Grinding Wheel Speed Research Articles

Assessment on surface integrity in electrochemical grinding of AISI 304.

Electrochemical grinding (ECG) offers advantages such as burr-free and stress-free material removal. Despite its proven potential, limited research has addressed the comprehensive effects of key process parameters on the surface integrity of AISI 304 stainless steel, particularly for applications requiring high-quality finishes, such as medical components. This study bridges this gap by systematically investigating the influence of ECG key parameters including voltage, rotational speed, and electrolyte concentration on main surface integrity parameters including current density, surface roughness, microhardness, and surface texture. Total of 20 experiments were carried out following a Response Surface Methodology (RSM) design, incorporating five levels of variation for the parameters of electrolyte concentration, voltage, and grinding wheel speed. Results revealed that voltage and electrolyte concentration were the dominant factors affecting current density, increasing it by 368% and 241%, respectively, while higher rotational speeds decreased it by 44.5% due to reduced contact time and electrolyte removal. Surface roughness decreased by up to 65% in the perpendicular direction as concentration and voltage increased, but higher voltages led to over-etching, increased the surface roughness. Electrolyte concentration and voltage also reduced surface microhardness by 10-14% through intensified corrosion, while higher wheel speeds increased microhardness due to enhanced mechanical removal. The maximum variation for in-depth microhardness extended up to a depth of 40μm below the surface. Surface texture analysis also revealed more uniform pitting across the surface at higher concentrations, indicating more consistent material dissolution. However, at higher voltages, deep pitting emerged, raising surface roughness.

Brittle-ductile transition mechanism during grinding 4H-SiC wafer considering laminated structure

4H-SiC wafer with alloy backside layer is gradually applied in power devices. However, the laminated structure presents various challenges in manufacturing. In this study, a model for brittle-ductile transition in grinding of laminated materials is established and verified by grinding experiment to ensure the complete removal of the alloy backside layer while achieving ductile removal of the 4H-SiC layer. In the modeling process, the maximum unreformed chip thickness and brittle-ductile transition critical depth of each-layer in the laminated material is deriving, taking into account the laminated structure. Consider the variability in proportion of dynamic active grits during grinding, set operation is introduced to analyze the relationship between sets maximum unreformed chip thickness and brittle-ductile transition critical depth, and to predict the removal mechanism of the 4H-SiC layer. Comparing the predicted results with experimental grinding data, found that under the conditions of grinding wheel with average size of abrasive 10 μm, grinding wheel speed vs of 74 m/s, grinding depth ap of 10 μm, and feeding speed vw of 2 mm/s, the alloy backside layer can complete removal while achieving ductile removal of the 4H-SiC layer. This study provides a new method for predicting removal mechanism in grinding of laminated material and theoretical guidance for optimizing machining parameters of 4H-SiC wafer with alloy backside layer.

Effect of Electroplastic-Assisted Grinding on Surface Quality of Ductile Iron

Ductile iron is a heterogeneous material. The presence of spherical graphite and a hard and brittle structure makes the surface of the workpiece easily form pits and crack defects under harsh grinding conditions, which seriously affects the service life and service performance of the workpiece. The new assisted grinding process based on the electroplastic effect is expected to avoid the surface defects of ductile iron. By comparing the surface roughness and microstructure of conventional grinding and electroplastic-assisted grinding, the superiority of electroplastic-assisted grinding surface quality is confirmed. Further discussion is presented on the impact of grinding parameters on the workpiece’s surface quality under the same electrical parameters. The results show that the sensitivity of surface roughness to grinding parameters from strong to weak is grinding wheel speed, feed speed and grinding depth. The optimal combination of grinding parameters is determined as a grinding wheel speed of 30 m/s, a feed speed of 0.5 m/min and a grinding depth of 10 μm.

Material Removal Mechanism of SiC Ceramic by Porous Diamond Grinding Wheel Using Discrete Element Simulation.

