Establishing the Relationship between Cutting Speed and Output Parameters in Belt Grinding on Steels, Aluminum and Nickel Alloys: Development of Recommendations

Abstract

This paper presents the research results of one of the main technological parameters of belt grinding, i.e., the cutting speed while machining corrosion- and heat-resistant, structural carbon and structural alloy steels, aluminum, and heat-resistant nickel alloys. Experimental and analytical methods are used to establish the dependence of the output parameters of surface belt grinding on the cutting speed and tool characteristics. An analytical model, considering the physical and mechanical properties of the grinding belt (strength depending on the base and bond; the thermal conductivity; the type of grinding operation) and the machined material, is created to determine the belt grinding speed. The output parameters, such as the arithmetic mean of the surface roughness (Ra) and the material removal rate (MRR) during the belt grinding of steels, heat-resistant and light alloys, have been studied. Based on the empirical dependencies of the belt grinding parameters, the model was developed for the selection and setting of the cutting speed of belt grinding for the aforementioned alloys, taking into account the type of operation, the type of the machined material, and the main characteristics of the sanding belt.

Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy

“…The tests were carried out with clamping forces of 14.7–98.1, N. Other test conditions: cutting speed v c = 25 m/s; workpiece speed v w = 0.058 m/s; vertical oscillation frequency w os = 200 mm −1 ; the value of the vertical oscillation Aos = 3 mm. Table 1 shows the chemical composition and physical and mechanical properties of these steels and alloy for blanks [ 15 , 30 ].…”

“…We proposed a formula to determine the value of the contact pressure ( p ) of the tool and workpiece for flat belt grinding [ 47 ]: where P y is the cutting force directed along the normal to the machinable surface (radial clamping force of the tool and workpiece); L is the contact length in the direction of belt movement; B is the contact width; and Kj is the coefficient depending on the deformation of the contact roller, material workpiece properties, the size of the stock, deformation of the belt and other factors. Comparable quantitative processing characteristics were selected, which reflect roughing and finishing operations as an interaction between contacting surfaces, for example, reduced cutting ability (performance index) ( ) [ 15 , 30 , 47 ]: where is the material removed over the i-th grinding period; is the clamping force of the tool to the workpiece; is the operating time of the tool until the resistance criterion (tool life); and is the cutting speed. is the characteristic of stock removal from the workpiece per unit of work expended.…”

“…However, flat belt grinding has been studied to a lesser degree. In our previous studies [ 15 , 30 ], the machinability and the influence of cutting speed during belt grinding of steels and alloys were investigated. However, the studies lack the effect of pressure for different groups of materials and alloys.…”

“…These include the main grinding mode parameters (pressure and cutting speed) when assigning tool properties and achieving the necessary results determined by the established performance indicators [ 26 , 39 ]. In previous papers [ 15 , 30 ], the authors of this work investigated belt grinding of heat-resistant and stainless steels and alloys. The results showed that the effect of pressure on the output parameters of belt grinding of such materials has not been sufficiently reported in the open literature.…”

A mathematical model for the cylindrical grinding responses of 18CrNiMo7-6 alloy steel

“…Furthermore, Winter et al [22] proposed a method to identify process parameters that can provide Pareto optimal solutions to improve the eco-efficiency of material grinding. Empirical formulas and mathematical models have been obtained through analytical studies to describe the relationship between the grinding parameters and responses [23,24]. Su et al [25] established a theoretical model of grinding force to predict the influence of machining parameters on grinding force.…”