RESEARCH ON MODELING AND CHARACTERISTICS OF THE SPINDLE DYNAMIC COUPLING ABSORBERING SYSTEM OF A SUPER-PRECISION SURFACE GRINDING MACHINE

The bearing is described by constrain matrix, and the spindle system of a NCsurface grinding machine is simplified as elastic-coupling beam, then modal synthesis method is usedto establish the dynamic model of beam. Moreover, the response of the end of rotor is analyzed, andthe natural frequency, principle mode and other dynamic characteristics of the coupling system arestudied, the law of bearing stiffness to coupling frequency and amplitude of rotor is also found.Finally, according to the actual condition, a dynamic absorber is designed. The simulation andexperimental results show that the amplitude of spindle can be declined effectively when the dynamicabsorber is attached.

Practical Calculation of Thermal Deformation and Manufacture Error in Surface Grinding

The paper submits a method to calculate thermal deformation and manufacture error in surface grinding. The author established a simplified temperature field model, and derived the thermal deformation of the ground workpiece. It is found that there exists not only a upwarp thermal deformation, but also a parallel expansion thermal deformation. A upwarp thermal deformation causes a concave shape error on the profile of the workpiece, and a parallel expansion thermal deformation causes a dimension error in height. The calculations of examples are given and compared with presented experiment data.

Effect of Grinding Temperatures on the Surface Integrity of a Nickel-based Superalloy

An experimental study was carried out to investigat e the influence of temperatures on workpiece surface integrity in surface grinding of a cast nickel-based superalloy with alumina abrasive wheels. Temperatur e response at the wheel-workpiece interface was measured using a grindable foil /workpiece thermocouple. Specimens with different grinding temperatures were obt ained through changing grinding conditions including depth of cut, workpiece fee d speed, and coolant supply. Changes in surface roughness, residual stress, meta llographies, ground surface morphology, and micro hardness on the specimens were then analyzed. Bending fatigue tests were separately conducted at room temperat ure and 950oC in an effort to evaluate the influence of temperatures on the serv ice life of the ground specimens. A different burning color was found on the gro und workpiece surfaces when grinding temperatures are over a critical value. Alo ng with the emergence of burning color, roughness of the ground workpiece surfac e increased greatly compared with the surfaces without burning color, which was attributed to the plastically deformed coatings on the workpiece surface with el evated temperatures. Excepting the surface roughness, other items concerning the surface integrity of the ground workpiece were not affected by temperatures pro vided that grinding temperatures are not high enough to cause grinding cracks. B ased on the findings in this study, the grinding of the nickel-based superalloy can be divided into two stages in order to increase production efficiency, in which case the first stage is to reach an high material removal rate without concerning of the presence of burning color, whereas the second stage is to remo ve the plastically deformed coatings in order to decrease surface roughness.

Research on temperature field of non-uniform heat source model in surface grinding by cup wheel

To address the problems of thermal damage to a workpiece surface caused by the instantaneous high temperature during grinding and the difficulty in monitoring temperature in real time,the temperature field in the case of composite surface grinding by a cup wheel is studied.In order to predict the grinding temperature,considering material removal and grinding force distribution,a nonuniform heat source model with different function distributions in the circumferential and radial directions in the cylindrical coordinate system is first proposed;then,the analytical model is deduced and the numerical model of the temperature field is established based on the heat source model.The validation experiments for grinding temperature field are carried out using a high-definition infrared thermal imager and an artificial thermocouple.Compared to the temperature field based on the uniform heat source model,the results based on the non-uniform heat source model are in better agreement with the actual temperature field,and the temperature prediction error is reduced from approximately 23% to 6%.Thus,the present study provides a more accurate theoretical basis for preventing bums in cup wheel surface grinding.

