Performance evaluation of the grinding wheel with aggregates of grains in grinding of Ti-6Al-4V titanium alloy

Abstract

The results of grinding are highly dependent on conditions of workpiece removal process. The material is removed by an unspecified number of abrasive grains of irregular shape and random distribution on the grinding wheel active surface. The interaction between the abrasive grain and the workpiece can be divided into three stages: (i) rubbing, (ii) ploughing and (iii) chip formation. Reciprocal contribution of each stage is dependent on the properties of the workpiece, the grinding parameters, the friction condition between the abrasive grain and the workpiece and the shape of the grains. In the article, the results of numerical and experimental process in the analysis of grinding of Ti-6Al-4V titanium alloy, using a conventional grinding wheel and a newly developed grinding wheel with aggregates of grains, were presented. The analysis of influence of the geometric parameters of the abrasive aggregates and the abrasive grains on the effectiveness of the workpiece removal process is presented. The effects of the geometrical parameters of grains and abrasive aggregates in direction of motion as well as in transversal direction on the size of ridges were determined. It has been observed that increase of the length of sideway material displacement results in the decrease of ridge formation. The results of a numerical analysis were confirmed by experimental research. The analysis of the impact of utilization of abrasive aggregates on the grinding forces, grinding-specific energy and surface roughness was performed. The impact of abrasive aggregates on the decrease of grinding forces and specific energy and the increase of quality of ground surface was observed.

Analysis and Modeling of the Micro-Cutting Process of Ti-6Al-4V Titanium Alloy with Single Abrasive Grain

“…The cross-sections of the cutting layer obtained from the blade penetrating into the processed material at 10 µm, 15 µm and 20 µm (Figures 7 and 8) indicate different sizes of side pile-ups for the ZS1 and ZS2 grains. The shape of the ZS1 grain, having a flat and wide cutting surface, makes it difficult to move the workpiece sideways and favors chip formation (which confirms the results of previous research on grinding with abrasive aggregates [40]). The average surface area of the side pile-ups in relation to the scratch surface is about 0.5% for the ZS1 grain, while for the ZS2 grain it is about 0.8%.…”

“…Johnson–Cook equations [ 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 ] are commonly used to model materials that are exposed to deformation in a wide range of strain rates and temperatures. The general form of the Johnson–Cook equation is [ 38 , 40 ]: where A —initial, static yield strength; B —parameter of plastic strength; ε p —effective plastic strain; n —exponent of plastic deformation strength; C —material parameter specifying the impact of the intensity of the plastic speed deformation; , —effective plastic and reference strain rates; T , T amb , T melt —current, ambient and melting temperatures; and m —exponent of thermal plasticity.…”

Analysis and Modeling of the Micro-Cutting Process of Ti-6Al-4V Titanium Alloy with Single Abrasive Grain

“…The cross-sections of the cutting layer obtained from the blade penetrating into the processed material at 10 µm, 15 µm and 20 µm (Figures 7 and 8) indicate different sizes of side pile-ups for the ZS1 and ZS2 grains. The shape of the ZS1 grain, having a flat and wide cutting surface, makes it difficult to move the workpiece sideways and favors chip formation (which confirms the results of previous research on grinding with abrasive aggregates [40]). The average surface area of the side pile-ups in relation to the scratch surface is about 0.5% for the ZS1 grain, while for the ZS2 grain it is about 0.8%.…”

“…Johnson–Cook equations [ 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 ] are commonly used to model materials that are exposed to deformation in a wide range of strain rates and temperatures. The general form of the Johnson–Cook equation is [ 38 , 40 ]: where A —initial, static yield strength; B —parameter of plastic strength; ε p —effective plastic strain; n —exponent of plastic deformation strength; C —material parameter specifying the impact of the intensity of the plastic speed deformation; , —effective plastic and reference strain rates; T , T amb , T melt —current, ambient and melting temperatures; and m —exponent of thermal plasticity.…”

Method for assessing the grinding wheels operational properties

“…Index K e (11), which task is economic description of the machining process, is equal to a well-known G-ratio grinding index expressing the relative grinding efficiency. Its value is the quotient of the material removal V m and the grinding wheel wear V s :…”

Testing and modeling the possibility of using a lamellar grinding wheel with an adaptive background structure

