Grinding Wheel Research Articles (Page 1)

Effect of carbon nanotubes on the performance of laser brazed diamond grinding wheel

Additive manufacturing of structured grinding wheels with a composite of Cu38Ni34Fe13Sn10Ti5 high-entropy alloy and Ni/Ti dual-coated diamonds: Interfacial characteristics, mechanical properties and grinding performance

The wear resistance of diamond dressing rolls depends on the manufacturing technology used and the characteristics of the working diamond layer, such as the type and grain size of the diamond grains, the type of bond, and the concentration and distribution of the diamonds. To optimise the lifetime of diamond rolls made of synthetic diamonds using the electroplating method, this paper proposes an innovative approach to compacting the intergranular spaces by treating them with diamond grains finer than the main fraction. To implement this approach, analytical dependencies were derived for the distance between the diamond grains. Intensive wear of the diamond roller bond was observed when the distance was exceeded as a result of contact with the abrasive grains of the grinding wheel. A ratio between the grain sizes of the main and additional diamond fractions is also recommended. Diamond roller dressers made of synthetic diamonds with a medium or high strength and a mixed grit size were created and their wear resistance was studied during the uni-directional and counter-directional dressing of electrocorundum grinding wheels using the plunge-grinding method. Theoretical and experimental models were constructed to predict the lifetime and the wear of diamond rolls in relation to the radial feed rate, the dressing speed ratio, the dress-out time, and the grit size ratio. Multi-objective optimisation based on a genetic algorithm was used to determine the optimal dressing conditions, ensuring the best combination of the maximum lifetime and minimum wear of the diamond rolls. The results obtained confirm the validity and correctness of the proposed approach for increasing the wear resistance of diamond roller dressers.

Abstract Chronic total occlusion (CTO) is a cardiovascular disease in which coronary arteries are completely obstructed by atherosclerotic plaques for more than three months. Percutaneous coronary intervention (PCI) treatment of calcified CTO is challenging because hardened plaques prevent the crossing and delivery of microcatheters and balloons. In this study, a two-step atherectomy method for CTO treatment using a miniature electroplated nickel (Ni)-diamond wheel is proposed. The Ni-diamond wheel first drills a hole in the CTO lesion with rotational and oscillatory translational motion along a guidewire and then grinds the lesion using orbital motion to enlarge the hole beyond the diameter of the grinding wheel. The feasibility of the proposed two-step atherectomy method, combining drilling and grinding, and the forces exerted during drilling and grinding were experimentally investigated using two types of calcified CTO plaque surrogates: gypsum cement and ex vivo bovine bone. Drilling experiments were conducted in both manual and automated feeding modes. The experimental results demonstrate that the proposed miniature wheel drills through both types of CTO surrogates in the manual and automated feeding modes with more consistent drilling forces of approximately 0.046 and 0.027 N in the rapid and slow modes under automated feeding, respectively, than under manual feeding. During grinding, the miniature wheel generates orbital motion in the hole and expands the hole diameter from 0.85 to 1.26 mm within 120 s. The proposed integrated drilling and grinding approach has promise in addressing the clinical challenges of microcatheter- and balloon-uncrossable lesions in PCI treatment of CTO.

Abstract To reduce production costs and defects in manufacturing, maintaining stability in production quality and timely prevention from equipment abnormalities have become essential. Usually, the quality of grinding processes is closely related to the health of the machinery and the grinding wheel. Real-time monitoring and assessment of the machine’s health can help to detect processing problems earlier and generate fewer defective products. In this study, accelerometers are installed in four axes on a commercial grinding machine to measure the temporal accelerations during processing of linear slide rails. The parallel accuracy of two points across the top surface of a standard slider block assembled on the produced rail was employed as the check for product quality. The abnormal causes included motor malfunction, grinding wheel defect, transmission belt deterioration, etc. The symmetrized dot pattern (SDP) was then adopted to convert the temporal acceleration signal into figurative expression for each plausible anomaly. From the SDPs of the measured accelerations which produced NG slide rail, the measurements from A and Y axes were more sensitive than their X and Z axes counterparts. The implementation of the proposed approach demonstrated an improved yield rate from 96.9% to 98.6% during a four-month study.