SiC ceramics are typically hard and brittle materials. Serious surface/subsurface damage occurs during the grinding process due to the poor self-sharpening ability of monocrystalline diamond grits. Nevertheless, recent findings have demonstrated that porous diamond grits can achieve high-efficiency and low-damage machining. However, research on the removal mechanism of porous diamond grit while grinding SiC ceramic materials is still in the bottleneck stage. A discrete element simulation model of the porous diamond grit while grinding SiC ceramics was established to optimize the grinding parameters (e.g., grinding wheel speed, undeformed chip thickness) and pore parameters (e.g., cutting edge density) of the porous diamond grit. The influence of these above parameters on the removal and damage of SiC ceramics was explored from a microscopic perspective, comparing with monocrystalline diamond grit. The results show that porous diamond grits cause less damage to SiC ceramics and have better grinding performance than monocrystalline diamond grits. In addition, the optimal cutting edge density and undeformed chip thickness should be controlled at 1-3 and 1-2 um, respectively, and the grinding wheel speed should be greater than 80 m/s. The research results lay a scientific foundation for the efficient and low-damage grinding of hard and brittle materials represented by SiC ceramics, exhibiting theoretical significance and practical value.

Investigation on the Deformation and Surface Quality of a Bearing Outer Ring during Grinding Processing.

Thin-walled bearings are widely used owing to the advantages of their light structure, high hardness, and strong load-carrying capacity. However, thin-walled bearings are often prone to deformation during the machining process, which can seriously affect the performance of the bearings. In addition, the machining deformation and quality of bearings are difficult to balance. To address the above issues, this paper investigates the effects of the machining parameters on the machining deformation, surface quality, and machining efficiency of a thin-walled bearing during the roughing stage. The dynamic balance between deformation inhibition and high quality in rough grinding was studied, and the optimal parameters for thin-walled bearing outer ring grinding were obtained. The deformation mechanism of thin-walled bearings caused by grinding was revealed through simulation and experimental analysis. The results show that the machining deformation and quality reach a balance when the workpiece speed is 55 r/min, the grinding wheel rotational speed is 2000 r/min, and the feed rate is 0.1 mm/min. Deformation increases with the increase in workpiece speed and grinding wheel speed. At the same time, the surface roughness increases with the increase in the workpiece speed, but the increase in the wheel speed will improve the surface roughness. As the workpiece speed increases, the surface topography shows a more pronounced stockpile of material, which is ameliorated by an increase in grinding wheel speed. As the rotational speed of the workpiece increases, the number of abrasive grains involved in the process per unit of time decreases, and the surface removal of the workpiece is less effective, while the increase in the rotational speed of the grinding wheel has the opposite effect. The grinding deformation of thin-walled bearings is mainly induced by machining heat and stress. As the rotational speed increases, the heat flux in the grinding zone increases. More heat flux flows into the surface of the workpiece, causing an increase in thermal stresses on the inner surface of the bearing collar, leading to greater deformation. The temperature in the grinding area can be reduced during machining, realizing a reduction in deformation. The research content contributes to the balance between high quality and low distortion in machining processes.

Grinding performance investigation of multidirectional CF/PEEK composites—A comparative with unidirectional CF/PEEK

