scholarly journals Optimizing the Sharpening Process of Hybrid-Bonded Diamond Grinding Wheels by Means of a Process Model

Machines ◽  
2021 ◽  
Vol 10 (1) ◽  
pp. 8
Author(s):  
Eckart Uhlmann ◽  
Arunan Muthulingam
Keyword(s):  
Economic Efficiency ◽  
Process Model ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Wheel Topography ◽  
Process Reliability ◽  
Grinding Wheel Topography ◽  
Conventional Grinding ◽  
Block Width

The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure of the grinding wheel. Due to the lack of scientific knowledge, the sharpening process is mostly performed manually in industrial practice. A CNC-controlled sharpening process can not only improve the reproducibility of grinding processes but also decrease the secondary processing time and thereby increase the economic efficiency significantly. To optimize the sharpening process, experimental investigations were carried out to identify the significant sharpening parameters influencing the grinding wheel topography. The sharpening block width lSb, the grain size of the sharpening block dkSb and the area-related material removal in sharpening V’’Sb were identified as the most significant parameters. Additional experiments were performed to further quantify the influence of the significant sharpening parameters. Based on that, a process model was developed to predict the required sharpening parameters for certain target topographies. By using the process model, constant work results and improved process reliability can be obtained.

Einfluss der Schärfparameter auf die Schleifscheibentopographie*/Influence of the sharpening parameters on the grinding wheel topography

2019 ◽  
Vol 109 (07-08) ◽  
pp. 582-588
Author(s):  
E. Uhlmann ◽  
A. Muthulingam
Keyword(s):  
Economic Efficiency ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Conditioning Process ◽  
Wheel Topography ◽  
Process Reliability ◽  
Grinding Wheel Topography ◽  
The Relationship

Einen wesentlichen Bestandteil der Schleiftechnik ist der Konditionierprozess zur Herstellung der Schleifscheibenform und -schnittigkeit. Durch das Schärfen wird die Bindung zurückgesetzt und der notwendige Schleifkornüberstand und Spanraum geschaffen. Ein CNC-gesteuerter Schärfprozess kann zur prozesssicheren und ressourceneffizienten Einstellung der gewünschten Schleifbelagstopographie genutzt werden. Umfangreiche Schärfuntersuchungen sollen hierbei Aufschluss über die Wirkzusammenhänge zwischen Schärfeinstellgrößen und Schärfergebnis geben.   An essential part of grinding technology is the conditioning process for the generation of the grinding wheel shape and of a sharp topography. Through the sharpening process the required cutting grains are exposed from the bond and sufficient chip space is ensured by putting back the bonding. A CNC-controlled sharpening process can lead to an improvement in process reliability and the economic efficiency. Extensive experimental investigations were carried out to determine the relationship between the sharpening parameters and the sharpening result.

Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Sebastian Barth ◽  
Michael Rom ◽  
Christian Wrobel ◽  
Fritz Klocke
Keyword(s):  
Research Work ◽  
Distribution Functions ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Edge Zone ◽  
Application Behavior ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool

The prediction of the grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used grinding wheel is still a great challenge for today's manufacturers and users of grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the grinding wheel, which comes into contact with the workpiece during the grinding process. The topography of a grinding wheel mainly depends on the structure of the grinding wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the grinding wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent grinding wheel structure is known. This paper presents an innovative approach for modeling the grinding wheel structure and the resultant grinding wheel topography. The overall objective of the underlying research work was to create a mathematical-generic grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a grinding wheel. This model enables the user to determine the resulting grinding wheel structure and the grinding wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) grinding wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of grinding tools, which takes into account the entire grinding wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of grinding wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the grinding wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of grinding processes.

