Probabilistic Aspects of Modeling and Analysis of Grinding Wheel Wear

Abstract

In this article, the methodology of using probabilistic models of the grinding tool wear process is presented. Probabilistic modeling with empirical data allowed determining the values of other important process features. Among them, the distribution of active grains lifetime or distribution of cumulative attritious wear of the grinding grain apex could be distinguished. The results of modeling and wear analysis of grinding wheels as well as experimental results on peripheral grinding with zoned grinding wheels are presented. The analyzed grinding wheels consisted of three layers: two identical external layers with conventional structure and one internal layer containing the addition of abrasive aggregates. The external layers were profiled by chamfering the edges. As a result, their nominal surfaces were conical. The internal layer had a cylindrical shape and was designed for smoothing the surface after machining with external part. The tools were designed to increase the grinding efficiency and hence a good quality of machined surfaces could be acquired. For the experimental tests, the Ti6Al4V titanium alloy was used. It was found that the change in the shape and position of the grinding zone, as a result of volumetric wheel wear, caused a significant change in fracturing intensity. In the case of multilayer grinding tools, the wear process depends on the physical properties of each layer and their participation during machining of the workpiece. The presented methodology could be applied to a study on the machining process stages, which concerns temporary states and their variability according to the machining time.This makes it possible to reduce the cost of developing new tools dedicated to specific applications.

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

“…As a result of a detailed analysis of the resulting traces, one can see a resemblance to surfaces shaped in the process with selected abrasive grains. The work of individual abrasive grains results in the formation of a pile-up of material between them, with a characteristic longitudinal course, which occurs as a result of plastic flow [ 56 ]. A similar effect was observed by Wang et al [ 57 ].…”

Metrological Aspects of Assessing Surface Topography and Machining Accuracy in Diagnostics of Grinding Processes

“…Simulation studies of the grinding process were carried out according to the scheme depicted on Figure 1 using calculation procedures developed in the Matlab ® environment. The input parameters and ranges of results for the analyses included, among others, the following: grinding wheels with the following geometric dimensions: D = 250 mm, H = 10–50 mm and the type of abrasive grains made of Al 2 O 3 , regular boron nitride and diamond with grain size from 46 to 240, generated and verified by comparing vertex angles, radii of vertex rounding, flatness of the surfaces of the abrasive grains, for the assumed average distances between grains in the range of 1.2 to 2.5 grain dimensions; workpiece characterized by the assessment of the ratio of pile-ups formation during microcutting with grains of various shapes and spatial orientation and by the values of the coefficient in the formulas for microcutting forces; process parameters: longitudinal feed speed in the process of grinding flat surfaces v w = 0.01–1 m/s, grinding speed v s = 20–60 m/s, depth of cut a e = 1–200 µm, cross feed of the table fa = 0.5–5 mm/stroke; parameters of calculation procedures: calculation resolution in the range of 0.1–0.5 µm, size of the geometry data matrix of individual models of abrasive grains, e.g., 120 × 120 cells, grinding wheel surface data matrix size cells (where is the number of grains), machined surface data matrix, e.g., 50,000 × 100,000 µm; calculation procedures for pile-ups developed from the 3D FEM analysis of single-grain micro-machining modeling processes [ 18 ]; analyses of the activity of the grains in individual fragments of the grinding zone as well as tangential and normal forces acting on individual grains, taking into account the shape of the grain and the cross-section of the machined layer and the characteristics of the material; analysis of the wear of the grains, taking into account their strength, resistance to chipping and random load, which were described in work [ 38 ]. …”

“…analysis of the wear of the grains, taking into account their strength, resistance to chipping and random load, which were described in work [ 38 ].…”

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

“…图 4 圆柱砂轮的不同磨损形式 [38,39] Figure 4 Different forms of wear of cylindrical grinding wheels [38,39]. Copyright © 2017, Springer 轮廓面扫描法 径向/轴向磨损量 1~5 μm [110][111][112][113][114][115][116][117][118][119][120][121] 3.1 离线接触式测量技术 常用的离线接触式测量技术如图 7 所示.…”

“…(4) 轮廓面扫描法 轮廓面扫描法是指通过轮廓扫描仪扫描砂轮表 面以获得砂轮轮廓数据, 并构造砂轮表面数字化轮 廓 模 型 [110] , 在 此 基 础 上 计 算 砂 轮 磨 损 量 , 如 图 8(d) [111] 所示. 首先在磨削加工前对砂轮进行坐标扫 描, 建立参考面作为定位面, 以保证被测表面的重复…”