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

Abstract

Grinding is one of the most complex and precise machining operations, with the performance of the grinding wheel being heavily reliant on its surface conditions. Removed chips tend to be forced back to the wheel surface due to the intense heat generated in the grinding zone. The loaded chips block the wheel's grinding capability, resulting in increased grinding force and temperature, wheel chatter, and workpiece thermal degradation. To solve these problems, this research examines the effectiveness of an auxiliary compressed air jet system during the grinding of spk tool steel with an alumina grinding wheel to clean the wheel surface of lodged chips and then the percentage of wheel loading for different tests will also be evaluated. The compressed air nozzle was examined from a variety of perspectives (0, 30, 45, and 60). Grinding with and without a cleaning system, as well as conventional cutting fluid, were also employed as comparisons. In certain output results, input parameters such as grinding wheel speed (20 m/s), cutting depth (20 m), and feed rate (100 mm/s) were maintained constant. When compared to other experiments with different cleaning nozzles, the optimal inclination angle of 45°, which allows the maximum air to reach the interface between the wheel surface and chips, removed chips by pushing them off the wheel surface. Other cleaning nozzles, such as 0°, 30°, and 60°, were less successful. The incidence angle of 45° produced the best results in terms of surface roughness, diametrical grinding wheel wear, G-ratio, tangential forces, specific energy, and wheel loading analysis. Image processing was used to detect and identify chips accumulated between abrasive grains on the wheel surface. To better understand the structure of the wheel and workpiece surface, optical and scanning electron microscopy pictures were taken and analyzed. This research adds to our understanding of the grinding wheel loading mechanism and its dynamics.

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

“…Therefore, specific grinding energy falls [ 66 ]. Similar to roughness, when the nozzle angle is 45, an optimum value of specific grinding energy is obtained due to better cleaning and cooling and lower grinding zone temperature [ 7 , 62 ].…”

“…In the following, Hatami Farzaneh et al used an auxiliary compressed air jet system to investigate the effect of the incidence angle at various angles to clean the wheel surface and reduce wheel loading. The results showed that an incidence angle of 45 de grees produced the best results in terms of surface roughness, diametrical grinding wheel wear, G -ratio, tangential forces, specifi;c energy, and wheel loading analysis [ 7 ].…”

Research on grinding wheel wear measurement methods: Current status and future perspectives

“…Wang [91] , Wang [85] 和 Wang [92] 等在砂带磨削过程中基 于砂带图像分析和分类提升算法, 对砂带的磨损类 型进行识别和分析. Farzaneh [93] 等采用计算机图像处 [94] ,…”

Computer Vision Algorithm for Characterization of a Turbulent Gas–Liquid Jet

“…Intense fluid jetting is a key technical element in a number of industrial devices, e.g., grinding [1][2][3], cutting [4,5], etc. The detailed characterization of multiphase gas-liquid flows is critical in metallurgical processes, the design of efficient air and ground devices, combustion devices in aircraft and aerospace systems, and engines in transportation and marine engines, as well as when developing new technologies leading to technological advances [6][7][8][9].…”