On-Machine Precision Form Truing and In-Situ Measurement of Resin-Bonded Spherical Diamond Wheel

Abstract

The resin-bonded spherical diamond wheel is widely used in arc envelope grinding, where the demands for form accuracy are high and the form truing process is challenging. In this paper, on-machine precision form truing of the resin-bonded spherical diamond wheel is accomplished by using a coarse-grained diamond roller, and in-situ measurement of the form-truing error is conducted through a laser scan micrometer. Firstly, a novel biarc curve-fitting method is proposed based on the in-situ measurement results to calculate the alignment error between the diamond roller and the spherical diamond wheel. Then, on-machine precision form truing of a D46 resin-bonded spherical diamond wheel is completed after alignment error compensation. The in-situ measurement results show that the low-frequency form-truing error is approximately 5 μm. In addition, the actual form-trued diamond wheel has been employed in grinding a test specimen, and the resulting form accuracy is approximately 1.6 μm without any compensation. The ground surface profile shared similar characteristics with the roller-trued diamond wheel profile, confirming that the diamond roller truing and in-situ measurements methods are accurate and feasible.

Special Issue on Manufacturing Metrology

“…For the purpose of in situ measurement, a design framework for optimizing spectral-domain low-coherence interferometric sensors was proposed for profilometry measurements to optimize system performance [14]. Another in situ measurement system dealing with the on-machine precision form truing of resin-bonded spherical diamond wheels was also proposed [15]. A novel nanotechnology presented a method for measuring the high-precision cutting edge radius of single point diamond tools using an atomic force microscope (AFM) and a reverse cutting edge artifact based on the edge reversal method [16].…”

Development of a longitudinal-torsional ultrasonic assisted roller dressing device for precision form grinding of GCr15 bearing rings

“…As the grinding wheel grinds the bearing ring, the grinding wheel surface will be affected by the grinding force and temperature, the abrasive grains will be blunted; the protrusion height of the abrasive grains gradually decreases; the holding force of the inter-granular bond on the abrasive grains decreases; the chip space of the grinding wheel be-comes smaller [1][2][3]. As the geometric accuracy and sharpness of the grinding wheel gradually decrease, the subsequent grinding process will result in the accumulation of grinding chips, which in turn will scratch the surface of the ground workpiece if it is not dressed in time [4,5]. The surface quality of bearing ring grinding will gradually deteriorate if high precision and high-quality dressing is not carried out [6].…”