AbstractTo distinguish the grinding performance of the multidirectional (MD) and unidirectional (UD) carbon fiber‐reinforced thermoplastic (CFRTP) composites, MD and UD carbon fiber‐reinforced poly‐etherether‐ketone (CF/PEEK) composites were employed in this study. Different ply stacking sequences and process parameters were set for grinding experiments. Subsequently, the surface morphologies and roughness were observed and measured. Experimental results indicated that the variations of grinding forces with grinding parameters of MD‐CF/PEEK and UD‐CF/PEEK were consistent. However, the heat transfer mechanism and the effects of grinding parameters on the maximum grinding temperatures were different between the two composites. The grinding forces and temperatures of MD‐CF/PEEK were slightly lower than UD‐CF/PEEK, and MD‐CF/PEEK reached better surface quality under the same parameters, indicating that the grinding performance of MD‐CF/PEEK was not the simple superposition of UD‐CF/PEEK. In addition, the chip formation and material removal mechanism of CF/PEEK were investigated. The grinding performance of MD‐CF/PEEK was primarily dependent on the θ elements of laminate while the grinding performance of UD‐CF/PEEK was closely related to the fiber orientation angles during grinding. This study established a more in‐depth understanding into the grinding performance of MD‐CF/PEEK and provided technical guidance for high‐quality grinding of CFRTP.Highlights The grinding performance of the multidirectional (MD) and unidirectional (UD) carbon fiber‐reinforced poly‐etherether‐ketone (CF/PEEK) is compared. The grinding forces and temperatures of MD‐CF/PEEK are slightly lower than that of UD‐CF/PEEK, and the MD‐CF/PEEK reach a better surface quality under the same grinding parameters. The grinding performance of MD‐CF/PEEK is primarily dependent on the θ elements of laminate, and the change of layering order is not a critical factor. The grinding performance of UD‐CF/PEEK is closely related to the fiber orientation angles during the grinding process. The surface quality of MD‐CFRTP can be effectively improved by reducing the grinding depth and feed speed, and increasing the grinding wheel speed.

Study of machining performance for electrochemical grinding of difficult-to-cut alloy U71Mn

PurposeThis study aims to apply an electrochemical grinding (ECG) technology to improve the material removal rate (MRR) under the premise of certain surface roughness in machining U71Mn alloy.Design/methodology/approachThe effects of machining parameters (electrolyte type, grinding wheel granularity, applied voltage, grinding wheel speed and machining time) on the MRR and surface roughness are investigated with experiments.FindingsThe experiment results show that an electroplated diamond grinding wheel of 46# and 15 Wt.% NaNO3 + 10 Wt.% NaCl electrolyte is more suitable to be applied in U71Mn ECG. And the MRR and surface roughness are affected by machining parameters such as applied voltage, grinding wheel speed and machining time. In addition, the maximum MRR of 0.194 g/min is obtained with the 15 Wt.% NaCl electrolyte, 17 V applied voltage, 1,500 rpm grinding wheel speed and 60 s machining time. The minimum surface roughness of Ra 0.312 µm is obtained by the 15 Wt.% NaNO3 + 10 Wt.% NaCl electrolyte, 13 V applied voltage, 2,000 rpm grinding wheel speed and 60 s machining time.Originality/valueUnder the electrolyte scouring effect, the products and the heat generated in the machining can be better discharged. ECG has the potential to improve MRR and reduce surface roughness in machining U71Mn.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0341/

Экспериментальные исследования режимов скоростного шлифования рельсов

Introduction. Rails’ grinding in the conditions of a railway track is a priority for extending its life cycle due to the timely removal of tread surface defects and formation of required transverse profile. Today, 14 RSHP-48 rail grinding trains are used in Russia. At the same time, most rail grinding trains are ending its service life. Therefore, the development of a fundamentally new rail grinding train with increased efficiency is an urgent task. Siberian transport university is working together with the Kaluga plant “Remputmash” to create a new rail grinding train named RSHP 2.0. The rail grinding train RSHP 2.0 is based on the technology of high-speed rail grinding, which is based on increasing working speed of rail grinding train by increasing rotational speed of grinding wheels and setting the angle of attack. The aim of this work is to study rails’ grinding modes on a specially designed installation URSH, which implements the technology of high-speed grinding rails by increasing speed of grinding wheels rotation up to 5,000 rpm. Research methods. Grinding wheel speed control was carried out by IT-5-ChM “Termit” electronic tachometer and “Megeon 18005” laser tachometer. The angle of attack of grinding wheel was measured by digital, three-axis accelerometer-inclinometer ATst 90. The force of pressing grinding wheel to the rail was evaluated by strain-resistive sensors M50-0.5-C3. The measurement of head rail transverse profile before and after grinding and evaluation of metal removal were carried out by a PR-03 rail profiler. The width of grinding track was controlled by ShTsTs-I-300-0.01 caliper. The surface roughness of rail sample after machining was measured by TR 200 portable instrument. Results and discussion. Based on research results of CRS, the parameters of the working equipment of designed grinding rail train, which implements the technology of high-speed rail grinding, the influence of grinding modes on the formation of the quality parameters of the machined rail surface are established, and the optimal values of the forces of pressing the grinding wheel to the rail are determined.

