EXPERIMENTAL RESEARCH ON SLOTTED & PERFORATED ELECTROPLATED CBN GRINDING WHEEL WITH RADIAL JET

A creative conception is proposed to enhance heat transfer in grinding contact zone through jet impinging on the basis of analysis on the mechanism of burn during creep feed grinding, and a new apparatus of slotted & perforated electroplated CBN grinding wheel with radial jet is developed, the effect on heat transfer is studied through the experiment of intermitted creep feed grinding. Experimental results show that the technology of enhancing heat transfer through jet impinging is valid to raise the efficiency of heat transfer in grinding contact zone and it is widely applied to solve the problem in grinding burn for difficult to machine materials.

New Vitrified Bond Diamond Grinding Wheel for Grinding the Cylinder of Polycrystalline Diamond Compacts

In this work, a kind of new vitrified bond based on Li2O-Al2O3-SiO2 glass ceramics was used to bond the diamond grains, which is made into grinding wheel and the cylindrical grinding process of polycrystalline diamond compacts （PDCs） by using the new vitrified bond diamond grinding wheel was discussed. Several factors which influence the properties of grinding wheel such as amount of vitrified bond and the kinds and amount of stuff in grinding wheel were also investigated. It was found that the new vitrified bond can firmly combine diamond grains, when there are only diamonds and vitrified bond in the structure of grinding wheel, the longevity of the grinding wheel is about 2.5-3 times as that of resin bond grinding wheel for processing PDCs. The grinding size precision of PDCs can be improved from 4-0.03 mm to 4-0.01 mm because of larger Young＇s modulus of vitrified bond than resin bond. The grinding time of a PDC product can be 1.75-2.0 min from 3.25-3.5 min, so this kind of grinding wheel can save much time for processing PDCs. Also, there is hardly noise when using this new vitrified bond diamond grinding wheel to process PDCs. The amount of vitrified bond in grinding wheel influences the longevity of grinding wheel. When the size of diamond grains is 90-107 μm, the optimal amount of vitrified bond in grinding wheel is 21% （wt pct）. When the amount of vitrified bond exceeds 21%, there are many pores in grinding block, which will decrease the longevity of grinding wheel. The existence of addition stuff such as Al2O3 or SiC can reduce the longevity of grinding wheel.

ONLINE GRINDING WHEEL WEAR COMPENSATION BY IMAGE BASED MEASURING TECHNIQUES

Automatic compensation of grinding wheel wear in dry grinding is accomplished by an image based online measurement method. A kind of PC-based charge-coupled device image recognition system is schemed out, which detects the topography changes of the grinding wheel surface. Profile data, which corresponds to the wear and the topography, is measured by using a digital image processing method. The grinding wheel wear is evalualed by analyzing the position deviation of the grinding wheel edge. The online wear compensation is achieved according to the measure results. The precise detection and automatic compensation system is integrated into an open structure CNC curve grinding machine. A practical application is carried out to fulfil the precision curve grinding. The experimental results confirm the benefits of the proposed techniques, and the online detection accuracy is less than 5 um. The grinding machine provides higher precision according to the in-process grinding wheel error compensation.

Design of a device for precision shaping of grinding wheel macro-and micro-geometry

The selected modifications to the construction of grinding wheels were described which facilitate an increase in the material removal rate （grinding wheels with conic chamfer and grinding wheels with microdiscontinuities on the active surface）. Using these background details, a suggested thesis was put forward regarding the need to develop a device which will allow for the shaping of the macrogeometry of the grinding wheel （cylindrical and conical surfaces） and the microdiscontinuities within the dressing operation simultaneously. The device was presented and prepared in two functional variants （horizontal and vertical mounting of the motor）, then a prototype was described. An example of the grinding wheel active surface, shaped by using this device, was also presented. The theoretical analysis and experimental verification performed determine that the error of shaping the conic chamfer angle within the range of 0-1.5°, using the developed device, is approximately ±3%.

Feasibility Study on Fabrication of Geopolymer Bricks by Wasted Grinding Wheel at Room Temperature

