A Grinding Power Model for Selection of Dressing and Grinding Conditions

103

This paper provides a state-of-the-art review on the investigations into the residual stresses in metallic structural materials generated by grinding. The materials covered include steels, titanium alloys, and nickel-based superalloys. The formation mechanisms of the residual stresses and their impacts are specifically discussed. Some major influential factors on the residual stresses formation in grinding, such as grinding wheel characteristics, dressing techniques, grinding parameters, cooling conditions, and properties of workpiece materials, are analyzed in detail. These include experimental measurement, modeling, simulation, knowledge-based monitoring, and fuzzy analysis. Finally, the paper highlights some important aspects of grinding-induced residual stresses for further investigation.

Section: Dressing Techniquesmentioning

confidence: 99%

Review on grinding-induced residual stresses in metallic materials

Ding

Zhang

et al. 2016

103

“…The measurement of grinding power is technically easier compared with grinding force, acoustic emission, acceleration, and temperature, and grinding power is proportional to grinding force [7,9]. Depending on the type of system used, current, voltage, and phase shift can be respectively detected.…”

Section: Grinding Powermentioning

confidence: 99%

A dynamic threshold-based fuzzy adaptive control algorithm for hard sphere grinding

Wei

et al. 2011

Grinding wheel wearing fast and metal adhering were severe in hard sphere grinding, which led to wheel overload and clogging. If a fixed-feed grinding was used, the normal pressure between the workpiece and the grinding wheel increased rapidly. Once the grinding load on the grinding wheel was greater than the strength of the retaining bond bridges, a large amount of grains dropped out, which can even damage the wheel. This led to the sphere surface to be scratched. In this study, a dynamic threshold-based fuzzy adaptive control algorithm (DTbFACA) is proposed for hard sphere grinding to avoid scratches on the workpiece. The grinding force was indirectly obtained by measuring the motorized spindle current which was used as a feedback to control hard sphere grinding process. The current threshold in DTbFACA was obtained and online-rectified automatically. The depth of cut and the cup wheel swing speed that affect the motorized spindle current was online-adjusted by fuzzy algorithm. The experimental results indicated that DTbFACA can avoid scratches on the workpiece without sacrificing the sphere form error and grinding efficiency. DTbFACA has been implemented on MD6050 sphere grinding machine tool in production.

“…The work on metal grinding shows many approaches to model grinding force [12]. They are based on empirical [13] or physical considerations [14,15]. The present work models the widespread process of stone machining by electroplated diamond tools, both mill and disk.…”

Section: Introductionmentioning

confidence: 99%

Cutting force and diamond tool wear in stone machining

Turchetta

2011

Stone machining by diamond tool is a widespread process to manufacture both standard products, such as tiles, slabs, kerbs, and so on, and design shapes. Cutting force and energy may be used to monitor stone machining. Empirical models are required to guide the selection of cutting conditions. In this paper, the effects of cutting conditions on cutting force and cutting energy are related to the shape of the idealized chip thickness. These effects are put into relationship with the diamond tool wear too. The empirical models developed in this paper can be used to predict the variation of the cutting energy. Therefore these models can be used to guide the selection of cutting conditions and to predict when it is needed to change the tool. The chip generation and removal process has been quantified with the intention of assisting both the toolmaker and the stonemason in optimizing the tool composition and cutting process parameters, respectively.