On texturing cBN grinding wheels and its effect on reduction of ploughing share and increased productivity

Ultra-precision truncation of coarse-grained electroplated diamond grinding wheels using triboelectrically excited nitrogen

CFD analysis of multi-layer cooling channels in three-dimensionally structured grinding wheels

Research on high-efficiency mechanochemical synergistic polishing of single crystal diamond based on anti-oxidation ceramic grinding wheels

The object of this study is the abrasive cutting process using thin grinding wheels, which is applied for cutting materials with various mechanical properties. The problem to be solved is mapping the energy consumption characteristics in this process through the control of cutting parameters such as grinding wheel thickness and feed rate. An experiment was conducted using grinding wheels with 1.2, 1.6, 2.0, and 3.0 mm for cutting metals. Various feed rates were used to cut Al, ST37, and cast iron, which are ductile, ductile-hard, and brittle materials. The results of the experiment show an inverse exponential relationship between the feed rate and specific energy. The 1.2 mm grinding wheel consumes up to 10% less power than the 3.0 mm wheel at low feed rates. The mapping of these characteristics enables the selection of recommended parameters. Achieving stability during the cutting process of ductile materials, the utilization of a 1.6 mm grinding wheel operating at a feed rate of 0.166 mm/s. The rigidity of the wheel determines the stability of the rotation, which depends on the thickness of the grinding wheel. The thickness of the grinding wheel determines the material removal rate of the abrasive process. Ductile-hard materials, such as ST37, require more energy because the abrasive particles must be able to break down the properties of the material to erode its surface. Ductile materials tend to cause high friction and generate heat, melting the material. The space between the abrasive particles can be filled with liquid material, causing BUE to cover the cutting edge of the abrasive particles. The application of the outcome is aimed at the machining, as a scientific basis for energy control at the manufacturing process

The weeds are undesirable, unwanted plants. Weeding is an important operation in crop production and labour-intensive agricultural operation. Weeding is generally done 15 - 20 days after sowing. Weeding is carried out at the initial stages of crop growth especially for controlling the weeds. After weeding operation, soil earthing-up provides favourable condition for crop growth. Weeding in narrow row spacing is difficult operation with less space between the two rows. In addition to that the soil compaction is the limiting factor due to the rotary motion of rotating blade in dry land weeder hence to avoid this, reciprocating motion type weeder was developed and performance was evaluated in narrow row spaced crop of 200 - 300 mm. The weeder consists of prime mover, ground wheel, power transmission unit, scotch yoke or spading mechanism, spading blade and earthing-up unit. Ground wheels were provided for the stability of the equipment. Scotch yoke mechanism consists of two turning pairs and two sliding pairs which were used for converting rotary motion into a reciprocating motion. The mechanism comprising of four links viz., fixed link or frame, rotating cam disc, connecting arm and spading arm. The inversion is obtained by fixing any one of the links namely as frame. Spading blade was mounted at the end of connecting arm. Earthing-up operation was done with ridger type blade which was provided at rear side of spacing mechanism. The maximum rotating speed of cam disc and forward speed of unit was measured as 125 rpm and 1.5 km h-1 respectively. The power required was calculated as 0.39 kW and bite length of cutting blade is 190 mm. The results for field evaluation of developed prototype weeder revealed that the weeding efficiency, plant damage, actual field capacity and performance index are 78.35 %, 5.1 %, 0.03 ha h-1 and 571.95 respectively. The cost of the developed prototype weeder was ₹35000. The cost of operation of the machine was ₹3871.66 ha-1 compared to ₹6152 ha-1 for hand weeding.

ABSTRACT The research objective of the present experimental work is to interpret the changes in the characteristics of Duplex stainless steel (2205/UNS S32205) during a surface grinding operation when subjected to different grinding environments provided between the grinding wheel and the surface. A total of nine test samples of dimensions 70 mm in length, 18 mm in breadth, and 6 mm thick were cut by a wire EDM machine from a raw material plate of 300 mm length, 300 mm breadth, and 6 mm thickness in order to minimise any kind of thermal gradient in the sample. The grinding is performed on a conventional surface grinding machine using an Aluminium Oxide grinding wheel (AA46/54 K5 V8). The grinding environments considered in our experimental work are Air, automotive coolant (Castrol Radicool: JIS K 2234 Class 2, ASTM D3306, BS 6580), and cutting fluid (Synth x). The process parameters considered are depth of cut and grinding environment; other parameters like tool rotational speed and flow rate of coolant and cutting fluid are kept constant. Various characterization tests were conducted, including Metallographic and microstructure Test, micro hardness test, and Micro Magnetic Brakhausen Noise Test, for surface characterization of duplex stainless steel.

