Ultra-high speed grinding is an effective method for increasing the productivity of automotive part manufacturing. A cylindrical grinding machine with a maximum wheel speed of 15000 rpm and a maximum work speed of 5000 rpm has been developed. Machining tests were performed at wheel speeds up to 240 m/s. Grinding tests conducted with a vitrified bonded CBN wheel revealed that the workpiece surface roughness was reduced by decreasing the traverse feed per workpiece revolution. Surface roughness remained small, even when the work speed was increased, so long as the wheel speed was sufficiently high. Furthermore, it was found that workpiece degradation due to heat generation was suppressed when the work speed was increased instead of reducing the depth of cut. As a result, the new approach for ultra-high speed grinding by simultaneously increasing the wheel and work speeds provides high grinding efficiency and small surface roughness without deterioration of material quality.
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