Dynamic characteristics of abrasive grains and machined surface features for variable axis diamond grinding of quartz glass

Abstract

There is a fine application prospect for multi-axis grinding of hard and brittle materials with diamond ball end tool. The effects of tool inclination angles and grinding modes of multi-axis grinding of quartz glass on the dynamic characteristics of the diamond abrasives, surface topography, surface fragmentation phenomenon, and surface roughness were investigated in this work. Material removal characteristics and surface formation conditions would be significantly affected by the effective cutting speed, material stress characteristics, and movement space path derived from different grinding modes and tool inclination angles. The surface texture direction is mainly determined by feed direction of the cutter and initial cutting moment and geometry feature of the engaged diamond abrasives. The surface fragmentation phenomenon of the formed surface is apparent when the corresponding surface roughness values are relatively larger. The machined surface with significant surface fragmentation phenomenon is mainly produced by materials' brittle fracture modes, such as larger positive lead and smaller negative tilt under conventional grinding and smaller negative lead angles and larger positive tilt angles under down grinding. Ideal surface evenness could be obtained by using lead or tilt 0° for conventional and down grinding. The ground surface with smaller surface roughness could be produced when employing tool postures, such as negative lead or positive tilt under conventional grinding and positive lead or negative tilt under down grinding condition.

Optimization of Grinding Parameters of Tool Steel by the Soft Computing Technique

“…In grinding operation, the workpiece material becomes more ductile throughout the process due to the generated heat, which increases chip adherence to the abrasive tool. Heated chips from the grinding zone could have the propensity to lodge the pores of the wheel if they are not entirely eliminated from the cutting zone [ 5 ]. The clogged chips reduce the wheel's ability to cut, increasing the force and temperature of the grinding process and leading to wheel chatter or workpiece thermal damage and wheel loading.…”

Evaluation of the grinding process utilizing an auxiliary compressed air jet on cleaning the grinding wheel surface

“…The depth of engagement will be less at low work speeds, resulting in a decrease in the average force per grain. 7 If the cut depth is reduced, the force on the grit is reduced, resulting in the utilization of more grains in the removal of metal over a given amount of material. At greater labor speeds, grain has a high average force.…”

“…If hot chips from the grinding zone are not completely removed from the cutting zone, they could have a tendency to clog the wheel's pores. 7 The cutting fluid's influence on the cutting zone is injured when they become caught in the pores of the grinding wheel, and the cooling and lubrication of the grinding zone are further disrupted. [8][9][10] In addition, because the porosity of the cutting surface is entirely filled with chips, the cutting fluid does not penetrate the cutting zone.…”

Polarized laser scattering detection of subsurface damage of quartz glass induced by grinding

“…Currently, grinding is one of the most important technologies in the manufacturing of quartz glass. During the grinding process, it inevitably produces SSD in the quartz glass (Guo et al, 2020), which has a great impact on the sustainability, lifetime, and optical performance of quartz glass components and systems (Chen et al, 2020). To reduce and eliminate quartz glass SSD in the next process, it is important to detect SSD.…”