of sub-millimeter-scale structure size on the contact angle of grinding fluid droplet on the surface of the grinding wheel and the surface hydrophilicity of the grinding wheel. Compared with that of the non-structured grinding wheel, the hydrophilicity of the structured grinding wheel was significantly improved, and its surface hydrophilicity increased with the increase of the structure spacing and depth, but had little correlation with the structure side length. The grinding performance of hydrophilic structured grinding wheels and non-structured grinding wheels was evaluated under extreme working conditions. Under the condition of grinding depth of 50 μm, 100 μm and 200 μm, compared with that of the non-structured grinding wheel, the peak grinding temperature of the structured grinding wheel was reduced by 18.0%, 30.4% and 15.2%, respectively, and the surface damage depth of the alumina ceramic after grinding by the structured grinding wheel was reduced by 53.7%, 46.8% and 24.3%, respectively. The hydrophilic structured grinding wheel can enhance the storage and transportation capacity of grinding fluid/chips, effectively relieve the clogging and dullness of the grinding wheel, and significantly reduce the high temperature and damage of grinding. In the next step, we will try to apply this type of grinding wheel to form grinding, in order to provide a reliable solution for suppressing form grinding damage of difficult-to-cut materials.

The effects of grit properties and dressing on grinding mechanics and wheel performance: Analytical assessment framework

This paper introduces an analytical assessment framework for evaluating grinding wheel performance derived from the model of cutting and sliding grinding force components. Four new parameters are proposed based on wheel topography. These parameters are normalized through the aggressiveness number, which circumvents the influences of grinding geometry and kinematics. The framework is validated through experiments with different wheel topographies obtained by changing dressing conditions and grit properties (toughness, thermal stability and shape). The framework and experiments quantify how wheel wear flat area influences the sliding component and how grit protrusion influences the intrinsic specific grinding energy. This framework provides a rational basis for evaluating grinding-wheel performance and abrasive-grit selection.

Design of a CBN composite abrasive to improve the performance of HSG rail maintenance grinding wheel

A heavy-load resin grinding wheel with zirconia alumina abrasives plays a vital role in rail high-speed grinding (HSG) maintenance. However, the grinding wheel has the defect of short service life. Abrasives are the central performers in the cutting behavior of grinding wheels. A cubic boron nitride (CBN) composite abrasive was developed to enhance the performance of grinding wheels. The results showed composite abrasives bonded more tightly with the resin matrix, strengthening the structure of the wheel. The grinding efficiency and ratio of the composite grinding wheel were improved by 99.8% and 102% respectively, and the rail morphology was optimized.

Effects of open pores on grinding performance of porous metal-bonded aggregated cBN wheels during grinding Ti–6Al–4V alloys

Porous metal-bonded wheels coupled with the aggregated cubic boron nitride (cBN) grains and water-soluble carbamide particles as pore-forming agents were fabricated, aiming to the improvement of grinding wheel performance and ground surface quality in grinding of Ti–6Al–4V alloys. Grinding forces and force ratio, ground surface roughness and microhardness were investigated to evaluate wheel performance. In addition, the wear evolutions of cBN grains and macropores were performed as the material removal volume increases during wheel wear tests. Findings show that the dynamic changing behavior of the coverage and exposure of open pores attributes to the improvement of grinding performance and ground surface quality of porous AcBN wheels. Meanwhile, the promising self-sharpening property of wheels can be guaranteed in basis of dynamic wear variations of multiple cBN abrasive grains layer by layer.

