Wheel Wear Mechanisms Research Articles

Wheel wear mechanisms for silicon grinding: a literature review

Grinding is an important flattening process for manufacturing of silicon wafers. The wear of grinding wheels has significant impacts on the manufacturing cost of silicon wafers and the quality of ground wafers. However, a thorough literature search has not resulted in any studies on wheel wear mechanisms in silicon grinding. The lack of understanding and knowledge about wheel wear mechanisms in silicon grinding has become a major barrier to the development of better wheels for the silicon wafer industry. This paper reviews the literature on the wear mechanisms for conventional wheels when grinding metals and for diamond wheels when grinding ceramics, aiming to provide a springboard for research on wheel wear mechanisms when grinding silicon wafers. It covers the types of wheel wear mechanisms, measurement methods for the wheel wear mechanisms, models constructed to study the wear mechanisms and feasibility of applying/extending them to silicon grinding. It concludes with a discussion on the challenges of conducting the research on wheel wear mechanisms in silicon grinding.

Model-Based Compensation of Geometry-Errors when Grinding Material Compounds

When grinding material compounds, different material properties cause significantly changed cutting conditions. Grinding forces, wheel wear and wear mechanisms as well as temperature load of the system differ due to these changes in mechanism, leading to deviant surface qualities and geometrical errors. If consistent quality at the compound’s transition from one material into the other is needed, these errors need to be compensated. In this paper geometry error sources are evaluated by comparing error cause models to experimental results.

Mechanisms in the generation of grinding wheel topography by dressing

For the process of dressing vitrified bonded grinding wheels with diamond tools it has been unknown how the wheel topography is generated. Moreover, the influence of the kinematical dressing parameters on the wheel wear behavior has not been quantified. In the course of this article the grinding wheel was dealt with as a porous ceramic composite. In FEM simulations common dressing forces and usual dressing tool geometries were applied. The results were verified by dressing tests and grinding wheel scratch tests which show the wheel wear mechanisms. The common practice of decreasing the grinding wheel surface roughness by a finishing dressing stroke has to be reconsidered, because previous dressing strokes with higher depths of cut can weaken the grinding wheel structure and lead to an unsteady phase with high grinding wheel wear after dressing.

Experimental observation of tool wear in rotary ultrasonic machining of advanced ceramics

As one of the cost-effective machining methods for advanced ceramics, rotary ultrasonic machining (RUM) has attracted much attention and there exist numerous publications on the process. However, few investigations on tool wear in the RUM process have been reported. This paper, for the first time in literature, presents an experimental observation on tool wear in RUM of silicon carbide (SiC). It first reviews some related wear mechanisms for grinding wheels and some techniques for studying the wheel wear mechanisms. After describing the experimental procedures, it presents and discusses the results on tool wear and cutting forces in RUM of SiC. It also discusses some practical implications of the findings from this study.

Wear of diamond wheels in creep-feed grinding of ceramic materials I. Mechanisms

The main objective of this paper is to study and quantify the wheel wear mechanisms in creep-feed grinding of ceramic materials with diamond wheels. A resin-bonded diamond wheel was selected for this study. Nine different states of wheel working surface were generated by grinding specified volumes of a selected silicon nitride material. It is found that: (1) the roughness of wheel profile decreased quickly and stayed about the same after approximately 30 cm 3 volume of material removal; (2) diamond grits experienced attritious wear, grit fracture, and grit dislodgment; (3) the wheel wear mechanism was dominated by grit dislodgment in the first 2 cm 3 volume of material removal and by attritious wear thereafter; (4) grit density per unit area can be expressed as an exponential decay function of cumulative volume removal. The percentage of each wear mechanism was obtained by tracing grits in the same area after 2.1, 4.2, 7.4, and 10.6 cm 3 volume of material removal using the lead-tape imprint technique.

円筒プランジ研削過程のシミュレーション(第1報)

A three-dimensional simulation model of cylindrical plunge-cut grinding was previously devised in order to examine the wheel and workpiece wear mechanisms by means of an analysis of displacement equations in the grinding zone. In this study, the same model was applied to the grinding of sinusoidal-waved work surface. The simulation on form accuracy has been developed from some assumptions and an experimentally obtained relationship between wheel removal and workpiece removal parameters. Thus, an analogy was drawn between the experimental and simulated results. It is evident that a newly developed computer model can fairly accurately simulate the profiles of wheel surface and ground surface for an equilibrium solution. The simulation algorithm seems to give an insight into wear mechanisms and, in particular, suggests that it is important for surface profiles to control rotational speed ratio.

