A comprehensive review of micro-grinding: emphasis on toolings, performance analysis, modeling techniques, and future research directions

Pratap, Ashwani; Patra, Karali; D’yakonov, A. A.

doi:10.1007/s00170-019-03831-x

Cited by 35 publications

(8 citation statements)

References 122 publications

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“…According to the analysis results of the adhesive materials composition, the adhesive materials were sourced from the workpiece (ISO C45E4 steel), and most of them were oxidized due to the high cutting temperature during the machining of ISO C45E4 steel. The iron oxide and unoxidized iron were strongly welded to the tool surface, and when the adhesive layer accumulated to large and becomes unstable, it would be removed with chip while shearing off part of the high‐entropy cutting tool material due to the higher adhesion strength of adhesive layer and tool interface than the inter‐grain binding strength 28 …”

Section: Resultsmentioning

confidence: 99%

“…The iron oxide and unoxidized iron were strongly welded to the tool surface, and when the adhesive layer accumulated to large and becomes unstable, it would be removed with chip while shearing off part of the high-entropy cutting tool material due to the higher adhesion strength of adhesive layer and tool interface than the inter-grain binding strength. 28 The SEM images of the wear morphology for the HEC3 tool after acid cleaning are shown in Figure 7. In order to remove the adhesive layer (iron oxide and iron), the HEC3 tool was cleaned by acid.…”

Section: Wear Mechanismmentioning

confidence: 99%

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High‐entropy carbide‐based ceramic cutting tools

2022

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In this study, a novel high-entropy carbide-based ceramic cutting tool was developed. The cutting performance of three kinds of high-entropy carbide-based ceramic tools with different mechanical properties for the ISO C45E4 steel were evaluated. Although the pure (Ti 0.2 Zr 0.2 Nb 0.2 Ta 0.2 Mo 0.2 )C 0.8 ceramic cutting tool exhibited the highest hardness of 25.06 ± 0.32 GPa, the cutting performance was poor due to the chipping and catastrophic failure caused by the low toughness (2.25 ± 0.27 MPa m 1/2 ). The (Ti 0.2 Zr 0.2 Nb 0.2 Ta 0.2 Mo 0.2 )C 0.8 -15 vol% cobalt cutting tool with highest fracture toughness (6.37 ± 0.24 MPa m 1/2 ) and lowest hardness (17.29 ± 0.79 GPa) showed the medium cutting performance due to the low wear resistance caused by the low hardness. The (Ti 0.2 Zr 0.2 Nb 0.2 Ta 0.2 Mo 0.2 )C 0.8 -7.7 vol% cobalt cutting tool showed the longest effective cutting life of ∼67 min due to the high wear resistance and chipping resistance caused by the high hardness (21.05 ± 0.72 GPa), high toughness (5.35 ± 0.51 MPa m 1/2 ), and fine grain size (0.60 ± 0.15 µm). The wear mechanisms of the cobalt-containing (Ti 0.2 Zr 0.2 Nb 0.2 Ta 0.2 Mo 0.2 )C 0.8 ceramic cutting tools included adhesive wear and abrasive wear and oxidative wear. This research indicated that the high-entropy carbide-based ceramics with high hardness and high toughness have potential use in the field of cutting tool application.

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Section: Resultsmentioning

confidence: 99%

Section: Wear Mechanismmentioning

confidence: 99%

High‐entropy carbide‐based ceramic cutting tools

2022

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“…Since polycrystalline diamond grains were sintered with cobalt binder, bulk PCD is electrically conductive. Therefore, electrical discharge has been widely used for manufacturing micron-sized PCD tools [22][23][24][25][26]. To manufacture the micro-tool, a 500-µm thick PCD layer is brazed to the end of a cemented carbide material with a diameter of 1000 µm.…”

Section: Methodsmentioning

confidence: 99%

Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

Lee

Kim

2021

Applied Sciences

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In this study, micro-grinding was performed to investigate the machining characteristics of alumina and zirconia. The machining of ceramics remains highly challenging owing to their properties, such as high brittleness and wear resistance, which leads to a shorter tool life and high machining costs. Polycrystalline diamond (PCD) was selected as the tool material, as it is suitable for machining hard and brittle materials, and micro-electrical discharge machining (EDM) was used to fabricate PCD micro-tools. When using a resistor-capacitor generator circuit in micro-EDM, the discharging energy is related to the working capacitance, and by controlling the working capacitance, the different edge radii and the surface roughness of the tool can be easily achieved. The feed rate, depth of cut, and rotation speed were set as experimental parameters to investigate the grinding characteristics of the ceramics. During the experiment, the grinding force and roughness of the bottom surface were monitored, and the roughness of the machined surfaces was measured using a three-dimensional surface profiler. A working capacitance of 1000 pF was used to fabricate a tool with an edge radius of 3.5 µm. The lower radius of the tool edge resulted in a decrease of the cutting force by 50% at most and a surface roughness of 19 nm Ra.

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“…In addition, the emergence of more modern construction materials with difficult to machine properties should be highlighted. Pratap et al [ 18 ] noticed more and more higher requirements concerning the quality of cutting tools. This has led to the construction of innovative machine tools, which are mainly based on new kinematic varieties of grinding processes.…”

Section: Introductionmentioning

confidence: 99%

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

et al. 2023

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Finishing operations are one of the most challenging tasks during a manufacturing process, and are responsible for achieving dimensional accuracy of the manufactured parts and the desired surface topography properties. One of the most advanced finishing technologies is grinding. However, typical grinding processes have limitations in the acquired surface topography properties, especially in finishing difficult to cut materials such as Inconel 625. To overcome this limitation, a new type of grinding wheel is proposed. The tool is made up of grains of different sizes, which results in less damage to the work surface and an enhancement in the manufacturing process. In this article, the results of an experimental study of the surface grinding process of Inconel 625 with single-granular and multi-granular wheels are presented. The influence of various input parameters on the roughness parameter (Sa) and surface topography was investigated. Statistical models of the grinding process were developed based on our research. Studies showed that with an increase in the cutting speed, the surface roughness values of the machined samples decreased (Sa = 0.9 μm for a Vc of 33 m/s for a multigranular wheel). Observation of the grinding process showed an unfavorable effect of a low grinding wheel speed on the machined surface. For both conventional and multigranular wheels, the highest value for the Sa parameter was obtained for Vc = 13 m/s. Regarding the surface topography, the observed surfaces did not show defects over large areas in the cases of both wheels. However, a smaller portion of single traces of active abrasive grains was observed in the case of the multi-granular wheel, indicating that this tool performs better finishing operations.

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A comprehensive review of micro-grinding: emphasis on toolings, performance analysis, modeling techniques, and future research directions

Cited by 35 publications

References 122 publications

High‐entropy carbide‐based ceramic cutting tools

High‐entropy carbide‐based ceramic cutting tools

Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

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