Simulation of the stock removal in the contact zone during internal grinding of brittle non-metallic materials

2021 ◽  
Vol 23 (2) ◽  
pp. 31-39
Author(s):  
Sergey Bratan ◽  
◽  
Stanislav Roshchupkin ◽  
Alexander Kharchenko ◽  
Anastasia Chasovitina ◽  
...  
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Physical Simulation ◽  
Analytical Models ◽  
Abrasive Tool ◽  
Metallic Materials ◽  
Deformable Solid ◽  
Internal Grinding ◽  
Wide Range ◽  
Stock Removal

Introduction. Finishing operations, in particular, cylindrical grinding, essentially form the quality parameters of products, its performance characteristics and functional suitability. At the same time, the cost of grinding work increases significantly in comparison with grinding metals, reaching an average of 20 ... 28% of the total cost of manufacturing products. The selection of the optimal parameters of the technological system based on the process simulation can improve the reliability, productivity and economic efficiency. To describe the processing of brittle nonmetallic materials, empirical dependences are mainly used, and the existing analytical models do not take into account the stochastic nature of the grinding operation and the combination of microcutting and brittle chipping when removing particles of brittle nonmetallic material and wear of the surface of the grinding tool. Purpose of the work: simulation of stock removal in the contact zone during internal grinding of brittle non-metallic materials. The task is to study the features and patterns of change in the probability of material removal when the treated surface comes into contact with an abrasive tool. In the work, the theoretical and probabilistic models are obtained, allowing to reveal the patterns of material removal in the contact zone. The models make it possible to trace the regularities of the interaction of cutting and piercing grains on the surface of the workpiece and the process of removing the allowance in the contact zone due to a combination of the phenomena of microcutting and brittle chipping, considered as a random event. The research methods are mathematical and physical simulation using the basic provisions of the theory of probability, the laws of distribution of random variables, as well as the theory of cutting and the theory of a deformable solid. Results and discussion. Data are obtained that provide a clear illustration of the patterns of material removal along the contact zone at various levels. Analysis of the results obtained shows that the peripheral speed of the tool and the rotation speed of the workpiece, which are directly included in the equation for calculating the probability of material removal, significantly affect the rate of material removal. The cross feed also has a significant effect on stock removal. A qualitative picture of the change in the probability of material removal in the contact zone during grinding of holes in brittle nonmetallic materials is obtained. The obtained patterns of change in the probability of material removal when the machined surface is in contact with an abrasive tool and analytical dependences are valid for a wide range of grinding modes, tool characteristics and other technological factors.

Probabilistic model of surface layer removal when grinding brittle non-metallic materials

2021 ◽  
Vol 23 (2) ◽  
pp. 6-16
Author(s):  
Sergey Bratan ◽  
◽  
Stanislav Roshchupkin ◽  
Alexander Kharchenko ◽  
Anastasia Chasovitina ◽  
...  
Keyword(s):  
Surface Layer ◽  
Contact Zone ◽  
Probabilistic Model ◽  
Material Removal ◽  
Brittle Materials ◽  
Grinding Wheel ◽  
Metallic Materials ◽  
Deformable Solid ◽  
Metallic Material ◽  
Wide Range