Structured CBN (cubic boron nitride) grinding wheels usually have a specially designed texture on their surface to reduce the grinding heat and grinding force. However, most structured grinding wheels are fabricated by electroplating, brazing, sintering, and mechanical or laser removal on the surface of conventional grinding wheels, which may have problems such as complicated processes, low processing efficiency, and unstable effects. In this paper, additive manufacturing was used to fabricate a radial straight groove-structured grinding wheel. Meanwhile, a corresponding mathematical model of the grinding wheel was also established considering the shape and position of the abrasive grains. Subsequently, the ground surface morphologies of the fabricated wheel and simulated wheel under different machining parameter conditions were compared to further prove the rationality of the simulated grinding wheel. The results showed that the ground surfaces of the fabricated wheel and simulated wheel had similar morphological characteristics. The trend in the surface roughness under the different machining parameter conditions was also analyzed and showed the same variation for fabricated and simulated wheels; the error rate was confined within 8%. This paper elucidates the grinding mechanism and surface morphology formation process of a radial straight groove-structured grinding wheel fabricated by additive manufacturing.

Coolant flow in structured grinding wheels: CFD validation via high-speed imaging and particle tracking

High-precision surface finishing in manufacturing relies heavily on the condition of the grinding wheel, where any imbalance, cracks, or wear can degrade quality. This research aims to develop an AI-driven health monitoring framework by integrating experimentally acquired vibration data with a validated mathematical model, enabling accurate detection of grinding wheel conditions in real time. The study introduces a dual-framework approach combining statistical feature extraction from vibration signals with a physics-based model rooted in Newtonian mechanics and Fourier analysis. This integration enhances both the interpretability and robustness of fault classification, providing a novel, data-validated solution for predictive maintenance. Vibration signals were recorded for four wheel states—good, unbalanced, cracked, and worn—under controlled operational conditions. Ten statistically significant features, ranked using a Random Tree algorithm, were classified using a Random Forest model. Parallelly, a dynamic response model of the grinding wheel was developed and validated against experimental results. The Random Forest classifier achieved a 98.5% overall accuracy (Kappa = 0.98) using the top 10 features, with minimal misclassification (1.5%, primarily between cracked and unbalanced wheels). Mean vibration amplitudes ranged from 0.014 g (good condition) to 0.078 g (unbalanced), with one-way ANOVA confirming significant differences ( p < 0.001). The mathematical model reproduced experimental accuracy trends, with classification performance stabilizing at 98.5% when ≥9 features were used, and maintained 96.8% accuracy under ±5% Gaussian noise. The proposed integrated approach enables high-fidelity, real-time condition monitoring of grinding wheels, reducing downtime and enhancing reliability. By coupling experimental validation with a physically grounded model and quantitative AI-based classification, this work surpasses conventional black-box approaches, offering an interpretable and industrially scalable predictive maintenance solution.

Experimental study on material removal mechanism and surface quality of 2.5D Cf/SiC composites machined by textured grinding wheel

Diamond grinding wheels, particularly the advanced single-layer brazed variants, are indispensable for efficiently machining hard materials such as ceramics. Effective dressing is crucial, as it optimizes the wheel's isotropy and rotational accuracy, thereby ensuring precise machining. The selection of dressing tools and the conditions under which they operate significantly influence wheel quality, impacting key factors including topography, sharpness, wear rate, grinding forces, temperatures, and the surface integrity of the machined part. Consequently, the development of costeffective, high-performance dressing devices is of paramount importance. Furthermore, to provide a comprehensive review of representative patents in diamond grinding wheel dressing and to analyze the unique features, advantages, and disadvantages of various diamond grinding wheel dressing methods. Differentiating by method, diamond grinding wheel dressing devices fall into mechanical, memorable, and compound categories. Each patent addresses traditional device drawbacks with unique innovations, highlighting technical gaps and development needs in respective fields. Contemporary research in diamond dressing technology predominantly revolves around optimizing mechanical dressing methodologies. This focus is complemented by pioneering advancements in the architectural design and performance augmentation of dressing apparatuses, aiming to elevate efficiency and precision in various industrial applications. Specialized dressing techniques have resulted in many superior devices that are now widely utilized. Modern dressing devices are characterized by their high accuracy, efficiency, and performance. The mechanical dressing method enjoys the broadest applicability, proving highly effective for dressing diamond grinding wheels. Specialized dressing methods, on the other hand, offer superior dressing effects and the distinct advantage of contactless operation, thereby extending the service life of diamond grinding wheels. The composite dressing approach, merging the best attributes of mechanical and specialized methods, presents significant potential. Though currently underrepresented in terms of available devices, this field is expected to see considerable development and expansion in the future.

