Tool optimization for high speed grinding

Uhlmann, Eckart; Hochschild, L.

doi:10.1007/s11740-013-0447-5

Cited by 20 publications

(6 citation statements)

References 5 publications

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“…To increase the MRR, the feed rate is increased. Cutting speed, depth of cut, and cutting speed ratio (q = v s / v w ) have been established during preliminary experiments [11] and are kept constant for all investigations. All fixed and varied process parameters are shown in the experimental plan in Table 1.…”

Section: Methodsmentioning

confidence: 99%

“…In order to improve the performance of CBN wheels, Aurich and Denkena focus on the patterning of the abrasive layer [9,10]. Marschalkowski and Uhlmann work specifically on the tool design [11] and use of electroplated tools [12] for high speed and high performance grinding processes. Ichida investigated the influence of ultrafine-crystalline abrasive grains in comparison to mono-and polycrystalline grains in vitrified CBN wheels on their performance [13].…”

Section: Introductionmentioning

confidence: 99%

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High performance peel grinding of steel shafts using coarse electroplated CBN grinding wheels

Denkena

Krödel

Wilckens

2021

Prod. Eng. Res. Devel.

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Grinding is widely known for its low material removal rates and high surface quality. However, recent developments in production processes for cubic boron nitride (CBN) abrasive grains have led to commercially available grain sizes larger than 300 µm. These superabrasive CBN-grains allow higher material removal rates during grinding of hardened steel components. Currently, these components are pre-machined with turning processes before hardening and finishing the work piece by grinding. However, the turning process can be eliminated by grinding with coarse CBN-grains since higher depths of cut are achievable when machining hardened components. This paper explores the limits of grinding wheels using grains with a size of B602 during soft and hard machining in comparison to conventional B252 grains. It is shown that the use of coarser grains leads to lower process forces, higher (tensile) residual stress and higher surface roughness. Residual stress and surface roughness are of less importance as these grains are to be used mainly in roughing operations with ensuing finishing operations for the required surface properties. Over all investigations, especially in hard machining, neither grain nor tool wear was observed for the B602 grains, whereas the B252 tool was severely clogged during the experiments. Additionally, the grinding force ratio indicates that the coarse grain tools have not yet reached their productivity limit as it increases over all investigated feeds. This indicates improving tool performance with lower amounts of rubbing for increasing feed rate during hard grinding and shows the potential for the industrial use of higher feed rates with larger grains.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

High performance peel grinding of steel shafts using coarse electroplated CBN grinding wheels

Denkena

Krödel

Wilckens

2021

Prod. Eng. Res. Devel.

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“…Therefore, the discontinuous grinding wheel was capable of reducing the grinding force and the grinding damage. In addition, arranging the grinding uid conveying microporous channel on the grinding wheel surface might further promote the grinding uid to enter the grinding area, clean the working surface of the grinding wheel, decrease the adhesion of grinding debris, and maintain the sharpness of the cutting edge [10]. As a result, the grinding force and wheel damage were also subsided.…”

Section: Introductionmentioning

confidence: 99%

Grinding Performance Integrated Experimental Evaluation on Alumina Ceramics with Leaf-Vein Bionic Grinding Wheel

Li¹,

Duan²,

Zhang

et al. 2022

Preprint

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In order to enhance the grinding performance of alumina ceramic materials, the surface of the grinding wheels are ablated by laser radiation before grinding, and the three types of leaf-vein bionic grinding wheels with different micro-groove pitches are formed to compare the grinding experiments with normal grinding wheels. The grinding forces and surface roughness were gauged and the morphological characteristics of ground workpiece surfaces were studied. The results showed that with the increase of groove pitch, the normal grinding force was reduced by 9.6-63%, while the tangential grinding force is reduced by 8.3-42%. The groove can promote the flow of coolant, accelerate the heat dissipation and chip removal in the grinding area, reduce the damage of the workpiece and the wear of the grinding wheel, so the vein bionic grinding wheel had more tremendous processing advantages. Among the four kinds of grinding wheels, the leaf-vein bionic grinding wheel with groove pitch equal to 8mm obtained the best grinding effect. The vein-shaped groove had a positive impact on the grinding process.

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“…Therefore, the grinding process is further developed in order to reduce the process load and thus increase the surface quality. Common approaches are the structuring [1,2] of grinding wheels as well as the change in grain or bond of the grinding wheel [3]. However, previous studies proofed that additional, subsequent processes such as the forming process deep rolling process can improve the surface quality [4,5].…”

Section: Introductionmentioning

confidence: 99%

Process design of a novel combination of peel grinding and deep rolling

Denkena

Kroedel

Gartzke

2021

Prod. Eng. Res. Devel.

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Grinding is mostly considered as a finishing operation by which a high surface quality is achieved. An increase in productivity is therefore limited by maintained surface properties such as the roughness or tensile residual stresses. Thus, a roughing operation is inevitable followed by a finishing operation, while both operations are separated, leading to larger cycle times and process costs. In this paper, a novel process combination is investigated in which the roughing is done by grinding and the finishing operation by deep rolling within one tool setup. In this way, both processes are conducted parallel within the primary processing time. The objective of this study is the knowledge of the characteristics of this process combination with regard to the workpiece surface integrity. Therefore, shafts are ground in peel grinding with varying grinding wheel types and process parameters and subsequently machined with deep rolling. The process combination is evaluated with regard to the process forces and the resulting surface properties. In addition, experiments using the process combination were conducted in order to investigate the transferability of the results towards the process combination. By this approach, it was found that the surface roughness was reduced up to 80% by deep rolling showing the potential of the process combination.

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Tool optimization for high speed grinding

Cited by 20 publications

References 5 publications

High performance peel grinding of steel shafts using coarse electroplated CBN grinding wheels

High performance peel grinding of steel shafts using coarse electroplated CBN grinding wheels

Grinding Performance Integrated Experimental Evaluation on Alumina Ceramics with Leaf-Vein Bionic Grinding Wheel

Process design of a novel combination of peel grinding and deep rolling

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