Experimental investigation on the feasibility of high-efficiency and precision grinding of silicon carbide ceramics with monolayer brazed diamond wheel

To explore the feasibility of high efficiency and precision grinding of brittle ceramics, the experimental grinding tests were conducted on SiC ceramics with monolayer brazed diamond wheels. The monolayer diamond grinding wheel with 80/100 mesh size diamond grains was brazed using high-frequency induction techniques. The binarization method was proposed to quantitatively characterize the brittle removed areas from the whole ground surface and oblique polishing method was used to assess the subsurface damage depth of the ground SiC samples. The results show that the maximum undeformed chip thickness (agmax) plays a crucial role in the material removal mode. When agmax increases from 0.08 µm to 1 µm, the brittle-removal ratio increases rapidly from 8.20 % to 48.24 % and the subsurface damage depth increase from 3.48 µm to 9.14 µm by 162.6 %. The grinding wheel speed also has a significant influence on the brittle-removal ratio. With the gradual increase of grinding wheel speed (vs) from 20 m/s to 160 m/s, the brittle-removal ratio of the ground surface decreases from 34.24 % to 25.56 %, and the depth of subsurface damage decreases from 5.68 µm to 3.58 µm by 36.97 %. The effect of the grinding depth on the ground surface and subsurface is comparatively not remarkable. The influence of grinding parameters on the grinding process of SiC ceramics indicate that high speed, creep infeed and deep depth grinding method makes it possible to realize high efficiency and low damage machining for SiC ceramics with monolayer diamond wheel.

Performance optimization and experimental analysis of angle grinder with dust collection hood

The grinding process of the angle grinder generates a large amount of dust, which present hazards to the environment and workers' health. In order to capture the grinding dust more efficiently, this paper optimizes the performance of the dust collection hood of the angle grinder by building a grinding experimental platform and using the response surface method (RSM). Using the Box-Behnken design method, the collection quantity Mtotal of all dust particles generated by grinding and the collection quantity MPM10 of PM10 are used as the main performance indicators of the dust collector. Four independent factors such as grinding wheel diameter, suction pipe diameter, mounting angle, and grinding wheel speed of the dust collection hood were optimized to arrive at the best combination of parameters. Through response surface analysis, a quadratic polynomial regression model between each influencing factor and performance indicator is established, and significance test and variance analysis are performed to verify the validity and applicability of the model. Finally, through three-dimensional response surface plots and contour plots, the interactions between each influencing factor are analyzed, and the predicted values of performance indicators under optimal experimental conditions are determined. The experimental results show that the mounting angle has the greatest impact on Mtotal, and the grinding wheel speed has the greatest impact on MPM10. The field engineering application shows that the optimized dust collection hood can effectively prevent dust from escaping. The reduction efficiency of total dust concentration in the grinding place is over 83.6 %, and the reduction efficiency of respirable dust concentration is over 90.0 %. The research results of this paper provide some reference value for the research and application in the field of dust control.

