Unsteady-State Grinding Technology (I) Theoretical Generalization and Research on Grinding Mechanism

In conventional grinding theory, it is obvious that there must be a very high hardness difference between grains of the grinding wheel and workpieces. The best grinding wheels are those giving the lowest "natural limiting surface roughness" while cutting at appreciable plunge velocities. With the development of new materials and new machining processes, conventional theories of grinding techniques are no longer suitable to explain many phenomena in the course of grinding procedures. In dealing with precision or ultra-precision grinding processes of advanced ceramics, many results of experiments and practical production have shown that grinding with super hard materials wheels is not the only method to machine advanced ceramics. This paper is intended to propose a new grinding theory named as unsteady-state grinding technique evolved from some phenomena that can not be explained by conventional grinding theory. Unsteady-state grinding technique means the technique which can make the surface roughness of the materials, especially hard and brittle, be up to the standard of ultra-precision machining by utilizing common wheels characteristic of inferior self-sharpening and wear-resistance. In the process of machining, the common wheel need to be redressed about 3～5 times and the time between two redressings is about 3～5 minutes. As a validation of the new grinding technology, experimental work was performed to prove the existence of the unsteady state in the process of ultra-precision grinding with common abrasive wheel-pink fused alumina wheel. From the results of the observation of the wheel topography, the whole grinding process in unsteady state was separated into three stages namely cutting by grains peaks, micro-cutting by micro edges of the broken grains and rubbing without material removal, which is different from conventional grinding theory. For the difference of hardness between grinding wheel and workpiece material is not so apparent, some people have doubts about whether the cutting especially micro-cutting actions exist in the process of unsteady state grinding. By utilizing the common abrasive wheel newly redressed to grind the finished surface of silicon nitride glut and comparing the finished surface with the damaged surface in SEM pattern and surface roughness, the existence of cutting and micro- cutting actions in the unsteady state grinding process was confirmed.

Phase Transformation Mechanism of Graphite-Turbostratic Graphite in the Course of Mechanical Grinding

The transformation from graphite to turbostratic graphite by means of the treatment with high energy ball milling was investigated by X ray powder diffraction method. It is believed that the size effect of nano crystal leads to this transformation. A possible transformation mechanism is proposed from the change of the eletronic structure of the hexagonal plane of the carbon atoms.

Development and Prospectives of Ultra-High-Speed Grinding Technology

Ultra-high-speed grinding(UHSG)is a significant and powerful machining method in view of the enhanced productivity and precision demands.Previous researches regarding formation mechanisms and crucial technologies are comprehensively and thoroughly summarized to highlight state-of-art technology of UHSG.On the basis of the interdependence between process and machine innovations,theoretically,grinding mechanisms in strain hardening,strain rate strengthening,thermal softening,size effect and process characteristics need more in-depth studies to clarify the dominance of UHSG.Technically,CFRP wheel integrating with the brazed bonding has a prominent advantage in bonding strength and grit′s configuration over vitrified bonding,which would be superior in UHSG.Furthermore,external high pressure cooling combining with inner jet cooling methods,accompanied by scraper plates to alleviate the effect of air boundary,are crucial and practical measures for realizing effective cooling in UHSG.Grinding processes,especially those being related to grinding parameters and precise in-process measuring approaches,are also prerequisite for fitting and investigation of UHSG.

Formation mechanism and wear behavior of gradient nanostructured Inconel 625 alloy

The formation mechanism and wear behavior of a gradient nanostructured(GNS) Inconel 625 alloy were investigated using SEM, TEM and ball-on-disc sliding wear tester. The results show that surface mechanical grinding treatment(SMGT) induced an approximately 800 μm-deep gradient microstructure, consisting of surface nano-grained,nano-laminated, nano-twined, and severely deformed layers, which resulted in a reduced gradient in micro-hardness from 6.95 GPa(topmost surface) to 2.77 GPa(coarse-grained matrix). The nano-grained layer resulted from the formation of high-density nano-twins and subsequent interaction between nano-twins and dislocations. The width and depth of the wear scar, wear loss volume, and wear rate of the SMGT-treated sample were smaller than those of untreated coarse-grained sample. Moreover, the wear mechanisms for both samples were mainly abrasive wear and adhesive wear, accompanied with mild oxidation wear. The notable wear resistance enhancement of the GNS Inconel 625 alloy was attributed to the high micro-hardness, high residual compressive stress, and high strain capacity of the GNS surface layer.

