Effect of different parameters on grinding efficiency and its monitoring by acoustic emission

Chen, Xun; Öpöz, Tahsin Tecelli

doi:10.1080/21693277.2016.1255159

Cited by 18 publications

(9 citation statements)

References 34 publications

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“…In this sense, the mechanical shocks become increasingly intensified due to impacts of the process which are originated by the couplings and uncouplings between the workpiece and grinding wheel. This will lead to fracture of bond and grits and, consequently, loss of grits cutting edges, thereby reducing cutting performance and adversely affecting surface finish [8,21]. In this current work, it was expected that the increase in number of grooves lead to more bond-grits fracture, but by the surface roughness and standard deviation values obtained, no influence of number of grooves was observed in the surface roughness.…”

Section: Surface Roughnessmentioning

confidence: 73%

Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

Mello

Rodriguez

et al. 2018

Int J Adv Manuf Technol

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Grinding is generally the first choice to provide combination of both superior surface finish and closer dimensional tolerances in a machined component. This process can be employed in manufacturing of continuous and interrupted surfaces. Crankshafts and engine piston rings are examples of ground precision mechanical components having interrupted surfaces. However, the specific literature about grinding of interrupted surfaces is still scarce. In this context, aiming to further contribute to the understanding of the behavior of surface integrity of interrupted surfaces during grinding, this paper presents an experimental investigation of interrupted surfaces ground with white aluminum oxide grinding wheel. Discs of AISI 4340 hardened steel with different number of grooves (2, 6, and 12) on the external surface were tested. Experiments with discs without interrupted surface were also carried out for comparisons. In addition to the number of grooves, three values of infeed rate (0.25, 0.50, and 0.75 mm/min) were used as input parameters. The output parameters investigated were the geometric errors (surface roughness and roundness) of the workpiece material as well as the diametric wheel wear. Analysis of variance (ANOVA) test was performed to verify any statistical difference among the output variables. Results showed that both surface finish and roundness of workpieces with interrupted surfaces were higher than those obtained for continuous surface. These parameters also increased with infeed rate up to 0.50 mm/min, whereas the grinding wheel wear was more sensitive to number of grooves and infeed rate. No thermal damages were observed on the machined workpieces under the conditions investigated.

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Section: Surface Roughnessmentioning

confidence: 73%

Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

Mello

Rodriguez

et al. 2018

Int J Adv Manuf Technol

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“…As the grinding depth increases, the area of pile of material is increased due to excessive plowing action at higher grinding depths. 20 Figure 5(c) presents the effect of grinding depth on chip formation force under different grinding wheels. The number of active grits is increased at higher grinding depth and thereby increases the chip formation force.…”

Section: Resultsmentioning

confidence: 99%

“…After this stage, the grit shears the material and facilitates the cutting action. 20 From the above discussion, the rubbing and plowing action does not support the material removal and increases the cutting force. The actual material removal is carried out by the cutting action.…”

Section: Introductionmentioning

confidence: 95%

Studies on the grinding force, size effect, surface texture, and mechanism of material removal in the grinding of AA6061-TiB₂/ZrB₂ in situ composite

Mahamani

2019

Journal of Micromanufacturing

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Machining and conversion of aluminum matrix composites into a desired shape with accuracy has been a challenge for many years. Grinding is a process aimed at achieving better-quality surface finish along with reasonable rate of material removal. The present article describes the influence of operating parameters on the tangential grinding force, size effect, and surface integrity in the grinding of in situ aluminum matrix composites using various grinding wheels. The material removal mechanism of the in situ composite under different grinding conditions is established. Experimental results show that the grinding operating parameters have significant influence on the tangential grinding force, size effect, surface integrity, and material removal. Scanning electron and atomic force microscopy findings indicate presence of numerous surface defects on the grounded surface under all grinding conditions. Diamond grinding wheel outperformed the CBN and Al2O3 wheels by requiring lower grinding force and specific grinding energy and generating lower surface defects. Surface defects, including grinding striation, delamination, and ridge formation are unavoidable under all machining conditions. However, the aforementioned surface defects indicate the ductile mode of material removal at all experimental conditions. Undeformed chip thickness under various grinding conditions plays a significant role in material removal and surface generation. These findings help to understand the mechanism of material removal in machining of in situ composites under various grinding conditions, which helps in attaining the economic production rate without compromising the surface integrity.

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“…By the fact that the MQL + WCJ technique resulted in lower roughness results, irrespective of the flow rate tested, in relation to those obtained for the traditional MQL technique, it can be inferred that a combination of flow rate, aluminum oxide grinding wheel, and compressed air wheel cleaning jet helped in promoting better evacuation of chips from the contact zone [20], thereby preventing the occurrence of wheel clogging. In addition, since the material removal mechanism in grinding occurs at a micro scale and consists of three phases (rubbing, plowing and cutting), rubbing and plowing stages are highly inefficient in terms of material removal [1,21], thus only on the cutting phase in fact chip formation takes place. In these phases, high amount of energy is spent in deformation and friction on the surface being machined which is converted to heat within the grinding zone [22].…”

Section: Surface Roughnessmentioning

confidence: 99%

Plunge cylindrical grinding with the minimum quantity lubrication coolant technique assisted with wheel cleaning system

Bianchi

Rodriguez

Hildebrandt

et al. 2017

Int J Adv Manuf Technol

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MQL technique is considered as a cleaner machining compared to the conventional coolant delivery one, thereby ensuring environmental sustainability and economic benefits. However, one of problems commonly reported when using the MQL technique is the wheel clogging phenomenon as a result of the inefficient chip removal from the cutting zone, then the chips lodge inside the pores of the grinding wheel, adversely affecting the quality and the finishing of the final product. In this context, this study was carried out to evaluate the performance of the minimum quantity lubrication coolant technique assisted with a wheel cleaning jet (MQL + WCJ) in plunge grinding of hardened steel. This cooling-lubrication technique was tested using the following flow rates: 30, 60, and 120 ml/h. Comparative tests were also carried out with the conventional coolant technique, as well as with the traditional MQL technique (without the wheel cleaning jet). The output variables used to assess the efficiency of the MQL + WCJ technique are roughness, roundness, workpiece microhardness, grinding wheel wear, and power consumption. The results showed that the machining with the MQL + WCJ technique outperformed the traditional MQL technique in all the output parameters investigated. Also, the efficiency of the MQL + WCJ technique increased with flow rate, thereby being an alternative coolant delivery technique in grinding due to cleaner environment, more sustainable and lower consumption of fluid compared to conventional coolant one. No thermal damages and cracks on the machined surface and sub-surfaces were observed after grinding AISI 4340 steel, irrespective of the technique.

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Effect of different parameters on grinding efficiency and its monitoring by acoustic emission

Cited by 18 publications

References 34 publications

Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

Studies on the grinding force, size effect, surface texture, and mechanism of material removal in the grinding of AA6061-TiB₂/ZrB₂ in situ composite

Plunge cylindrical grinding with the minimum quantity lubrication coolant technique assisted with wheel cleaning system

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Effect of different parameters on grinding efficiency and its monitoring by acoustic emission

Cited by 18 publications

References 34 publications

Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

Studies on the grinding force, size effect, surface texture, and mechanism of material removal in the grinding of AA6061-TiB2/ZrB2 in situ composite

Plunge cylindrical grinding with the minimum quantity lubrication coolant technique assisted with wheel cleaning system

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Studies on the grinding force, size effect, surface texture, and mechanism of material removal in the grinding of AA6061-TiB₂/ZrB₂ in situ composite