Evaluating the performance of electrical discharge face grinding on super alloy monel 400

Conventional machining of super alloy Monel 400 is difficult due to its high strength, low heat conductivity, and gummy nature. In this work, the performance of the electrical discharge diamond face grinding (EDDFG) while processing supper alloy Monel 400 is assessed using the super abrasive diamond-coated grinding wheels of three different grit numbers. Preliminary experiments highlighted the superior performance of the EDDFG as compared to that of electrical discharge machining (EDM) and electrical discharge face grinding (EDFG); in terms of material removal rate (MRR), average surface roughness (Ra), and microscopic images of surfaces using scanning electron microscope (SEM). This work aimed to assess the influence of the diamond grit number (DG n ) of the grinding wheel along with other process parameters, viz. grinding wheel speed (GWS), peak current (I p ), and pulse-on-time (T on ) on Ra and MRR. The analysis of variance (ANOVA) confirmed that DG n and GWS significantly affect the response variables. Finally, the multi-objective genetic algorithm (GA) optimization approach was used to determine the optimal parametric settings of the EDDFG process.

Experimental investigation of electrochemical cut-off grinding for Inconel-718 and comparative study with Ti-6Al-4V alloy

ABSTRACT In the present study, a hybrid machining process known as an electrochemical cut-off grinding (ECCG) is used for grinding of Inconel-718 material. The specimen (superalloy) contains nickel as major component. It cannot be machined conventionally due to its outstanding properties. During the electrochemical grinding of Inconel 718, the author examines the effects of input voltage (v), tool feed rate (mm/min), electrolytic concentrations (g/ltr), electrolytic flow rate (ltr/min), and grinding speed (rpm) on responses such as material removal rate (MRR) and surface roughness (Ra). The tests contains the bronze-bonded diamond abrasive grinding wheel. The MRR and surface roughness of Inconel 718 and titanium super alloy during the ECCG process are also compared in this research project. Based on the findings of the studies, it appears that the tool feed rate, the flow rate of the electrolyte, and the rotation of the grinding wheel are the maximum influential parameters for enhancing MRR and surface finish during electrochemical cut-off grinding of Inconel 718. Tool feed rates of 0.09 mm/min to 0.18 mm/min, electrolyte flow rates of 5 ltr/min to 8 ltr/min, and grinding wheel speeds of 800 rpm to 2000 rpm are the ideal influencing factors. The comparative analysis demonstrates that Ti-6Al-4 V alloy cannot match Inconel 718’s machinability. Compared to Ti-6Al-4 V alloy, Inconel-718 has an average material removal rate that is up to 1.73 times higher and an average surface quality that is up to 3.16 times better.

Surface topography of cylindrical precision grinding based on multi-source information fusion

In this study, spindle precision bearings and rotary vector (RV) reducer thin-walled bearings were taken as research objects. Based on the analysis of the metamorphic layer of bearings, the multidimensional research on the surface topography of parts by multisource information fusion (grinding force, grinding temperature, grinding strain, grinding vibration, and grinding acoustic emission (AE)) was put forward. The research shows that there are “dark layers” in the outer ring and inner ring of spindle precision bearings, and “white layers” and “dark layers” in the outer ring and inner ring of RV reducer thin-walled bearings. Feed speed has the greatest influence on grinding force, wheel speed, and grinding depth have the greatest influence on grinding temperature, wheel speed has the greatest influence on grinding strain, feed speed, and wheel speed have the greatest influence on grinding vibration, and workpiece speed has the greatest influence on grinding AE. When the grinding force is minimum ( x-axis: 1.3 N, y-axis: 0.9 N); the grinding temperature is highest (110.8°C), the grinding strain is maximum (46.6%), the grinding vibration is maximum (vibration range: 400 m/s2–400 m/s2) and the grinding AE is maximum (variation range: 2 V–1 V), the surface topography is most prominent (Ra: 0.97 μm). Grinding wheel speed and grinding depth have the greatest influence on surface topography, followed by feed speed, while workpiece speed has less influence.