Introduction. The final quality of products is formed during finishing operations, which include the grinding process. It is known that when grinding brittle materials, the cost of grinding work increases significantly. It is possible to reduce the scatter of product quality indicators when grinding brittle materials, as well as to increase the reliability and efficiency of the operation, by choosing the optimal parameters of the technological system based on dynamic models of the process. However, to describe the regularities of the removal of particles of a brittle non-metallic material and the wear of the surface of the grinding wheel in the contact zone, the known models do not allow taking into account the peculiarities of the process in which micro-cutting and brittle chipping of the material are combined. Purpose of the work: to create a new probabilistic model for removing the surface layer when grinding brittle non-metallic materials. The task is to study the laws governing the removal of particles of brittle non-metallic material in the contact zone. In this work, the removal of material in the contact zone as a result of microcutting and brittle chipping is considered as a random event. The research methods are mathematical and physical simulation using the basic provisions of the theory of probability, the laws of distribution of random variables, as well as the theory of cutting and the theory of a deformable solid. Results and discussion. The developed mathematical models make it possible to trace the effect on material removal of the overlap of single cuts on each other when grinding holes in ceramic materials. The proposed dependences show the regularity of stock removal within the arc of contact of the grinding wheel with the workpiece. The considered features of the change in the probability of material removal upon contact of the treated surface with an abrasive tool and the proposed analytical dependences are valid for a wide range of grinding modes, wheel characteristics and a number of other technological factors. The obtained expressions make it possible to find the amount of material removal also for schemes of end, flat and circular external grinding, for which it is necessary to know the amount of removal increment due to brittle fracture during the development of microcracks in the surface layer. One of the ways to determine the magnitude of this increment is to simulate the crack formation process using a computer. The presented results confirm the prospects of the developed approach to simulate the processes of mechanical processing of brittle non-metallic materials.

Contact Zone Force Profile and Machining Performance of Filamentary Brush1

2005 ◽  
Vol 127 (1) ◽  
pp. 217-226 ◽  
Author(s):  
R. J. Stango ◽  
V. Cariapa ◽  
M. Zuzanski
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Removal Rate ◽  
Contact Region ◽  
Force Sensor ◽  
Surface Finishing ◽  
Production Environment ◽  
Machining Performance ◽  
Wide Range ◽  
Force Profile

Filamentary brushing tools are used in a wide range of surface finishing processes, such as deburring, edge radiusing, polishing, and surface decontamination applications. Moreover, these tools are easily adapted to automation because the filament tips, which perform the machining operation, readily conform to the workpart surface without the need for sophisticated control systems technology. However, little is known about the material removal mechanics of filamentary brushes and, therefore, trial-and-error experimentation is often necessary before the tool is implemented in a production environment. This uncertainty of performance can be traced to a lack of understanding of the actual forces that are generated within the contact zone, that is, along the interface of the filament tip and workpart surface. Although previous experimental research has focused on the overall (i.e., resultant) brush force exerted onto the workpart, no information exists in the literature regarding the variation of force within the contact zone. Such information is essential for understanding the material removal profile within the contact zone, and could provide valuable information regarding the most active machining site along the contact surface. In this paper, a novel experiment is proposed for evaluating the force profile of filament tip forces that are generated within the contact region of a brushed surface. A specially designed workpart fixture is constructed and used in conjunction with a multiaxis force sensor for measuring the detailed force variation within the contact zone. The experiment is conducted using a wire brush at several different rotational speeds, which enables one to ascertain the role of filament inertia in the material removal process. Findings are reported which suggest that a significantly enhanced material removal rate can be achieved at a selective location within the contact zone at moderately elevated spindle speeds.

The Correlation of Movements in the Technological System during Grinding Precise Holes

2021 ◽  
Vol 1037 ◽  
pp. 384-389
Author(s):  
Sergey Bratan ◽  
Stanislav Roshchupkin ◽  
Anastasia Chasovitina
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Spatial Location ◽  
Quality Parameters ◽  
Micro Cutting ◽  
Internal Grinding ◽  
Processing Modes ◽  
Temperature Deformations ◽  
Abrasive Tools ◽  
Flow Cross

The article presents the results of the study of the quality parameters of the precise hole, depending on the size, spatial location and condition of the contacting surfaces, the parameters of the state of the contact zone, during finishing grinding. The correlation between the processing modes and the current parameters of the contact zone during internal grinding is established. Dependencies describe the flow cross-feed for the i-th turn increment of the depth of micro-cutting, compensation of radial material removal previous turn, deterioration of the wheel, the increment of the elastic and thermal strains. At the same time, the depth of micro-cutting and the increment of elastic and temperature deformations affect the values of the radial wear of the tool and the radial removal of the material. The equation of displacement balance is developed for discrete processes of hole processing with abrasive tools, during which the analyzed surface area comes into contact with the abrasive tool periodically.

