An experimental study of the effects of dressing parameters on the topography of grinding wheels during roller dressing

Abstract

Vitreous-bonded grinding wheels are widely used for machining features on aerospace components achieving high material removal rates under high pressure coolant. Dressing is a vital stage in the grinding process to ensure a consistent wheel topography and performance. However, the effects of roller dressing on functional performance of vitreous grinding wheels as well as its influence on different abrasive grit morphologies have not been fully characterised. This paper studies the influence of dressing parameters on the topography, morphology and characteristics of the surface of different vitrified abrasive wheels in order to better understand the process and therefore optimise the preparation of grinding wheels for industrial machining. Alumina grinding wheels with conventional and engineered grit shapes were dressed at two different infeed rates over a range of seven different speed ratios (from -0.8 to +1). An experimental methodology has been developed incorporating a range of known techniques to define the abrasive wheel condition including measured power consumption and ground graphite coupons as well as using optical microscopes to measure grain fracture flats, peak density and abrasive grain shape. It has been found that power consumption of the grinding wheel spindle increases at higher infeed rates and speed ratios. This leads to increased fracturing of the grains and whole-grain pull out. According to the results the infeed rate has a more substantial effect on wheel topography than speed ratio and the response of engineered grit morphologies to dressing is dependent on grit orientation.

Multi-Objective Optimization of the Dressing Parameters in Fine Cylindrical Grinding

“…The impact of f rd rises with a decrease in q g . Тhis character of change is explained by an increase in the area of the removed abrasive layer, as well as an increase in the forces and heat which results in quality deterioration of the grinding wheel profiled surface and in a decrease in ground surface accuracy, respectively [10] and [30]. (3.…”

“…Cebalq [5] found that the different combinations between the dressing mode, dressing conditions, and the grinding wheel specification lead to different inter-grit spacing between the abrasive grits of the grinding-wheel cutting surface and, as a result, different response variables of the grinding process (equivalent grinding thickness, specific metal removal rate, roughness of the grinding-wheel cutting surface, roughness of the ground surface, etc.). Baseri et al [6] and [7] and Baseri [8], Wegener et al [9] and Palmer et al [10] proved that the grindingwheel topography and the conditions under which it is prepared have a profound influence upon the grinding performance, defined by the grinding forces, the power consumption, the cutting zone temperature, the radial wear of the wheel and also the surface finish of the workpiece. Chen et al [11] found that a satisfied and stable grinding process can be controlled in real-time by means of utilizing the combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits.…”

A Novel Approach for Surface Topography Simulation Considering the Elastic-Plastic Deformation of a Material During a High-precision Grinding Process

“…Generally, the abrasive-grains are simplified as spheres ignoring the complexity of their shape [26][27][28][29]. From a mathematical viewpoint, these abrasive-grains are a set of points with an average distribution in the two-dimensional direction of the wheel surface, and the distances between the grains obey an even distribution [30] in the radial direction. The protrusion-heights of these abrasive-grains are described with a distribution [31], furthermore, the size of the abrasive-grain is approximately equal to the number of grains.…”

On The Influence of Rotary Dresser Geometry on Wear Evolution and Grinding Process

“…The main conclusion reached by the authors was that extremely high values of overlap ratios were suitable for achieving high surface quality in micro-grinding processes. Finally, Palmer et al [10] analysed the characteristics of the dressed wheel surface when using roller dressers.…”