Parameter optimization and prediction of surface roughness in grinding using CNSL as a cutting fluid

Surface grinding is one of the versatile processes in manufacturing, performed to achieve a smooth finish and close tolerance. The process is associated with high temperatures which influence the workpiece surface integrity, surface finish, and dimensional delicacy because of complex thermal stresses and thermal deformation of the workpiece. The usage of a cutting fluid becomes inevitable to address these problems.Cashew nut shell oil is a non-edible vegetable oil that is eco-friendly and possesses some potential properties required for cutting fluid. In this study, cashew nut shell oil is tried as a cutting fluid and its performance is compared with the traditional synthetic cutting fluid in surface grinding of EN8 material. The cutting parameters with two levels considered are the type of cutting fluid, grinding wheel speed, grinding wheel grade, depth of cut, and workpiece speed with the surface roughness or finish as the output response. The design of experiments has been carried out using the factorial method to analyze the effects of factors on the response. Parameter optimization has been done to get the optimum cutting parameters for minimum surface roughness. A model for predicting surface roughness has been proposed and the optimum cutting parameters for minimum surface roughness have been obtained. Also, validation experiments have been performed at an optimal condition and selected three conditions to prove the proposed model’s accuracy and confirm the potentiality of the cashew nut shell oil as a cutting fluid. The results show that the performance of cashew nut shell oil as a cutting fluid is better as compared to the conventional synthetic cutting fluid in obtaining a better surface finish.

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625.

Finishing operations are one of the most challenging tasks during a manufacturing process, and are responsible for achieving dimensional accuracy of the manufactured parts and the desired surface topography properties. One of the most advanced finishing technologies is grinding. However, typical grinding processes have limitations in the acquired surface topography properties, especially in finishing difficult to cut materials such as Inconel 625. To overcome this limitation, a new type of grinding wheel is proposed. The tool is made up of grains of different sizes, which results in less damage to the work surface and an enhancement in the manufacturing process. In this article, the results of an experimental study of the surface grinding process of Inconel 625 with single-granular and multi-granular wheels are presented. The influence of various input parameters on the roughness parameter (Sa) and surface topography was investigated. Statistical models of the grinding process were developed based on our research. Studies showed that with an increase in the cutting speed, the surface roughness values of the machined samples decreased (Sa = 0.9 μm for a Vc of 33 m/s for a multigranular wheel). Observation of the grinding process showed an unfavorable effect of a low grinding wheel speed on the machined surface. For both conventional and multigranular wheels, the highest value for the Sa parameter was obtained for Vc = 13 m/s. Regarding the surface topography, the observed surfaces did not show defects over large areas in the cases of both wheels. However, a smaller portion of single traces of active abrasive grains was observed in the case of the multi-granular wheel, indicating that this tool performs better finishing operations.

An investigation on tool wear rate in the electrical discharge face grinding process for the machining of Monel 400

This paper attempts to model the electrical discharge face grinding (EDFG) process, while machining the Monel 400 superalloy, using the response surface methodology (RSM) and artificial neural network (ANN) for process performance prediction. Initially, the experiments were designed using the central composite design of RSM. The grinding wheel speed, peak current, pulse-on-time, and pulse-off-time were chosen as input process parameters, while tool wear rate (TWR) as the performance attributes. Analysis of variance was to identify the significant model terms and their influence on TWR. The grinding wheel speed was identified as the most influencing parameter, and a 61% reduction in TWR was recorded when increasing the speed from 200 rpm to 600 rpm. The developed ANN model (4-20-1) reduced the mean square prediction error up to four times, outperforming the RSM model.

Surface grinding responses optimization with a promising eco-friendly cutting fluid

Lubrication and cooling are very important to safeguard grinding quality, in terms of surface integrity, surface texture, and accuracy of dimensions of the workpiece, because of the friction and the heat generation associated with the surface grinding process. So, cutting fluids are used to achieve this. Due to the ecological and health hazards of cutting fluids formulated from mineral oil and chemicals, the focus is on the use of bio-oil-based cutting fluids. Owing to the desirable properties of cashew nut shell liquid, it is attempted as a cutting fluid to optimize the surface roughness and cooling in surface grinding of EN8 material. The study deals with the analysis of the grinding parameters such as the type of cutting fluid, grinding wheel speed, grinding wheel grade, depth of cut, and workpiece speed as influential factors on the responses i. e. surface finish and grinding temperature. The performance of cashew nut shell liquid is compared to traditional synthetic cutting fluid using Taguchi’s 25 experimental design and L16 Orthogonal Array. A prediction model is proposed for both surface roughness and grinding temperature to get the optimum grinding parameters. The accuracy of the models is tested by conducting validation and confirmation experiments. The experimental results confirm well with those predicted and show that there is an improvement in the surface grinding responses when cashew nut shell liquid is used as a cutting fluid.