“…The authors proposed a quantitative model of the chip formation that takes into account the three-dimensional shape of the grains as well as the cutting speed and cooling conditions in the cutting zone. A similar topic was discussed by Kacalak et al [9]. The interaction between a single abrasive grain and the workpiece has been divided into three stages, where the share of each stage depends on the properties of the workpiece, grinding parameters, the state of friction between the abrasive grain and the workpiece and the shape of the grains.…”

Analysis and Modeling of the Micro-Cutting Process of Ti-6Al-4V Titanium Alloy with Single Abrasive Grain

“…The cross-sections of the cutting layer obtained from the blade penetrating into the processed material at 10 µm, 15 µm and 20 µm (Figures 7 and 8) indicate different sizes of side pile-ups for the ZS1 and ZS2 grains. The shape of the ZS1 grain, having a flat and wide cutting surface, makes it difficult to move the workpiece sideways and favors chip formation (which confirms the results of previous research on grinding with abrasive aggregates [40]). The average surface area of the side pile-ups in relation to the scratch surface is about 0.5% for the ZS1 grain, while for the ZS2 grain it is about 0.8%.…”

“…Johnson–Cook equations [ 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 ] are commonly used to model materials that are exposed to deformation in a wide range of strain rates and temperatures. The general form of the Johnson–Cook equation is [ 38 , 40 ]: where A —initial, static yield strength; B —parameter of plastic strength; ε p —effective plastic strain; n —exponent of plastic deformation strength; C —material parameter specifying the impact of the intensity of the plastic speed deformation; , —effective plastic and reference strain rates; T , T amb , T melt —current, ambient and melting temperatures; and m —exponent of thermal plasticity.…”

Method for assessing the grinding wheels operational properties

“…Index K e (11), which task is economic description of the machining process, is equal to a well-known G-ratio grinding index expressing the relative grinding efficiency. Its value is the quotient of the material removal V m and the grinding wheel wear V s :…”

Testing and modeling the possibility of using a lamellar grinding wheel with an adaptive background structure

“…The authors proposed a quantitative model of the chip formation that takes into account the three-dimensional shape of the grains as well as the cutting speed and cooling conditions in the cutting zone. A similar topic was discussed by Kacalak et al [9]. The interaction between a single abrasive grain and the workpiece has been divided into three stages, where the share of each stage depends on the properties of the workpiece, grinding parameters, the state of friction between the abrasive grain and the workpiece and the shape of the grains.…”

Analysis and Modeling of the Micro-Cutting Process of Ti-6Al-4V Titanium Alloy with Single Abrasive Grain

“…The cross-sections of the cutting layer obtained from the blade penetrating into the processed material at 10 µm, 15 µm and 20 µm (Figures 7 and 8) indicate different sizes of side pile-ups for the ZS1 and ZS2 grains. The shape of the ZS1 grain, having a flat and wide cutting surface, makes it difficult to move the workpiece sideways and favors chip formation (which confirms the results of previous research on grinding with abrasive aggregates [40]). The average surface area of the side pile-ups in relation to the scratch surface is about 0.5% for the ZS1 grain, while for the ZS2 grain it is about 0.8%.…”

“…Johnson–Cook equations [ 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 ] are commonly used to model materials that are exposed to deformation in a wide range of strain rates and temperatures. The general form of the Johnson–Cook equation is [ 38 , 40 ]: where A —initial, static yield strength; B —parameter of plastic strength; ε p —effective plastic strain; n —exponent of plastic deformation strength; C —material parameter specifying the impact of the intensity of the plastic speed deformation; , —effective plastic and reference strain rates; T , T amb , T melt —current, ambient and melting temperatures; and m —exponent of thermal plasticity.…”

Method for assessing the grinding wheels operational properties

“…Index K e (11), which task is economic description of the machining process, is equal to a well-known G-ratio grinding index expressing the relative grinding efficiency. Its value is the quotient of the material removal V m and the grinding wheel wear V s :…”

Testing and modeling the possibility of using a lamellar grinding wheel with an adaptive background structure

“…The authors proposed a quantitative model of the chip formation that takes into account the three-dimensional shape of the grains as well as the cutting speed and cooling conditions in the cutting zone. A similar topic was discussed by Kacalak et al [9]. The interaction between a single abrasive grain and the workpiece has been divided into three stages, where the share of each stage depends on the properties of the workpiece, grinding parameters, the state of friction between the abrasive grain and the workpiece and the shape of the grains.…”