Calculation of radial material removal and the thickness of the layer with the current roughness when grinding brittle non-metallic materials

2021 ◽  
Vol 23 (3) ◽  
pp. 31-44
Author(s):  
Sergey Bratan ◽  
◽  
Stanislav Roshchupkin ◽  
Aleksander Kharchenko ◽  
Anastasia Chasovitina ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Physical Simulation ◽  
Surface Condition ◽  
Grinding Wheel ◽  
Metallic Materials ◽  
Machined Surface ◽  
Micro Cutting ◽  
Real Process ◽  
Experimental Values

Introduction. The quality parameters of products, which determine its performance and functionality, are finally formed in the finishing operations, which include the internal grinding process. In this case, the removal of material from the rough surface of the workpiece occurs due to the presence of several simultaneously running random processes of shaping, occurring during the contact of the grinding wheel and the workpiece. A probabilistic theoretical approach is used to simulate grinding operations. However, for determination of radial material removal and thickness of layer with current roughness, the known models cannot be used, as it does not allow taking into account specific features of machining products made of brittle non-metallic materials. Purpose of the work. Creation of a new theoretical and probabilistic model allowing to calculate radial material removal and layer thickness, in which current roughness is distributed during grinding of brittle non-metallic materials. The aim is to investigate the regularities of brittle non-metallic material particles removal by radial removal and study the current (for the moment) roughness formed after every radial removal in the contact area. In the work, radial material removal and the layer with current roughness are determined by grinding modes, tool surface condition, workpiece and wheel dimensions, and the initial condition of the machined surface after the previous contact. The research methods are mathematical and physical simulation using basic probability theory, distribution laws of random variables, as well as the theory of cutting and the theory of deformable solids. Results and discussion. The developed mathematical models make it possible to trace the dimensions and shape of the contact zone when grinding holes in billets made of silicon, which are somewhat different from those known when machining billets made of metal. The proposed dependencies show that with an increase in the depth of micro-cutting, the radial material removal and the thickness of the layer with the current surface roughness increase for all values of wheel speed and workpiece speed. From the experimental values obtained, the maximum micro-cutting depth and the thickness of the layer with current surface roughness are calculated. The thickness of the said layer is compared with the experimental values obtained from the ground surface profilographs. A comparison of the calculated and experimental data indicates its compliance with almost all feed values, which confirms the adequacy of the obtained equations, which model the real process of grinding holes made of brittle non-metallic materials quite well.

Contact Zone Force Profile and Machining Performance of Filamentary Brush

Manufacturing ◽  
2002 ◽  
Author(s):  
Robert J. Stango ◽  
Vikram Cariapa ◽  
Mark Zuzanski
Keyword(s):  
Contact Zone ◽  
Material Removal ◽  
Removal Rate ◽  
Contact Region ◽  
Force Sensor ◽  
Surface Finishing ◽  
Production Environment ◽  
Machining Performance ◽  
Wide Range ◽  
Force Profile

Filamentary brushing tools are used in a wide range of surface finishing processes, such as deburring, edge radiusing, polishing, and surface decontamination applications. Moreover, these tools are easily adapted to automation because the filament tips, which perform the machining operation, readily conform to the workpart surface without the need for sophisticated control systems technology. However, little is known about the material removal mechanics of filamentary brushes and, therefore, trial-and-error experimentation is often necessary before the tool is implemented in a production environment. This uncertainty of performance can be traced to a lack of understanding of the actual forces that are generated within the contact zone, that is, along the interface of the filament tip and workpart surface. Although previous experimental research has focused on the overall (i.e., resultant) brush force exerted onto the workpart, no information exists in the literature regarding the variation of force within the contact zone. Such information is essential for understanding the material removal profile within the contact zone, and could provide valuable information regarding the most active machining site along the contact surface. In this paper, a novel experiment is proposed for evaluating the force profile of filament tip forces that are generated within the contact region of a brushed surface. A specially designed workpart fixture is constructed and used in conjunction with a multi-axis force sensor for measuring the detailed force variation within the contact zone. The experiment is conducted using a wire brush at several different rotational speeds, which enables one to ascertain the role of filament inertia in the material removal process. Findings are reported which suggest that a significantly enhanced material removal rate can be achieved at a selective location within the contact zone at moderately elevated spindle speeds.