Experimental study on residual stress in high-speed grinding of noncircular equidistant profile

To explore the formation mechanism of residual stress in the high-speed grinding of noncircular equidistant profiles, orthogonal experiments of three grinding parameters—the grinding wheel speed, workpiece speed, and grinding depth—were designed. A ceramic bond CBN grinding wheel was used for the high-speed grinding of noncircular equidistant profile by the X-C axis linkage. The effects of the grinding parameters on the grinding temperature, surface roughness, and residual stress were analyzed. The results show that with the increase of grinding wheel speed, the grinding temperature and residual stress increase, and the surface roughness decreases. With the increase of workpiece speed, the grinding temperature and residual stress decrease, and the surface roughness increases. With the increase of grinding depth, the grinding temperature, residual stress, and surface roughness increase. Besides, the grinding depth has the greatest influence on the residual stress, followed by the grinding wheel speed and workpiece speed.

Study on the CBN Wheel Wear Mechanism of Longitudinal-Torsional Ultrasonic-Assisted Grinding Applied to TC4 Titanium Alloy.

In this study, the CBN (cubic boron nitride) wheel wear model of TC4 titanium alloy in longitudinal-torsional ultrasonic-assisted grinding (LTUAG) was established to explore the grinding wheel wear pattern of TC4 titanium alloy in LTUAG and to improve the grinding efficiency of TC4 titanium alloy and the grinding wheel life. The establishment of the model is based on the grinding force model, the abrasive surface temperature model, the abrasive wear model, and the adhesion wear model of TC4 titanium alloy in LTUAG. The accuracy of the built model is verified by the wheel wear test of TC4 titanium alloy in LTUAG. Research has shown that the grinding force and grinding temperature in LTUAG increase with the increase of the grinding depth and workpiece feed rate and decrease with the increase of the longitudinal ultrasonic amplitude. It also shows that the grinding force gradually decreases with the increase of the grinding wheel speed, while the grinding temperature gradually increases with the increase of the grinding wheel speed. In addition, the use of LTUAG can significantly reduce the wear rate of the grinding wheel by 25.2%. It can also effectively reduce the grinding force and grinding temperature.

Experimental Study on the Grinding of an Fe-Cr-Co Permanent Magnet Alloy under a Small Cutting Depth.

A small cutting depth is the key parameter to realize precision in the machining process. The stability of the machining process will directly affect the quality of machining. In this study, dry grinding experiments using an Fe-Cr-Co permanent magnet alloy with small cutting depths (5 μm) were carried out. The relationship between the number of peaks and valleys and the quality control of the grinding force, wheel speed and feed speed were analyzed. The relationship between the peak and valley values of the grinding force signals and the peak and valley values of the grinding surface obtained using a white light interferometer was revealed. The influence of the grinding parameters on the grinding forces was analyzed by processing the grinding force signals with a low-pass filter based on the rotational speed of the grinding wheel. The experimental results indicated that the difference in grinding force between the peak and valley could be reduced by increasing the grinding wheel speed, which was mainly due to a decrease in average grinding force when the maximum undeformed cutting thickness of the single abrasive decreased. The actual height difference between the grinding surface peak and valley could be realized by increasing the grinding wheel speed. The feed speed of the worktable had no effect on the grinding force signal and the peaks and valleys of the surface morphology. Lower surface roughness could be achieved by reducing the feed speed and increasing the grinding wheel speed.