Ultrasonic-assisted grinding finds its main application in the processing of hard, brittle materials. In particular through the superposition of the conventional feed rate and the high velocity with ultrasonic frequency, advantages in drilling processes can be reached. The application of ceramic and glass materials for high performance parts in the aerospace and aeronautical industries, in biomedical components and for parts exposed to wear in the automotive industry is steadily increasing due to their favorable properties. The drilling of these materials in their sintered state with high accuracy and reproducibility presents a significant challenge with respect to the choice of tool and the process parameters implemented. This paper focuses on the influence of the cooling lubricant in combination with different tool specifications on the grinding process. The grain size of the diamond grinding pins was varied in the range of 30 to 126 lm. As bond types, electroplated, sintered bronze and sintered Fe/Co bonds were investigated as well as the pressure of the cooling lubricant and the influence of these factors on the process behavior. In additional to the process behavior, the residual stress profiles of the workpieces were evaluated.
In order to provide solutions to the current challenges and discussions on resource efficiency and energy savings, the manufacturing industry must present saving methods, in particular in energy intensive applications. The grinding technologies, with their high demands on precision and integrity of the boundary layer of components are one such application area which must source new and innovative solutions. Due to the ever increasing complexity of components, such as cooling lubricant systems and arrangements for maintaining temperatures of axes and guideways, the demand on machine tools to reach these high accuracies is constantly rising. In order to make a significant contribution to resource efficiency and energy savings, along with research on tool and process optimisation and innovative machining kinematics, the activities of the IWF focus on the substitution of complex machine tools with robot assisted machining strategies in order to simultaneously achieve high flexibility and productivity.
The application of high performance materials can lead to enhanced product properties. The associated challenging material properties set higher demands on the manufacturing processes. However, the ever-present demand for cost reduction of the manufacturing processes conflicts with the continuously increasing demands on product quality. In principle, higher surface quality results in higher energy consumption. Higher geometrical demands in combination with difficult to cut materials lead to increasingly complex machine tool and subsystem solutions, which also contribute to the higher energy consumption. However, the full potential of a process is often not utilized in order to ensure that damages to the workpiece at the end of cost intensive and long value chains are avoided. This leads to the situation that complex machine tools equipped with high performance tools operate under significantly reduced productivity. This means that the production process itself must be reliable in particular during high performance machining. In this paper, various grinding strategies were regarded in terms of possible increase in productivity and process stability. Furthermore a nonconventional option of flexible machining is presented. It will be shown that the process of speed stroke grinding of ceramic materials can be used as a highly productive alternative to reciprocating grinding and external cylindrical grinding with grooved cBN-grinding-wheels for example in the grinding of rolling bearing rings. The machining of high performance materials with simple machine concepts, such as robots, is presented with regards to more flexibility and at the same time machine accuracies comparable to these machine tools.
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