Digital design and performance evaluation of porous metal-bonded grinding wheels based on minimal surface and 3D printing

Porous metal-bonded grinding wheel is in great demand but hard to realize with traditional fabrication process. In this article, a novel design and fabrication method of porous metal-bonded grinding wheel is proposed based on minimal surface and 3D printing. With this novel method, numerous interconnected pores and liquid channels can be realized for metal-bonded grinding wheel. Schwarz P, Schwarz D and Schoen I-WP minimal surfaces are adopted to construct the porous structures of grinding wheel. The formability is investigated for 3D-printed binder-abrasive composite and 3D-printed wheel porous structure. The mechanical properties of wheel porous structure are evaluated based on experiment and finite element method. The grinding performance of 3D-printed grinding wheel is evaluated and compared to the electroplated wheel. Results indicate that the pore morphology and mechanical performance of wheel porous structure can be controlled by design parameters. Moreover, grinding wheels with well-bonded abrasives and well-formed pores can be realized by 3D printing. Finally, the excellent grinding performance of 3D-printed grinding wheel proves the effectiveness and advantages of proposed novel design and fabrication method.

Performance comparison of seeded-gel and CBN grinding wheels for cylindrical plunge grinding of 100Cr6 steel

The selection of the grinding wheel is an important step during the process planning of grinding operations, especially for high-quality small components of hardened steel. The correct choice of the grinding wheel and the proper selection of cutting parameters can provide ground surfaces with high quality and positively affect the economic aspects of the process. The present work compares the performance of seeded-gel and CBN grinding wheels in external cylindrical plunge grinding of 100Cr6 steel in a range of high peripheral speeds, where it is possible to use both grinding wheels. The comparison was made taking into account the workpiece surface roughness and indices like the grinding ratio, specific grinding energy and grinding efficiency. The use of the CBN grinding wheel resulted in lower surface roughness values than those obtained with the seeded-gel grinding wheel. For both grinding wheels, there was a tendency that increasing peripheral speed reduces the surface roughness values. The best performance of the seeded-gel grinding wheel was found at 150 mm3/min/mm, where the grinding efficiency increased with the peripheral speed, and the highest value of all the performed experiments was achieved at 80 m/s. This value was approximately three times the grinding efficiency of the CBN grinding wheel under the same cutting conditions. The highest grinding efficiency for the CBN grinding wheel was achieved at 200 mm3/min/mm and 80 m/s. The grinding efficiency of the seeded-gel wheel dropped for this cutting condition due to higher wheel wear.

A Novel Optimization Design Method of Form Grinding Wheel for Screw Rotor

The profile accuracy of screw rotors plays a vital role in stabilizing the meshing operation between mated rotors. Such stability can minimize the vibration and noise, as well as improve the sealing performance and wear resistance. This is the main reason why form grinding is extensively applied as a finishing process to maintain high screw rotor profile accuracy. Since the installation parameters for form grinding wheels affect both the grinding wheel profile accuracy and grinding performance, it is essential to obtain reasonable installation parameters to guarantee the high precision and good grinding performance of form grinding wheels. In this paper, a novel optimization design method for form grinding wheels for screw rotors has been proposed. For the first time, the relationship between the grinding wheel installation parameters and profile accuracy is established to evaluate the grinding performance. A parameterized program has been designed based on space engagement theory. The characteristics of the contact line and profile features of form grinding wheels under different installation parameters have been investigated. Then, the proposed method was employed to select the correct range of installation parameters. To validate the proposed method, a set of experiments, including the manufacture and measurement of several screw rotors, was carried out. The results reveal that the precision of the screw profile is significantly improved compared with the empirical method, thus showing the effectiveness of the proposed method.

Preparation and performance of resin-bonded grinding wheel with braze-coated diamond grits

The use of braze coating is proposed to obtain a layer of filler alloy on different types of diamond grits for improving diamond grit retention in resin-bonded diamond wheels. The effects of brazing on surface morphology and mechanical properties of diamond grits were evaluated. Resin-bonded diamond wheels with braze-coated diamond grits were prepared, and the grinding performances of cemented carbide wheels with different diamond grits were tested. Brazing could successfully cover most of the diamond grits with a layer of filler alloy. Pores and bumps of several microns in size were observed as well as the formation of titanium carbide (TiC) between the coating and diamond grit. Toughness indexes (TIs) of coated single-crystal diamond grits (RVD) decreased only slightly, but significantly increased for coated polycrystal diamond grits (PDGF1). The wheel containing coated PDGF1 diamond grits exhibited the lowest grinding forces and highest grinding ratio among the four wheels evaluated, whereas the wheel with coated RVD diamond grits produced the highest grinding force and a relatively low grinding ratio.

