Model for Predicting the Micro-Grinding Force of K9 Glass Based on Material Removal Mechanisms

Abstract

K9 optical glass has superb material properties used for various industrial applications. However, the high hardness and low fracture toughness greatly fluctuate the cutting force generated during the grinding process, which are the main factors affecting machining accuracy and surface integrity. With a view to further understand the grinding mechanism of K9 glass and improve the machining quality, a new arithmetical force model and parameter optimization for grinding the K9 glass are introduced in this study. Originally, the grinding force components and the grinding path were analyzed according to the critical depth of plowing, rubbing, and brittle tear. Thereafter, the arithmetical model of grinding force was established based on the geometrical model of a single abrasive grain, taking into account the random distribution of grinding grains, and this fact was considered when establishing the number of active grains participating in cutting Nd-Tot. It should be noted that the tool diameter changed with machining, therefore this change was taking into account when building the arithmetical force model during processing as well as the variable value of the maximum chip thickness amax accordingly. Besides, the force analysis recommends how to control the processing parameters to achieve high surface and subsurface quality. Finally, the force model was evaluated by comparing theoretical results with experimental ones. The experimental values of surface grinding forces are in good conformity with the predicted results with changes in the grinding parameters, which proves that the mathematical model is reliable.

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

“…By assuming that the material properties will not be affected by the grinding parameters, the critical transformation point from ductile to brittle rip is calculated through the properties of the material as Young's modulus E p , hardness H P , and fracture toughness K IC . Thus, the critical depth of cut can be calculated through Equation ( 7) [34][35][36]:…”

Experimental investigations into the effect of process parameters on the machining quality for ITO conductive glass using by micro grooves grinding

“…They analyzed the effects of different micro-grinding tools and process parameters on micro-grinding quality. Manea et al [15] conducted a study on micro-grinding of K9 glass, analyzing the grinding force component and grinding path based on the critical depths of plowing, sliding friction, and brittle tearing. They established an arithmetic model of grinding force based on the geometric model of abrasive particles, and finally verified the reliability of the model through experimental results.…”

Research on Self-Aligning Flanges Based on Piezoelectric Actuators Applied to Precision Grinding Machines

“…In the grinding process, the high hardness and low fracture toughness make the cutting force fluctuate greatly during grinding, which affects the surface quality of the components. Therefore, if there is a large eccentricity error in the grinding wheel installation, it will lead to an increase in the fluctuation of grinding force and affect the machining quality [3,4]. The causes of grinding wheel mounting errors are as follows: roundness error of the grinding wheel and coaxiality error of the grinding machine spindle, both of which are generally small.…”