In this study,the feasibility of producing eco-friendly bricks by using geopolymer technology and a waste grinding wheel(WGW)from the grinding wheel industries was investigated.Nowadays,in order to meet industrial needs,for instance,in Taiwan,approximately 500,000 grinding wheels are used annually.That is,a large number of“waste”grinding wheels are produced.Furthermore,few studies have been conducted on the use of WGWs as raw materials in geopolymer applications.The use of geopolymer technology to form bricks can avoid the utilization of clay and cement and even prevent the use of a high-temperature process in kilns.Moreover,it can decrease CO_(2) emission and energy consumption and thus,protect the environment.In this study,the following three major factors were considered:press-forming pressure(70 and 100 kgf/cm2),NaOH molar concentration(2 and 4M),and the ratio of binder fineaggregate(1:3,1:4,and 1:5).Under these conditions,the specimens were tested using the compressive strength test,water absorption test,microstructure analysis,a freezing–thawing test and toxicity characteristic leaching procedure test.The optimal formulation was composed of 1:4 binder fine-aggregate ratio,4M NaOH concentration,and 100-kgf/cm2 pressure.Furthermore,we used a WGW and achieved a compressive strength of 50.6 MPa after 28 days,which was greater than 32 MPa and conformed to the Grade A brick standard of National Standards of the Republic of China(13295).In conclusion,this brick fabrication method based on geopolymer technology was not only beneficial to the environment but also improved the efficiency of reutilizing WGW.

Thermo-mechanical properties of bowl-shaped grinding wheel and machining error compensation for grinding indexable inserts

In order to meet the technical requirements of grinding the circumferential cutting edge of indexable inserts, thermo-mechanical properties of bowl-shaped grinding wheel in high speed grinding process and the influence of dimension variations of the grinding wheel on machining accuracy were investigated. Firstly, the variation trends of the dimension due to centrifugal force generated in different wheel speeds were studied and the effect of stress stiffening and spin softening was presented. Triangular heat flux distribution model was adopted to determine temperature distribution in grinding process. Temperature field cloud pictures were obtained by the finite element software. Then, dimension variation trends of wheel structure were acquired by considering the thermo-mechanical characteristic under combined action of centrifugal force and grinding heat at different speeds. A method of online dynamic monitoring and automatic compensation for dimension error of indexable insert was proposed. By experimental verification, the precision of the inserts satisfies the requirement of processing.

Regeneration of grinding wheel active surface using high-pressure hydro-jet

The possibility of applying a high-pressure hydro-jet for renewal of the grinding wheel cutting ability was presented.This work was conducted in the internal cylindrical grinding process of the Titanium Grade 2 alloy,which belongs to the group of hard-to-cut materials.The analysis shows that the impact on the erosion effectiveness of the grinding wheel active surface(GWAS)depends upon the hydro-jet inclination angle and working pressure.Experimental results reveal that application of hydro-jet working pressure of 25 MPa allows for effective cleansing of the grinding wheel surface.Depending on the initial GWAS condition and the level of its smearing with chips of machined material,it is possible to increase the number of grinding wheel unevenness apexes by as much as 4.5 times.

Prediction of Grinding Force by an Electroplated Grinding Wheel with Orderly-Micro-Grooves

The ability to predict a grinding force is important to control,monitor,and optimize the grinding process.Few theoretical models were developed to predict grinding forces when a structured wheel was used in a grinding process.This paper aimed to establish a single-grit cutting force model to predict the ploughing,friction and cutting forces in a grinding process.It took into the consideration of actual topography of the grinding wheel,and a theoretical grinding force model for grinding hardened AISI 52100 by the wheel with orderly-micro-grooves was proposed.The model was innovative in the sense that it represented the random thickness of undeformed chips by a probabilistic expression,and it reflected the microstructure characteristics of the structured wheel explicitly.Note that the microstructure depended on the randomness of the protruding heights and distribution density of the grits over the wheel.The proposed force prediction model was validated by surface grinding experiments,and the results showed(1)a good agreement of the predicted and measured forces and(2)a good agreement of the changes of the grinding forces along with the changes of grinding parameters in the prediction model and experiments.This research proposed a theoretical grinding force model of an electroplated grinding wheel with orderly-micro-grooves which is accurate,reliable and effective in predicting grinding forces.

Preparation of an Abrasive Grinding Wheel Based on Tannin Resin Cross- Linked by Furfuryl Alcohol, Urea and Glyoxal

Simple bio-based abrasive grinding wheel based on thermosetting resin matrix was developed starting with condensed tannin and furfuryl alcohol,which are mainly derived from forest and agricultural products like tree barks,wheat and crops.Fourier transform infrared spectra(FTIR)signified the acidic conditions are quiet efficient for the reaction of furfuryl alcohol,urea and glyoxal all together and the-CH_(2)-NH-and-CH_(2)-O-CH(OH)-groups are predominating in cross-linking of the tannin-furfuryl alcohol-urea-glyoxal(TFUG)resin.The strengthening contribution of the tannin was also confirmed by the preservation of its distinct crystallinity using X-ray diffraction(XRD).Differential scanning calorimetry(DSC)and thermogravimetric analysis(TGA)ensured that TFUG resin can be cured at low temperature and offer higher heat resistance compared with phenol-formaldehyde(PF)resin.The high hardness and excellent compressive strength revealed by the corresponding investigations such as Brinell hardness,compression resistance,and grinding tests suggested a strong abrasive ability using the new grinding wheel compared with lab-made grinding wheel based on PF resin.This could be ascribed to the absence of cracks and low content of formed holes as confirmed using scanning electron microscopy(SEM)and balanced reaction conditions that leads to network structure with regular local reinforcements and homogeneous crosslink density.