Strain gradient induced grain refinement far below the size limit in a low carbon hypoeutectoid steel(0.19 wt%C)via pipe inner surface grinding treatment

A low carbon hypoeutectoid steel(0.19 wt%C)with proeutectoid ferrite and pearlite dual-components was subjected to surface plastic deformation via pipe inner surface grinding(PISG)at room temperature.The deformation microstructures for each component were systematically characterized along depth,and the patterns of structural evolution toward nanometer regime as well as the governing parameters were addressed.Proeutectoid ferrite grains were refined down to 17 nm,and the pattern covering a length scale of 4–5 orders of magnitude from micron-to nanometer-scale follows:formation of cellular dislocation structure(CDS),elongated dislocation structure(EDS),ultrafine lamellar structure(UFL)and finally the nanolaminated structure(NL).The pearlite experiences the deformation and refinement,and finally the transforming the ultrafine pearlite(UFP)into nanolaminated pearlite(NLP)with the ferrite lamellae as thin as 20 nm.Refinement for both UFL(UFP)and NL(NLP)can be realized via forming novel extended boundaries within ferrite lamellae.A critical lattice curvature of~2.8°is required for forming such extended boundary,corresponding to a minimum strain gradient of 0.25μm^(-1)for a 100 nm-thick lamella.Refinement below size limit(expressed by lamellar thickness d_Tin nm)is correlated with the strain gradient(χ,inμm^(-1))by:d_T=12.5/x.Refinement contributions from strain gradient caused by PISG processing and material heterogeneity were discussed.

Surface Waviness in Grinding of Thin Mould Insert Using Chilled Air as Coolant

On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is an ardent task due to its warpage, induced by the high specific grinding energy (2～10 J/mm 3). Therefore, coolant is often used to avoid thermal damage, obtai n better surface integrity and to prolong wheel life. However coolant, the incomp ressibility media introduce high forces at the grinding zone creating dimensiona l as well as shape instability. In view of these situations chilled air was ap plied in place of conventional coolant. The chilled air is produced using a two -stage vapor compression refrigeration cycle with characteristics of: temperatu re -35 ℃, pressure 0.2～0.3 MPa and flow rate 0.4 m 3/min. Also traces of eco - oil mist that encompass the chilled air are supplied to the grinding zone. B oth chilled air and eco-oil mist are applied through two independent paths of a specially designed twin compartment nozzle for maximizing the penetration. This paper investigates the grinding characteristics of mold insert which is closer to M2 tool steel (component widely used in connector industries) when using chil led air as coolant media. Grinding experiments were conducted using a vitrified bond CBN wheel (B91N100V) and a surface grinder. Initial study was focussed on establishing the most suita ble clamping method for the thin mold insert. FEM analysis and grinding experime nt studies were performed to quantitatively analyze the clamping induced deflect ion. Waviness value (W t) of (24～62) μm was achieved for resin clampi n g whereas (4～8) μm, (4～6) μm were achieved for magnetic and wax clamping res pe ctively. Wax clamping is predominantly used in all the grinding experiments that characterize the grinding process, which use chilled air as the coolant media. Between 0.15 to 0.9 mm 3/mm.s of specific material removal rate, ground sur face temperature of mold insert was increased from 0.3 ℃ to 59.7 ℃ for chi lled air. For the similar grinding conditions with the coolant fluid an increase from 0.9 ℃ to 14.4 ℃ was recorded. With increase of specific material removal rate from 0.15 to 0.65 mm 3/mm.s, F t/F n ratio was increased from (0.2 to 0.4), (0.6 to 1.67) for wet coolant and chilled air respectively. Despite of high F t/F n ratio and ground surface temperature, chilled air method has shown a surface waviness, W t from (2 to 5.6) μm. Microstructure examination of chilled air produced ground surface was comparable to those of using coolant fluids. Surface finish, R a of (0.45～0.7) μm was achieved for mold insert . This work will enable to have clear understanding about the quantitative influe nce of chilled air as well as the clamping method against the surface waviness o f thin mold insert.

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.