Hochharte Schleifscheiben als 4-Stoffsystem*/Superabrasive grinding wheels as quaternary system - Influence of secondary grains in vitrified-bonded cBN grinding wheels

2016 ◽  
Vol 106 (06) ◽  
pp. 407-411
Author(s):  
E. Prof. Uhlmann ◽  
J. Thalau
Keyword(s):  
State Of The Art ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grain Sizes ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Tool ◽  
Process Behavior ◽  
External Cylindrical Grinding ◽  
Stand Der Technik

Der Schleifbelag hochharter CBN (kubisches Bornitrid)-Schleifscheiben in keramischer Bindung enthält neben der Primärkörnung in der Regel eine Sekundärkörnung, die aus einem konventionellen Schleifmittel besteht. Im 3-Stoffsystem, das dem Stand der Technik entspricht, wird die Sekundärkörnung als Bindungsbestandteil betrachtet, der vorrangig die Härte des Belages beeinflusst. Computertomografische Analysen und Untersuchungen von Schleifscheibentopografien zeigen jedoch, dass die Sekundärkörnung sowohl einen Einfluss auf das Gefüge als auch auf die Gestalt des Schneidenraums der Schleifscheibe hat. Technologische Untersuchungen zum Quer-Umfangs-Außen-Rundschleifen mit Schleifwerkzeugen, die sich in der Sekundärkorngröße unterscheiden, bestätigen diese Beobachtungen und zeigen einen Einfluss der Sekundärkörnung sowohl auf die Prozesskennwerte als auch auf das Arbeitsergebnis.   The grinding layer of vitrified-bonded superabrasive grinding wheels contains, in addition to its primary cBN-grains, in many cases secondary conventional abrasive grains. The ternary system considers secondary grains according to the state of the art as part of the bonding, which primarily affect the bond hardness. However, computer tomographic measurements and the analysis of grinding wheel topographies indicate that the secondary grains affect both the inner structure of the grinding wheel as well as the characteristic of the grinding wheel topography which directly influences the interaction of grinding tool and workpiece. Technological investigations on external cylindrical grinding across the circumference using grinding wheels with different secondary grain sizes confirm those observations and show a direct influence of the secondary grains on the grinding process behavior as well as on the grinding results.

T-Dress, A Novel Approach in Dressing and Structuring of Grinding Wheels

2012 ◽  
Vol 565 ◽  
pp. 217-221 ◽  
Author(s):  
Taghi Tawakoli ◽  
Amir Daneshi
Keyword(s):  
Ground Surface ◽  
Decisive Role ◽  
Bearing Steel ◽  
Formation Condition ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grinding Forces ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Ground Surface Roughness

Since the grinding wheel topography directly influences the grinding forces and material removal mechanism, the dressing of grinding wheels has a decisive role in the desired product quality achievement. A new dressing concept is introduced in this paper in order to reach the optimum chip formation condition. The novel dresser, T-Dress, creates a new structure on the grinding wheel owing to which remarkable reduction in grinding forces occur. These lead to the lower heat generation in the wheel-workpiece contact zone and consequently lower thermal damages. The experiments prove about 40% lower grinding forces in grinding of bearing steel materials, 100Cr6, when dressing with T-Dress compared to the case of dressing with conventional profile rollers with almost no difference in the ground surface roughness values.

Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition

2017 ◽  
Author(s):  
Fritz Klocke ◽  
Sebastian Barth ◽  
Michael Rom ◽  
Christian Wrobel
Keyword(s):  
Spatial Arrangement ◽  
Distribution Functions ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Wheels ◽  
Mathematical Methods ◽  
Edge Zone ◽  
Application Behavior ◽  
Wheel Topography ◽  
Grinding Wheel Topography

The prediction of the grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used grinding wheel is a great challenge for todays manufacturers and users of grinding tools. This is mainly caused by inadequate predictability of the forces and temperatures acting in the process, which depend on the topography of the grinding wheel coming into contact with the workpiece during the grinding process. The topography of a grinding wheel depends, beside the dressing process, on the structure of the grinding wheel, which is determined by its recipe-dependent volumetric composition. The structure of a grinding tool therefore determines its application behavior strongly. As a result, the knowledge-based prediction of the grinding wheel topography and its influence on the machining behavior is only possible if the recipe-dependent grinding wheel structure is known. In this paper, an innovative approach for modeling the grinding wheel structure and the resultant grinding wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical-generic grinding wheel model in which the spatial arrangement of the components grains, bond and pores is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a grinding wheel. With this model it is possible to determine the resulting grinding wheel structure and the grinding wheel topography of vitrified and synthetic resin-bonded CBN grinding wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of grinding wheels, taking into account the entire grinding wheel structure and build up the topography based on it. Using original mathematical methods, the components of grinding wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the grinding wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of grinding processes.