scholarly journals Electrodeposited Hydroxyapatite-Based Biocoatings: Recent Progress and Future Challenges

Coatings ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 110
Author(s):  
Mir Saman Safavi ◽  
Frank C. Walsh ◽  
Maria A. Surmeneva ◽  
Roman A. Surmenev ◽  
Jafar Khalil-Allafi
Keyword(s):  
Recent Progress ◽  
Tribological Behavior ◽  
Metallic Materials ◽  
Industrial Processing ◽  
Component Size ◽  
Polymeric Particles ◽  
Operational Variables ◽  
Wide Range ◽  
Future Challenges ◽  
Coating Methods

Hydroxyapatite has become an important coating material for bioimplants, following the introduction of synthetic HAp in the 1950s. The HAp coatings require controlled surface roughness/porosity, adequate corrosion resistance and need to show favorable tribological behavior. The deposition rate must be sufficiently fast and the coating technique needs to be applied at different scales on substrates having a diverse structure, composition, size, and shape. A detailed overview of dry and wet coating methods is given. The benefits of electrodeposition include controlled thickness and morphology, ability to coat a wide range of component size/shape and ease of industrial processing. Pulsed current and potential techniques have provided denser and more uniform coatings on different metallic materials/implants. The mechanism of HAp electrodeposition is considered and the effect of operational variables on deposit properties is highlighted. The most recent progress in the field is critically reviewed. Developments in mineral substituted and included particle, composite HAp coatings, including those reinforced by metallic, ceramic and polymeric particles; carbon nanotubes, modified graphenes, chitosan, and heparin, are considered in detail. Technical challenges which deserve further research are identified and a forward look in the field of the electrodeposited HAp coatings is taken.

scholarly journals Universal mobility characteristics of graphene originating from charge scattering by ionised impurities

2021 ◽  
Vol 4 (1) ◽  
Author(s):  
Jonathan H. Gosling ◽  
Oleg Makarovsky ◽  
Feiran Wang ◽  
Nathan D. Cottam ◽  
Mark T. Greenaway ◽  
...  
Keyword(s):  
Electrical Conductivity ◽  
Carrier Density ◽  
Carrier Mobility ◽  
Carrier Transport ◽  
Analytical Models ◽  
Pristine Graphene ◽  
High Electron ◽  
Boltzmann Transport ◽  
Transport Parameters ◽  
Wide Range

AbstractPristine graphene and graphene-based heterostructures can exhibit exceptionally high electron mobility if their surface contains few electron-scattering impurities. Mobility directly influences electrical conductivity and its dependence on the carrier density. But linking these key transport parameters remains a challenging task for both theorists and experimentalists. Here, we report numerical and analytical models of carrier transport in graphene, which reveal a universal connection between graphene’s carrier mobility and the variation of its electrical conductivity with carrier density. Our model of graphene conductivity is based on a convolution of carrier density and its uncertainty, which is verified by numerical solution of the Boltzmann transport equation including the effects of charged impurity scattering and optical phonons on the carrier mobility. This model reproduces, explains, and unifies experimental mobility and conductivity data from a wide range of samples and provides a way to predict a priori all key transport parameters of graphene devices. Our results open a route for controlling the transport properties of graphene by doping and for engineering the properties of 2D materials and heterostructures.

scholarly journals Development of Permeability Models for Saturated Fluid Flow across Arrays of Fibre Clusters