Surface integrity of GH4169 affected by cantilever finish grinding and the application in aero-engine blades

GH4169 is the main material for aero-cngine blades and integrated blisks. Because GH4169 has a poor milling performance, the profile precision and surtace integrity of blades and integrated blisks are difficult to be met by utilizing the conventional milling process, which directly influence the global performance and reliability of aero-engines. Through grinding experiments on parameters and surface integrity optimization, the helical cantilever grinding process utilizing a 300# CBN RB wheel is presented and applied in finish machining of GH4169 blades. The profile errors of the blade surface are within ±0.01 mm, the roughness is less than 0.4μm, the residual compressive stresses and the hardening rate are appropriate, there are no phenomena of burr and smearing with the grinding chips, and the leading/trailing edge can be smoothly connected with the suction/pressure surface. All the experimental results indicate that this grinding process is greatly suitable for the profile finish machining of GH4169 blades.

Grinding behavior and surface appearance of(TiC_p+ TiB_w)/Ti-6Al-4V titanium matrix composites

（TiCp＋ TiBw）/Ti-6Al-4V titanium matrix composites（PTMCs） have broad application prospects in the aviation and nuclear field. However, it is a typical difficult-to-cut material due to high hardness of the reinforcements, high strength and low thermal conductivity of Ti-6Al-4V alloy matrix. Grinding experiments with vitrified CBN wheels were conducted to analyze comparatively the grinding performance of PTMCs and Ti-6Al-4V alloy. Grinding force and force ratios, specific grinding energy, grinding temperature, surface roughness, ground surface appearance were discussed. The results show that the normal grinding force and the force ratios of PTMCs are much larger than that of Ti-6Al-4V alloy. Low depth of cut and high workpiece speed are generally beneficial to achieve the precision ground surface for PTMCs. The hard reinforcements of PTMCs are mainly removed in the ductile mode during grinding. However, the removal phenomenon of the reinforcements due to brittle fracture still exists, which contributes to the lower specific grinding energy and grinding temperature of PTMCs than Ti-6Al-4V alloy.

Noise emission of concrete pavement surfaces produced by diamond grinding

In Germany, diamond grinding is frequently used to improve the evenness and skid resistance of concrete pavement surfaces. Since diamond grinding has been observed to affect tyre/pavement noise emission favourably, the relationship among surface texture, concrete composition and noise emission of concrete pavement surfaces has been sys- tematically investigated. The simulation program SPERoN was used in a parameter study to investigate the main factors which affect noise emission. Based on the results of the simulations, textured concrete surfaces were produced by using a laboratory grinding machine. As well as the composition of the concrete, the thickness and spacing of the diamond blades were varied. The ability of the textured surfaces to reduce noise emission was assessed from the texture characteristics and air flow resistance of textured surfaces measured in the laboratory. It was found that concrete composition and, in particular, the spacing of the blades affected the reduction in noise emission considerably. The noise emission behaviour of numerous road sections was also considered in field investigations. The pavement surfaces had been textured by diamond grinding during the last years or decades. The results show that diamond grinding is able to provide good, durable noise- reducing properties. Several new pavement sections were investigated using thicknesses and spacings of the blades similar to those used in the laboratory to optimize noise emission reduction. It is concluded that diamond grinding is a good alternative to exposed aggregate concrete for the production of low-noise pavement surfaces.

High-Accuracy Polishing Technique Using Dwell Time Adjustment

Two algorithms for dwell time adjustment are evaluated under the same polishing conditions that involve tool and work distributions.Both methods are based on Preston’s hypothesis.The first method is a convolution algorithm based on the Fast Fourier Transform.The second is an iterative method based on a constraint problem,extended from a one-dimensional formulation to address a two-dimensional problem.Both methods are investigated for their computational cost,accuracy,and polishing shapes.The convolution method has high accuracy and high speed.The constraint problem on the other hand is slow even when it requires larger memory and thus is more costly.However,unlike the other case a negative region in the polishing shape is not predicted here.Furthermore,new techniques are devised by combining the two methods.