Grinding Characteristics of MoS_(2)-Coated Brazed CBN Grinding Wheels in Dry Grinding of Titanium Alloy

As an important green manufacturing process,dry grinding has problems such as high grinding temperature and insufficient cooling capacity.Aiming at the problems of sticking and burns in dry grinding of titanium alloys,grinding performance evaluation of molybdenum disulfide(MoS_(2))solid lubricant coated brazed cubic boron carbide(CBN)grinding wheel(MoS_(2)-coated CBN wheel)in dry grinding titanium alloys was carried out.The lubrication mechanism of MoS_(2)in the grinding process is analyzed,and the MoS_(2)-coated CBN wheel is prepared.The results show that the MoS_(2)solid lubricant can form a lubricating film on the ground surface and reduce the friction coefficient and grinding force.Within the experimental parameters,normal grinding force decreased by 42.5%,and tangential grinding force decreased by 28.1%.MoS_(2)lubricant can effectively improve the heat dissipation effect of titanium alloy grinding arc area.Compared with common CBN grinding wheel,MoS_(2)-coated CBN wheel has lower grinding temperature.When the grinding depth reaches 20μm,the grinding temperature decreased by 30.5%.The wear of CBN grains of grinding wheel were analyzed by mathematical statistical method.MoS_(2)lubricating coating can essentially decrease the wear of grains,reduce the adhesion of titanium alloy chip,prolong the service life of grinding wheel,and help to enhance the surface quality of workpiece.This research provides high-quality and efficient technical support for titanium alloy grinding.

Optimization Design of the Grinding Wheel Topography for High Efficiency Grinding

On the basis of the measurement of grains distribution on the grinding wheel surface, many experiential models of the grinding wheel topography were set up. But it is pity that few of them yield practical and valuable achievement as yet. The essential reason is that the common foundation of all these models was based on the actual measurement of specific wheel topography. So it didn’t have universal applicability. Considering that the absolute irregular distribution of grains is not the requirement of the grinding process, contrarily it will bring much negative influence to grinding process. By conversely reasoning, a new conception on the relatively regular and reasonable distribution of grains on the wheel surface in accordance with different machining demands is put forward in this paper, and furthermore a creative idea of optimization design of grinding wheel topography in accordance with machining demands and grinding parameters as well as the optimization of grinding parameters in accordance with machining demands and grinding wheel topography is proposed. In the light of this idea, not only the modeling and simulation of grinding process can be really carried out, but also the optimization of grinding process and the estimation of grinding results can be realized straightway. In conclusion, a superabrasive slotted grinding wheel is designed as a practical application of the optimization model and a creep feed deep grinding experiment is carried out to verify the optimization results.

Grinding Characteristics Of Directionally Aligned SiC Whisker Wheel - Comparison With A12O3 Fiber Wheel

A unique SiC whisker wheel was invented,in which the whiskers were aligned normally to the grinding wheel surface.In this paper,grindabilities of the SiC whisker wheel are investigated and compared with those of other wheels of SiC grains,Al2O3 grains,as well as Al2O3 long and short fibres which were also aligned normally to the grinding wheel surface,respectively.The main research contents concern grinding characteristics of a directionally aligned SiC whisker wheel such as material-removal volume,wheel-wear rates,integrity of the ground surfaces,grinding ratios and grinding efficiency.Furthermore,grinding wheels of whiskers and fibres have a common disadvantage:they tend to load easily.The authors have proposed a simple method of loading-free grinding to overcome this propensity and investigate some related grinding characteristics under loading-free grinding conditions.

Research on CNC Turning System of Aspheric Machining Grinding Wheel

The technology of machining aspheric surface with high precision is the premise for the application of aspheric surface. The grinding machining with error compensation is a commonly used method to machine aspheric surface, which will directly influence the quality of aspheric workpiece surface. Multifunctional CNC grinding wheel truing system is a four-axis CNC truing system which can be applied to grinding wheel truing. In this system, DSP-based multi-axes motion control card is adopted as the controller, and visual C++ is used as development tool. When the design of hardware and software is completed, the system can implement truing of various grinding wheel with high precision aspheric machining such as plane grinding wheel, arc grinding one, and sphere grinding one.