Hydriding/dehydriding properties of Mg-Ni-based ternary alloys synthesized by mechanical grinding

The Mg-Ni-based ternary alloys Mg2-xTixNi(x=0,0.2,0.4)and Mg2Ni1-xZrx(x=0,0.2,0.4)were successfully synthesized by mechanical grinding.The phases in the alloys and the hydriding/dehydriding properties of the alloys were investigated.Mg2Ni and Mg are the main hydrogen absorption phases in the alloys by XRD analysis.Hydriding kinetics curves of the alloys indicate that the hydrogen absorption rate increases after partial substitution of Ti for Mg and Zr for Ni.According to the measurement of pressure-concentration-isotherms and Van't Hoff equation,the relationship between ln p(H2)and 1 000/T was established.It is found that while increasing the content of correspondingly substituted elements at the same temperature,the equilibrium pressure of dehydriding increases,the enthalpy change and the stability of the alloy hydride decrease.

High Efficiency Axial Deep Creep-Feed Grinding Machining Technology of Engineering Ceramics Materials

Axial deep creep-feed grinding machining technology is a high efficiency process method of engineering ceramics materials, which is an original method to process the cylindrical ceramics materials or hole along its axis. The analysis of axial force and edge fracture proved the cutting thickness and feed rate could be more than 5-10 mm and 200 mm/min respectively in once process, and realized high efficiency, low-cost process of engineering ceramics materials. Compared with high speed-deep grinding machining, this method is also a high efficiency machining technology of engineering ceramics materials as well as with low cost. In addition, removal mechanism analyses showed that both median/radial cracks and lateral cracks appeared in the part to be removed, and the processed part is seldom destroyed, only by adjusting the axial force to control the length of transverse cracks.

Influence of Mechanical Grinding on the Interface Characteristics of Rice/Wheat Straws

The mechanical grinding method was used to make rice and wheat straw flakes and the properties of the interface of straws before and after grinding were evaluated. The particle boards were prepared using two kinds of straw flakes, respectively and their physical and mechanical properties were investigated. The results showed that the rice straw was easier to be broken when compared with wheat straw and the inner surface of cells in grinded straws was exposed remarkably. The characteristic peaks of lignin and cellulose on the surface of wheat straw were more significant than rice straw. The free-radical concentrations of straws were increased dramatically after being grinded with heating in the range from I00 ~C to 200 ~C. The surface free energy of straws was also improved after being grinded and the value in wheat straw was higher than that of rice straw, which implies that wheat straw was easier to be bonded than rice straw. The physical and mechanical properties of two kinds of straw particle boards could achieve the requirements of Chinese National Standards of GB 4897.3-2003, while wheat straw particle boards had better properties than those made from rice straws.

The Effect of the Grinding Time on the Mechanical Activation of MnO2 Ore and Tea Plant Waste Carbonization Product

In this study, pyrolusiteore （MnO2） was subjected to mechanical milling with a high-energy mill with carbonized tea plant wastes and the effect of grinding time on the crystal structure of the material was investigated. The ratio of Mn/Fe was 8/1, the ratio of C/（MnO2 ＋ Fe3O4） was 2 and the ratio of ball to ore was 10/1. The samples were mechanically ground at 10, 15, 20, 30, 60, 90 and 120 hours. In the processes performed on the attritor, the rotation speed of the mill shaft was determined to be 350 rpm. The results were characterized by TG-DTA, SEM and XRD analyzes. As a result of the experimental studies, it was observed that the samples subjected to mechanical grinding for 120 hours were gradually reduced due to the increasing grinding time at all the diffraction peaks when the XRD peaks were compared with the grinding times. In the thermogravimetric analysis, the sample milled for 120 hours, 50% weight loss was observed at 470 ℃, weight loss of up to 56% was observed at progressive temperatures.