ABSTRACT To address the challenges such as excessive grinding forces, poor surface quality, and severe wheel wear during grinding of zirconia ceramic with traditional brazed diamond grinding wheels, the diamond grinding wheels were fabricated using Ni-Cr alloy modified with carbon nanotubes (CNTs) and graphene (Gr) respectively in this study. Comparative grinding experiments on zirconia ceramics were performed. The results showed that the carbon modified composite filler had an inhibition effect on the thermal damage to diamond. Compared with traditional Ni-Cr alloy brazed diamond wheel, the grinding force of CNTs modified Ni-Cr alloy brazed diamond wheel and Gr modified Ni-Cr alloy brazed diamond wheel in grinding zirconia ceramics decreased by 45% and 41% respectively, and the surface roughness decreased by 29.5% and 40.6% respectively. The Gr modified Ni-Cr alloy brazed diamond grinding wheel showed the best wear performance than the other two grinding wheels.

To address the challenge of improving the accuracy and efficiency of automatic transplanting operations in pepper plug seedling transplanters, this study innovatively designed a follow-up seedling picking and depositing mechanism. The core innovation lies in the synchronization of the seedling picking claws with the moving seedling cups, which was achieved by coordinating the motion speeds of the seedling picking and depositing mechanism with the seedling conveying mechanism. This synchronization ensured relative spatial stillness during seedling deposition, significantly enhancing seedling depositing accuracy. To meet the design requirements of this follow-up mechanism, this study presents a comprehensive design of the transplanter, including a three-dimensional model. Key mechanisms, namely the seedling picking and depositing mechanism and the seedling conveying mechanism, were thoroughly analyzed, with detailed explanations of their working principles. The transmission system was designed for reliability and stability, being towed by a tractor with the ground wheel driving the motion of the seedling conveying and distributing mechanisms. The motion mode of the seedling picking and depositing mechanism combined a crank–rocker mechanism and a crank–slider mechanism, utilizing a gear transmission rod for seedling picking and carrying actions, and rail guidance for follow-up seedling depositing. Experimental results validated the effectiveness of this design. In bench tests, the success rates of the seedling picking and depositing mechanism at operating speeds of 100 seedlings/min, 150 seedlings/min, and 200 seedlings/min were 97.4%, 98.44%, and 95.03%, respectively. In field tests, at operating speeds of 90 seedlings/min, 120 seedlings/min, and 150 seedlings/min, the planting success rates were 99.65%, 94.95%, and 89.18%, respectively. These results demonstrated that the follow-up seedling picking and depositing mechanism met the demands of automatic transplanting operations, offering an effective solution to enhance both the operating speed and quality of the transplanter.

The cup-shaped grinding wheels with arc-shaped edges provide a satisfactory precision grinding solution for high-accuracy optical surfaces on hard and brittle materials. However, the complex profile of the arc-shaped edges of cup-shaped grinding wheels makes them challenging to truing. This paper proposes an on-machine truing technique targeting cup-shaped grinding wheels with arc-shaped cutting edge. First, a mathematical model was established to simulate the three-axis of on-machine truing the arc-shaped cutting edge using a diamond roller. Based on this model, a theoretical analysis is conducted to investigate the impact of tool setting errors, measurement errors of the diamond roller, and the pose error on truing accuracy. A compensation method was proposed, and experimental results validated its effectiveness. To investigate the grinding performance of cup-shaped grinding wheels after truing, a complex component is ground using a truing diamond grinding wheel. The experimental results demonstrate that this method enables precise on-machine truing of the arc-shaped edges of cup-shaped grinding wheels and is efficient. The average dimensional accuracy of the grinding wheel’s arc-shaped edge is reduced to 1.5 μm, with the profile accuracy (PV) of 0.89 μm.