STUDY ON A NEW TYPE OF THROW-AWAY SOFT GRINDING WHEELS

In accordance with the difficult problems of belt cross vibrations and effects of belt tension on machine spindle precision in abrasive belt grinding, a new soft grinding wheel is put forward, which is provided with the advantages of belt grinding and can he installed directly on the grinding machine spindle substituting for common grinding wheels. The new soft grinding wheel does not need any ancillary facilities and dressing devices in banding. With analyzing error of wheel and grinding experiment, the high-efficiency grinding characteristics grinding hard-brittle materials has been obtained.

YM7132A——GEAR GRINDING MACHINE WITH CONICAL GRINDING WHEEL

The YM7132A gear grindingmachine with a conical grindingwheel is used for grindingcylindrical spur and helical involutegears,especially for hardenedprecision gears of small andmedium sizes.

YK7232——GEAR GRINDING MACHINE WITH WORM GRINDING WHEEL

The machine is used for precisiongrinding of hardened cylindricalgears with medium module inbatches for the industries ofaircraft,automobile,machine tool,gear box and various transmissiondevices.

Computer Aided Design of Grinding Wheel for Drill Flute Production

Twist drill flute profile design is necessary in order to determine the required grinding wheel profile for a flute production. An accurate drill flute profile design is generated for two-flute conical twist drills using analytical equations to generate a drill flute profile design needed for the production of twist drills with straight lips. The required grinding wheel profile for a flute production was expressed in digitized form as well as in terms of two curve-fitted circular arcs. The drill flute profile geometry can never be precisely generated when required grinding wheel profile is represented by two circular arcs and the generated flute profile is just a very good approximation of the design flute profile. A CAD （computer aided design） software has been developed using MATLAB to determine the required grinding wheel profile for generating a given drill flute profile design.

YK7250 Gear Grinding Machine With Worm-Grinding Wheel

The YK7250 gear grinding machine with worm grinding wheel is manufactured by the Qinchuan Machine Tool Group Co., Ltd. in Baoji City, Shaanxi Province.

Improved Relief Grinding Method of Gear Hob with Equal Relief Angle

The regrinding error is the main factor affecting the eligible length of hob tooth,how to decrease the regrinding error is a hot issue in the research area of hob grinding.At present,researches focus on changing the trajectory of relief moving,because of no unified relief grinding path planning method,the research result is restricted in the practical application.For solving the problem,the calculation model of the hob relief angle is established with the Archimedes relieving motion to analyze the interaction between the increasing relief angle of the hob and the accelerating tooth profile errors.Based on it,the improved relief grinding method of gear hob is proposed with equal relief angle（ERA）.Furthermore,the relief grinding method with ERA is developed with the following two steps.Firstly,the convergence numerical solution algorithm of the tooth top curve is designed to form the wheel motion path which is compared with that of traditional grinding.The second step is to establish the solution model of ERA grinding wheel.In order to verify the effect of the method,hob grinding simulation system of 3D solid was built under the AutoCAD environment.The regrinding errors is analyzed by intercepting the hob axial profiles of the various regrinding angles with Boolean operations and further converting it to basic rack tooth,then the simulation example of zero rake straight flute hob is used to compare the regrinding errors between ERA grinding and traditional grinding.Finally,the experiments were implemented on the five-axis CNC relief grinder with the relief motion of ERA grinding driven by cam.The results of experiments show that the method can effectively reduce the regrinding errors of hob and grind expediently gear hob of AA rank and over.This research provide an effective model of relief moving path plan reducing regrinding error,and have practicable value in CNC relief grinder.

New method for calculating face gear tooth surface involving worm wheel installation errors

The machining principle and realization method for the continuous generative grinding face gear by a worm wheel are introduced. Based on a five-axis linked CNC grinding machine, a new method is presented to deprive the equation of face gear error tooth surface by assuming the tool surface as the error surface, where actual tool installation position error is introduced into the equation of virtual shaper cutter. Surface equations and 3-D models for the face gear and the worm wheel involving four kinds of tool installation errors are established. When compared, the face gear tooth surface machined in VERICUT software for simulation based on this new method and the one obtained based on real process(grinding face gear by using a theoretical worm wheel with actual position errors) are found to be coincident, which proves the validity and feasibility of this new method. By using mesh planning for the rotating projection plane of the face gear work tooth surface, the deviation values of the tooth surface and the difference surface are acquired, and the influence of four kinds of errors on the face gear tooth surface is analyzed. Accordingly, this work provides a theoretical reference for assembly craft of worm wheel, improvement of face gear machining accuracy and modification of error tooth surface.