Proportion Integration Differentiation(PID)Control Strategy of Belt Sander Based on Fuzzy Algorithm

Aiming at solving the problems of response lag and lack of precision and stability in constant grinding force control of industrial robot belts,a constant force control strategy combining fuzzy control and proportion integration differentiation(PID)was proposed by analyzing the signal transmission process and the dynamic characteristics of the grinding mechanism.The simulation results showed that compared with the classical PID control strategy,the system adjustment time was shortened by 98.7%,the overshoot was reduced by 5.1%,and the control error was 0.2%-0.5%when the system was stabilized.The optimized fuzzy control system had fast adjustment speeds,precise force control and stability.The experimental analysis of the surface morphology of the machined blade was carried out by the industrial robot abrasive grinding mechanism,and the correctness of the theoretical analysis and the effectiveness of the control strategy were verified.

Enhanced initial biodegradation resistance of the biomedical Mg-Cu alloy by surface nanomodification

Mg-Cu alloys are promising antibacterial implant materials.However,their clinical applications have been impeded by their high initial biodegradation rate,which can be alleviated using nanotechnology by for example surface nanomodification to obtain a gradient nanostructured surface layer.The present work(i)produced a gradient nanostructured surface layer with a∼500µm thickness on a Mg-0.2 Cu alloy by a surface mechanical grinding treatment(SMGT),and(ii)studied the biodegradation behavior in Hank's solution.The initial biodegradation rate of the SMGTed samples was significantly lower than that of the unSMGTed original counterparts,which was attributed to the surface nanocrystallization,and the fragmentation and re-dissolution of Mg_(2)Cu particles in the surface of the SMGTed Mg-0.2 Cu alloy.Furthermore,the SMGTed Mg-0.2 Cu alloy had good antibacterial efficacy.This work creatively used SMGT technology to produce a high-performance Mg alloy implant material.

Deformation and fracture behavior of commercially pure titanium with gradient nano-to-micron-grained surface layer

Titanium with gradient nano-to-micron scale grains from surface to matrix was fabricated by surface mechanical grinding treatment(SMGT) at room temperature.The SMGT-treated titanium shows higher strength than that of as-received one,but moderate ductility between those of ultra-fine grained(UFG) and coarse-grained titanium.Tensile stress-strain curves of SMGT-treated titanium show double strain hardening regimes.The strain hardening rate(dσ/dε) decreases with increasing strain in tensile deformation.The high strain hardening rate at initial yielding is attributed to nano-to-micron-grained surface layer.The low strain hardening rate at large plastic strain regime primarily results from coarse-grained matrix.The SMGT-treated titanium shows a ductile fracture mode with a large number of dimples.The small size of dimples in the treated surface layer is due to the combination of the high strength and strain hardening exponent.The difference between dimple size in nano-to-micron-grained surface layer and coarse-grained matrix is discussed in terms of plastic zone size at the tip of crack in the SMGT-treated titanium.

Modelling of grinding mechanics:A review

Grinding is one of the most widely used material removal methods at the end of many process chains.Grinding force is related to almost all grinding parameters,which has a great influence on material removal rate,dimensional and shape accuracy,surface and subsurface integrity,thermodynamics,dynamics,wheel durability,and machining system deformation.Considering that grinding force is related to almost all grinding parameters,grinding force can be used to detect grinding wheel wear,energy calculation,chatter suppression,force control and grinding process simulation.Accurate prediction of grinding forces is important for optimizing grinding parameters and the structure of grinding machines and fixtures.Although there are substantial research papers on grinding mechanics,a comprehensive review on the modeling of grinding mechanics is still absent from the literature.To fill this gap,this work reviews and introduces theoretical methods and applications of mechanics in grinding from the aspects of modeling principles,limitations and possible future trendencies.