Effect of the grit shape on the performance of vitrified-bonded CBN grinding wheel

Abstract This paper deals with the effect of the CBN grit shape on the grindability of a low alloy chrome steel, 100Cr6. Firstly, a simple wheel-workpiece interaction model is introduced to investigate the grinding response. The formulation considers the global grinding forces, which embodies all the properties of the wheel acting at the interface. The use of this approach eliminates the need to consider the interaction of each individual grit with the workpiece during the grinding process. Next, a series of tailored grinding tests conducted with a creep-feed grinding machine are used to evaluate the grinding performance and the wheel wear. The results have shown that the specific grinding energy ( u e ) is affected by the CBN grit shape, and the wheel wear is proportional to the ratio of the CBN shape factor (Aspect Ratio) and the overall bearing surface of the wheel-workpiece contact area ( a f ).

Effects of O2 Fine Bubbles on ELID Grinding Using Conductive Rubber Bond Grinding Wheel

This study proposes a new grinding system using grinding fluid containing oxygenic fine bubbles (O2FBs) to realize high-performance electrolytic in-process dressing (ELID) using a conductive rubber bond grinding wheel. It was found that grinding fluid containing O2FBs dramatically increases the dissolved oxygen in the grinding fluid. In addition, the O2FBs in the fluid are drawn to the conductive rubber bond grinding wheel, which is the positive pole, during ELID. These effects are thought to enhance the dressing performance of the conductive rubber bond grinding wheel. Grinding of pure titanium using the proposed grinding system was found to realize mirror surface finishing while increasing the amount of removed workpiece material, compared to when ELID was not applied and to when ELID grinding was conducted using a normal grinding fluid. Effects of ELID grinding on surface modification were also observed, confirming that the proposed grinding system is able to form a thick oxidized film on pure titanium.

Selective laser sintering and grinding performance of resin bond diamond grinding wheels with arrayed internal cooling holes

In this study, selective laser sintering was used to 3D print resin bond diamond grinding wheels with internal cooling holes. The mechanical properties and microstructures of the resin bond diamond grinding wheel were investigated. The grinding performance of 3D printed resin bond diamond grinding wheels with different internal cooling holes on the glass and cemented tungsten carbide was examined. The results show that 3D printed resin bond diamond wheels can be used to grind the glass and cemented tungsten carbide. Wheels containing internal cooling holes have lower grinding force. With increasing number and diameter of internal cooling holes, grinding forces on the glass decreased. Surface roughness up to 2–4 μm on the glass and cemented carbide was obtained by present 3D printed resin bond diamond wheel.

Modeling and optimization of machining parameters during grinding of flat glass using response surface methodology and probabilistic uncertainty analysis based on Monte Carlo simulation

In this paper, the performance of diamond grinding wheels was investigated. The industrial diamond crystals with a size of 140/170 mesh were utilized. The microstructure of the grinding tool was observed using a Scanning Electron Microscope (SEM) and Energy Dispersive X-ray Analysis Device (EDX). The experiments were designed using Box–Behnken method and optimum grinding parameters for glass were analytically determined. Experimental studies were carried out on a surface grinding machine in a flat glass factory. Grinding characteristics were examined with respect to surface roughness. The effects of grinding parameter on output responses were studied using analysis of variance (ANOVA). Probabilistic uncertainty analysis depends on Monte Carlo simulation was applied. Moreover, after the experiments using the optimized cutting parameters, the microstructure of the grinding wheels was analyzed. From results, the established model and optimization method could be employed for predicting surface roughness and this work is reliable and suitable for solving the problems encountered in machining operations. The lifetime of Cu-based grinding discs can be increased by adding Zn and Fe to the matrix material.