The Rating of Wheels in Laboratory Snag Grinding

Summary Although it is often required in snag grinding factories to know which type of wheel is most suitable, correct selection of wheel types for given steel grades is hampered by the lack of exact information on snag grinding. In this study, a laboratory snag grinding test under constant load was made on S55C. SUS304 and SUJ2 steels to compare the grinding performance of different resinoid wheel types. Here, the metal removal rate, the wheel wear rate and the surface roughness were measured. Wheel wear mechanism was also studied with particular attention to grain feature at wheel's working surface. It is apparent that there is little difference in metal removal rates between wheel types whereas the wheel wear rate is largely dependent on wheel type.

Some Aspects of Flat Surface Grinding with Intermittent Cross-Feed

Part I: A Wheel Wear Mechanism. Using a constant maximum grit-force hypothesis for a fixed wheel-work combination, a stable and progressive wear-land model is developed as a function of the machine settings and its mechanical and thermal limitations are discussed. Experiments conducted with several wheel-work materials, both during dry and wet grinding justify the proposed wear mechanism and its limitations with respect to the machine settings. Part II: The Force Equilibrium. Under a stable wear mechanism as proposed in Part I, the grinding force is shown to be a simple linear function of a combined machine settings’ parameter; the slope of the line gives, in the range of the machine settings used, a constant specific energy for a given wheel-work material combination. Thermal expansion as well as grit rubbing, while not necessarily altering the basic wear-land geometry, tend to change this force relation. Experimental results over a wide range of the machine settings and for different wheels and workpieces agree with the force relation, and the specific energy calculated therefrom coincides quantitatively with the other published results on similar workpiece materials.

The effect of grinding fluid additives on diamond abrasive wheel efficiency

When grinding high speed tool steel, the wear mechanism of a diamond abrasive grinding wheel can be attributed to the combined actions of carbon diffusion and mechanical abrasion due to the presence of extremely hard carbide particles. Additionally, it is known that the wheel efficiency is particularly low if the high speed tool steel is deficient in carbon content. The present investigation looks into a few types of commercially available grinding fluids and the introduction of certain types of elements which may enhance wheel performance. Solid lubrication technique was also briefly examined. It was found that by introducing colloidal graphite into the grinding fluid, wheel efficiency was improved in terms of higher G-ratios. This observation was attributed to the reduced carbon diffusion between the workpiece and diamond abrasive grits.

Wheel wear and surface roughness in cross feed surface grinding

A wheel wear mechanism is proposed for the cross feed surface grinding process which is consistent with that reported for other grinding processes. Test results are presented which confirm the proposed wear mechanism. The effects of cross feeding in both directions and using automatic feeding arrangements are discussed. The workpiece surface roughness is shown to be dependant on the ratio of wheel width to cross feed increment. The influence of a range of grinding conditions on both wheel wear and surface roughness is investigated.

研削砥石の高温摩耗特性

There are few reports about the wear of grinding wheel when grinding hot steels. In the present study the constant pressure plunge grinding tests have been performed with carbon steels, SUS 24 and SUS 27 stainless steels at the workpiece temperature range of room temperature to 600°C under the loads of 1.0, 2.0, and 3.0 kg/cm2. With increasing the workpiece temperature the wear of wheel increased on grinding SUS 24 stainless steel, but a completely different result were seen on grinding SUS 27 steel, while the wheel wear was shown to take a maximum value in the temperature range of 150 to 450°C. According to microscopic observations, a distinct difference was found in the workpiece temperature dependence of the wear mechanism of wheel.

Discussion: “The Wheel Wear and Metal Removal Mechanisms in Vertical Spindle Abrasive Machining of Mild Steel” (Pollock, C., 1968, ASME J. Eng. Ind., 90, pp. 365–369)

Discussion: “The Wheel Wear and Metal Removal Mechanisms in Vertical Spindle Abrasive Machining of Mild Steel” (Pollock, C., 1968, ASME J. Eng. Ind., 90, pp. 365–369)

The Wheel Wear and Metal Removal Mechanisms in Vertical Spindle Abrasive Machining of Mild Steel

The primary metal removal mechanisms in vertical spindle abrasive machining are chip removal by firmly bonded abrasive grains in the wheel matrix, and secondary removal by the reuse of loose abrasive between the wheel-work interface. As you increase the strength (go to harder grades) of segments, the secondary metal removal rate tends to remain constant. However, the metal removed by firmly bonded abrasive increases rapidly. Changing from an E to an F grade approximately doubles the primary metal removal rate. Segmental wheels sharpen themselves by two major mechanisms—primary and secondary wear. Primary wear is caused by the common mechanisms of attrition, grain fracture, and bond failure. The secondary mechanism is caused by loose abrasive and metal chips in the wheel-work interface.