Prediction on grinding force during grinding powder metallurgy nickel-based superalloy FGH96 with electroplated CBN abrasive wheel

In this article,a grinding force model,which is on the basis of cutting process of single abrasive grains combined with the method of theoretical derivation and empirical formula by analyzing the formation mechanism of grinding force,was established.Three key factors have been taken into accounts in this model,such as the contact friction force between abrasive grains and materials,the plastic deformation of material in the process of abrasive plowing,and the shear strain effect of material during the process of cutting chips formation.The model was finally validated by the orthogonal grinding experiment of powder metallurgy nickel-based superalloy FGH96 by using the electroplated CBN abrasive wheel.Grinding force values of prediction and experiment were in good consistency.The errors of tangential grinding force and normal grinding force were 9.8%and 13.6%,respectively.The contributions of sliding force,plowing force and chip formation force were also analyzed.In addition,the tangential forces of sliding,plowing and chip formation are 14%,19%and 11%of the normal forces on average,respectively.The pro-posed grinding forcemodel is not only in favor of optimizing the grinding parameters and improving grinding efficiency,but also contributes to study some other grinding subjects(e.g.abrasive wheel wear,grinding heat,residual stress).

Subsurface damage and bending strength analysis for ultra-thin and flexible silicon chips

Subsurface damage(SSD) is an unavoidable problem in the precision mechanical grinding for preparing ultra-thin and flexible silicon chips. At present, there are relatively few studies on the relationship between SSD and the bending strength of ultra-thin chips under different grinding parameters. In this study, SSD including amorphization and dislocation is observed using a transmission electron microscope. Theoretical predictions of the SSD depth induced by different processing parameters are in good agreement with experimental data. The main reasons for SSD depth increase include the increase of grit size, the acceleration of feed rate, and the slowdown of wheel rotation speed. Three-point bending test is adopted to measure the bending strength of ultra-thin chips processed by different grinding conditions. The results show that increasing wheel rotation speed and decreasing grit size and feed rate will improve the bending strength of chips, due to the reduction of SSD depth. Wet etching and chemical mechanical polishing(CMP) are applied respectively to remove the SSD induced by grinding, and both contribute to providing a higher bending strength, but in comparison, CMP works better due to a smooth surface profile. This research aims to provide some guidance for optimizing the grinding process and fabricating ultra-thin chips with higher bending strength.

Surface preparation by mechanical polishing of the 1.3-GHzmono-cell copper cavity substrate prior chemical etching for niobium coating

Purpose Surface quality of the substrate is widely acknowledged to be essential for the niobium thin film deposition. Mucheffort has thus been spent to improve the surface roughness by using various chemical etching techniques. However, surfacepreparation before the chemical etching also plays a part in obtaining a satisfactory substrate, but has rarely been studiedbefore. This paper aims to define a specification for the pre-polished copper substrate prior chemical etching and searches forsuitable alternative non-chemical grinding methods for the copper cavity.Methods Copper samples were mechanically pre-polished at first by using flap sanding wheels of different grits and thenchemically etched by using the well-established SUBU solutions. Surface roughness, as a figure of merit, was measuredand compared before and after SUBU. Optimum practice for pre-polishing may therefore be determined. The mechanicalgrinding was subsequently applied on the 1.3-GHz mono-cell copper cavity. Meantime, the previously reported centrifugalbarrel polishing method was also applied with new abrasive materials and modified schemes. A comprehensive study ofetching rate, surface roughness and morphologies was conducted.Results and conclusions The specification for surface roughness prior SUBU was determined. Due to a complex geometryand curved surfaces possessed by the 1.3-GHz copper cavity, the traditional mechanical grinding was proved to be not ideal.Satisfactory surface quality was obtained by using the alternative centrifugal barrel polishing on the cavity. The proposed newscheme and new abrasive materials were demonstrated to be effective, and a mirror-like surface was achieved on the coppercavity. The traditional mechanical grinding can therefore be replaced. This constitutes a dedicated study on pre-polishing ofthe 1.3-GHz copper cavity substrate prior chemical etching for niobium sputtering.