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Grinding Wheels and Abrasives Wheel Conditioning (Truing and Dressing) Honing Lapping Polishing

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Grinding Wheels and Abrasives Wheel Conditioning (Truing and Dressing) Honing Lapping Polishing MATERIAL REMOVAL PROCESSES 2 ABRASIVE (FINISHING) TECHNOLOGIES Prof. Peter Krajnik Presented by Dr. Dinesh Mallipeddi Contents Abrasive finishing Fundamentals of grinding Grinding wheels and abrasives Wheel conditioning (truing and dressing) Honing Lapping Polishing 3 Abrasive technologies Technology Finishing Technology Process Motion-copying processes Pressure-copyingPressure processes- Principles Dimensional finishing Abrasive fine -finishing Abrasive Single- point Multiple Bonded abrasive Un-bonded abrasive States Cutting edge cutting edges Cutting Grinding Abrasive Coated Abrasive Free Abrasive Abrasive Tools tool wheel stone abrasive media abrasive slurry flow Media g Buffing Grinding Honing Lapping Blasting Finishing Polishing Brushing Jet finishing Magnetic Hard turning machinin Superfinishing Mass finishing Methods Abrasive flow Film/tape finishingFilm/tape abrasive finishing Finishing processes in manufacturing Finishing Precision components (Grinding) Precision components Finishing is the (Hard turning) final step in the manufacture of components which require the highest Bearings Engine block cylinders Precision components Turbine blades quality in terms (superfinishing) (honing) (mass finishing) (blasting) of form, accuracy, and surface integrity. Optics Silicon wafers Jewels Manifolds (lapping/polishing) (lapping/polishing) (polishing/buffing) (abrasive flow machining) Why abrasive technologies are important? 10 Hard Workpiece: hardened steel Can be used on all Grinding types of materials turning Peel Some can produce µmRa 1 extremely fine surface Superfinishing finishes (nanometer- Honing Vibratory roughness scale, e.g. 10-100 nm) 0.1 Finishing Tape Can hold dimensions to Lapping/ Surface Polishing extremely close tolerances (e.g. 1 mm) 0.01 1 10 100 1,000 10,000 Specific energy u J/mm³ Difference between milling and grinding Source: Klocke, F., Basisseminar Schleiftechnik, WZL RWTH Aachen, 2006. Grinding mechanisms Basic material removal Source: Klocke, F., Basisseminar Schleiftechnik, WZL RWTH Aachen, 2006. Chip formation in abrasive machining Does not remove material Causes burr Generates heat Removes material Generates heat Does not remove material Causes scratches Generates heat Does not remove material Generates heat Source: Torrace, A.A.: An Approximate Model of Abrasive Cutting, Wear, 1987 Thermal loads in machining processes Source: Klocke, F., Basisseminar Schleiftechnik, WZL RWTH Aachen, 2006. Thermal analysis of grinding Heat flux to the workpiece e ×F ×v e ×P e ×e×Q' é W ù q = t s = = w w ê 2 ú lg ×b lg ×b lg ëmm û Energy partition e: 60-85% (conventional abrasives) e: 20% (CBN abrasives) Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Surface integrity in grinding Surface integrity describes the attributes of a ground surface and its relationship to functional performance. For grinding, the most important aspects of surface integrity are associated with thermal damage caused by excessive grinding temperatures. Thermal damage affects workpiece quality and limits the production rate. Source: : Brinksmeier, E., et al.: Chemical aspects of machining processes, CIRP Annals, 2004. Thermal damage in gear grinding ∆s s e a nS vfa Source: Leibniz-Institut für Werkstofforientierte Technologien – IWT, Bremen Material changes due to thermal loads surface subsurface damage-free surface and subsurface formation of fine-grained microstructure local formation of „White Etching Areas“ „White Etching Areas“ with high vertical 10 mm load thermal of degree increasing extension, grinding induced cracks 40 µm Source: Leibniz-Institut für Werkstofforientierte Technologien – IWT, Bremen Classification of grinding operations Material removal process in which abrasive particles are contained in a bonded grinding wheel that operates at very high surface speeds. Machining with geometrically undefined cutting edges also includes honing, superfinishing, lapping, polishing, etc. Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Centerless grinding Source: INA Schaeffler KG Centerless grinding Centerless grinding is a grinding operation in which cylindrical work parts (e.g. rods) are fed between two rotating wheels: (1) high-speed grinding wheel (2) low-speed regulating wheel which is tilted at a slight angle (1) to control the feed through rate (2) Source: Studer Mikrosa GmbH Grinding wheel Grinding wheel constituents: Abrasive particles for cutting Bond holds abrasives in place and establishes shape and structure of wheel Source: The Book of Grinding Source: Tyrolit Abrasives Aluminum oxide (Al2O3) – common conventional abrasive used to grind steel and other ferrous CBN grits high-strength alloys Silicon carbide (SiC) - harder than Al2O3 but not as tough – used on aluminum, stainless steel, cast irons and ceramics Cubic boron nitride (cBN) – very hard, very expensive; suitable for hardened steels and aerospace alloys Diamond – hardest, very expensive. Not Source: Element Six suitable for grinding steels! Used on hard materials such as ceramics, cemented carbides Properties of abrasives Source: Basisseminar Schleiftechnik, WZL RWTH Aachen Source: Badger, J.: The Book of Grinding, The Grinding Doc, 2010 Marking system for conventional abrasives Source: FEPA, Federation of European Producers of Abrasives Grit size to achieve a given surface finish 1.6 ] m 1.4 µ Hardened steel [ Al O a 1.2 2 3 CBN plunge R s Hardened steel s 1.0 e CBN traverse n h 0.8 g Diamond on u carbide o 0.6 r e c 0.4 a f r u 0.2 S 46 60 80 100 120 150 180 220 250 280 320 Grit mesh size Source: Badger, J.: The Book of Grinding, The Grinding Doc, 2010 Marking system for superabrasives Source: FEPA, Federation of European Producers of Abrasives Three types of wheel wear Source: Source: Badger, J.: The Book of Grinding, The Grinding Doc, 2010 Wheel conditioning Wheel truing, dressing and topography Wheel topography Truing after truing Gives the wheel the required geometry (macro) Enables the wheel to run with minimum run-out Profiling of the wheel to particular shape Wheel topography Dressing after dressing Gives the wheel the required topography (micro) Source: Basisseminar Schleiftechnik, WZL RWTH Aachen Dressing a wheel Source: Badger, J.: The Book of Grinding, The Grinding Doc, 2010 Dressing tools Diamonds for dressing radius & diameter Diamonds for dressing flank Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Honing Honing is an abrasive process common in finishing the bores (inside diameter) of internal combustion engines and gears. The process uses fixed abrasive tools – abrasive stones (sticks) – as the cutting medium Grit sizes range between 30 and 600 Creates a characteristic cross-hatched surface that retains lubrication Source: Gehring GmbH Surface finishes of 0.1-0.2 mm or better Kinematics of honing Honed surface texture Source: Scania CV AB Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Superfinishing Superfinishing is a fine finishing process which uses abrasive grits bonded in a stone for cutting. Widely used as a subsequent operation after grinding to enhance finish of the outside diameter (OD) and remove any chatter marks. Superfinishing also corrects size & shape variations, and improves roundness. The mechanisms associated with superfinishing are similar to those for grinding and honing. Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Lapping Lapping is an abrasive machining process in which abrasive grains are dispersed either in a paste or a fluid are applied to the moving surface of an opposing formed tool (the lap) so that the individual grains follow a complex path (DIN 8589). Suitable for processing almost every material. Lapping is increasingly used to process parts Source: Peter Wolters GmbH with a sealing function, high geometrical precision, as well as workpieces which show characteristic crater surfaces. Lapping setup Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Lapping material removal mechanism Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Lapped surface texture Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Polishing Polishing is an abrasive process in which loose abrasives – dispersed in a fluid or paste – are rubbed against the workpiece using a soft pad in order to smooth the surface of the workpiece without changing its dimensions, or shape. Laps for industrial polishing consist of a soft pad adhered to a rigid plate onto which the normal load is applied. The surfaces are smoothed to a “mirror” level – with roughness Ra of 20-200. nm. Polishing interface Source: Gehring GmbH Source: Klocke, F., Manufacturing Processes 2: Grinding, Honing, Lapping, Springer-Verlag Berlin Heidelberg, 2009 Ground Surface Topography Honed Polished 4µm 10/04/2018 [email protected] 42 GE- Ground efficiency tested GE-RI9 HE- Honed efficiency tested SFE- superfinished efficiency HE-RI5 tested SFE-RI9 20µm 12/5/2019 [email protected] 43 Review questions 1. What are the principal abrasive materials used in grinding wheels? 2. Grinding creates high temperatures. How is temperature harmful in grinding? 3. Which are the most common grinding operations? Illustrate them. 4. What are the three mechanisms of grinding-wheel wear? 5. What is (a) dressing and (b) truing, in reference to grinding wheels? .
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