2002 ◽  
Vol 11 (3) ◽  
pp. 096369350201100
Author(s):  
E.M. Gravel ◽  
T.D. Papathanasiou
Keyword(s):  
Analytical Models ◽  
Dual Porosity ◽  
Hydraulic Permeability ◽  
Fibrous Media ◽  
Fibre Bundles ◽  
Hexagonal Packing ◽  
Composites Manufacturing ◽  
Starting Point ◽  
Wide Range ◽  
Flow Through

Dual porosity fibrous media are important in a number of applications, ranging from bioreactor design and transport in living systems to composites manufacturing. In the present study we are concerned with the development of predictive models for the hydraulic permeability ( Kp) of various arrays of fibre bundles. For this we carry out extensive computations for viscous flow through arrays of fibre bundles using the Boundary Element Method (BEM) implemented on a multi-processor computer. Up to 350 individual filaments, arranged in square or hexagonal packing within bundles, which are also arranged in square of hexagonal packing, are included in each simulation. These are simple but not trivial models for fibrous preforms used in composites manufacturing – dual porosity systems characterised by different inter- and intra-tow porosities. The way these porosities affect the hydraulic permeability of such media is currently unknown and is elucidated through our simulations. Following numerical solution of the governing equations, ( Kp) is calculated from the computed flowrate through Darcy's law and is expressed as function of the inter- and intra-tow porosities (φ, φt) and of the filament radius ( Rf). Numerical results are also compared to analytical models. The latter form the starting point in the development of a dimensionless correlation for the permeability of such dual porosity media. It is found that the numerically computed permeabilities follow that correlation for a wide range of φ i, φt and Rf.

A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 142-151 ◽  
Author(s):  
Z. J. Pei ◽  
D. Prabhakar ◽  
P. M. Ferreira ◽  
M. Haselkorn
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Diamond Particle ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Stabilized Zirconia ◽  
Mechanistic Approach ◽  
Wide Range

An approach to modeling the material removal rate (MRR) during rotary ultrasonic machining (RUM) of ceramics is proposed and applied to predicting the MRR for the case of magnesia stabilized zirconia. The model, a first attempt at predicting the MRR in RUM, is based on the assumption that brittle fracture is the primary mechanism of material removal. To justify this assumption, a model parameter (which models the ratio of the fractured volume to the indented volume of a single diamond particle) is shown to be invariant for most machining conditions. The model is mechanistic in the sense that this parameter can be observed experimentally from a few experiments for a particular material and then used in prediction of MRR over a wide range of process parameters. This is demonstrated for magnesia stabilized zirconia, where very good predictions are obtained using an estimate of this single parameter. On the basis of this model, relations between the material removal rate and the controllable machining parameters are deduced. These relationships agree well with the trends observed by experimental observations made by other investigators.

The Processing of Ultrafine-Grained Materials Using High-Pressure Torsion

2007 ◽  
Vol 558-559 ◽  
pp. 1283-1294 ◽  
Author(s):  
Cheng Xu ◽  
Z. Horita ◽  
Terence G. Langdon
Keyword(s):  
Plastic Deformation ◽  
Grain Size ◽  
High Pressure ◽  
High Pressure Torsion ◽  
Metallic Materials ◽  
Grain Sizes ◽  
Ultrafine Grained ◽  
Wide Range ◽  
Ultrafine Grained Materials ◽  
Thin Disks

It is now well-established that processing through the application of severe plastic deformation (SPD) leads to a significant reduction in the grain size of a wide range of metallic materials. This paper examines the fabrication of ultrafine-grained materials using high-pressure torsion (HPT) where this process is attractive because it leads to exceptional grain refinement with grain sizes that often lie in the nanometer or submicrometer ranges. Two aspects of HPT are examined. First, processing by HPT is usually confined to samples in the form of very thin disks but recent experiments demonstrate the potential for extending HPT also to bulk samples. Second, since the strains imposed in HPT vary with the distance from the center of the disk, it is important to examine the development of inhomogeneities in disk samples processed by HPT.

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