scholarly journals EFFECTS OF GRINDING WHEEL WEAR ON THE THERMO-MECHANICAL LOADS IN THE GRINDING PROCESS

2021 ◽  
Vol 2021 (3) ◽  
pp. 4675-4682
Author(s):  
M. Bredthauer ◽  
◽  
T. Bergs ◽  
S. Barth ◽  
P. Mattfeld ◽  
...  
Keyword(s):  
Negative Influence ◽  
Bearing Steel ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Wheel Wear ◽  
Thermally Induced ◽  
Creep Feed ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Cooling Lubricant

A large amount of the energy produced during grinding is converted into heat. Since not all of the heat can be dissipated by the cooling lubricant, thermally induced displacements in machine components occur, which has a negative influence on the component quality. The generation and distribution of heat is influenced by the change of the grinding wheel topography due to wear.Therefore, the wear mechanisms of grains were identified and quantified and their effect on heat generation was investigated. For this purpose, creep feed grinding investigations on bearing steel were conducted with electroplated CBN grinding wheels with different grain specifications.

scholarly journals Performance of Norton Quantum Grinding Wheels

2016 ◽  
Vol 686 ◽  
pp. 125-130 ◽  
Author(s):  
Miroslav Neslušan ◽  
Jitka Baďurová ◽  
Anna Mičietová ◽  
Maria Čiliková
Keyword(s):  
Surface Roughness ◽  
Ground Surface ◽  
Bearing Steel ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Grinding Forces ◽  
Removal Rates ◽  
Surface Burn ◽  
Conventional Grinding

This paper deals with cutting ability of progressive Norton Quantum grinding wheel during grinding roll bearing steel 100Cr6 of hardness 61 HRC. Cutting ability of this wheel is compared with conventional grinding wheel and based on measurement of grinding forces as well as surface roughness. Results of experiments show that Norton Quantum grinding wheels are capable of long term grinding cycles at high removal rates without unacceptable occurrence of grinding chatter and surface burn whereas application of conventional wheel can produce excessive vibration and remarkable temper colouring of ground surface. Moreover, while Norton Quantum grinding wheel gives nearly constant grinding forces and surface roughness within ground length at higher removal rates, conventional grinding wheel (as that reported in this study) does not.

Einfluss der Abrichtgrößen beim Schleifen*/Influence of dressing parameters on the grinding process - Systematic research of dressing parameters on workpiece roughness and surface integrity

2016 ◽  
Vol 106 (01-02) ◽  
pp. 44-50
Author(s):  
T. Lierse ◽  
B. Karpuschewski ◽  
T. R. Kaul
Keyword(s):  
Aluminum Oxide ◽  
Surface Integrity ◽  
Cvd Diamond ◽  
Grinding Wheel ◽  
Systematic Research ◽  
Grinding Process ◽  
Wheel Topography ◽  
Grinding Wheel Topography

Dieser Beitrag zeigt, dass die durch die Abrichtparameter erzeugte Schleifscheibentopographie nicht nur die Oberflächengüte des Werkstücks, sondern auch dessen Eigenspannungszustand in der Werkstückrandzone in weiten Grenzen verändert. Die Untersuchungen zum Abrichten von Korundschleifscheiben mit einer CVD-Diamantformrolle stellen den Zusammenhang zwischen dem Abrichten unterschiedlicher Schleifscheiben zur Bauteilqualität in Form der Oberflächenrautiefe und randzonennahen Eigenspannungen her.   The quality of the workpiece rim is changed by every grinding process. The grinding wheel topography created by the dressing process has not only influence on the workpiece roughness but also on the surface integrity. The pointed research using aluminum oxide abrasive wheels dressed by CVD diamond dressing discs shows a correlation between the dressing parameters, the workpiece roughness and the surface integrity.

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