Machining with Abrasives Mark J. Jackson l J. Paulo Davim Editors Machining with Abrasives Editors Mark J. Jackson J. Paulo Davim Purdue University University of Aveiro MET, Center for Advanced Manufacturing Department of Mechanical Engineering College of Technology 3810-193 Aveiro, Portugal West Lafayette, IN 47907-2021 [email protected] USA [email protected] ISBN 978-1-4419-7301-6 e-ISBN 978-1-4419-7302-3 DOI 10.1007/978-1-4419-7302-3 Springer New York Dordrecht Heidelberg London # Springer Science+Business Media, LLC 2011 All rights reserved. This work may not be translated or copied in whole or in part without the written permission of the publisher (Springer Science+Business Media, LLC, 233 Spring Street, New York, NY 10013, USA), except for brief excerpts in connection with reviews or scholarly analysis. Use in connection with any form of information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed is forbidden. The use in this publication of trade names, trademarks, service marks, and similar terms, even if they are not identified as such, is not to be taken as an expression of opinion as to whether or not they are subject to proprietary rights. Printed on acid-free paper Springer is part of Springer ScienceþBusiness Media (www.springer.com) Preface Machining with abrasives is a widely used process for producing intricate shapes on components and artifacts and for providing precise tolerances that are required especially for the manufacture of engineering components. Grinding technology is associated with the current developments in this area and this book contains chapters on abrasive materials, bonding systems, grinding wheel design, micro and nanogrinding, control of grinding processes, abrasive grinding, abrasive water jet grinding, and dressing of grinding wheels. The chapters are written by subject matter experts from around the world and provide an authoritative text on the current developments in machining with abrasive tools. Chapter 1 focuses on new developments in abrasive materials and associated bonding systems ranging from conventional abrasives to superabrasive materials. Chapter 2 provides an interesting prose on heat treatment and the performance of vitrified bonds, while Chap.3 takes a look at the design of grinding wheels and wheel safety. The dressing of grinding wheels is discussed in Chap.4 and leads into a chapter on the on the surface integrity in ground surfaces (Chap.5). The control aspect of grinding is explained lucidly in Chap.6, while Chap.7 focuses on the exciting new area of nanogrinding. The final chapters deal with polishing with loose abrasive particles and an authoritative overview of impact abrasive machining. The structure of the book is based on matter provided by many colleagues and the author wishes to thank the contributors of this book for helping construct a source of knowledge and information on machining with abrasives and for granting the editors permission to use such material. The editors also acknowledge the help and support of Inderscience Publishers for allowing the chapter contributors and editors to reproduce their work that was originally published in refereed Inderscience journals and other refereed journals where permissions have been acknowledged. Dr. Mark J. Jackson Dr. J. Paulo Davim v About the Editors Dr. Mark J. Jackson C. Eng., Engineering Council of London, U.K., 1998 M. A. Status, Natural Sciences, University of Cambridge, U.K., 1998 Ph.D., Mechanical Engineering, Liverpool, U.K., 1995 M.Eng., Mechanical & Manufacturing Engineering, Liverpool, U.K., 1991 O.N.D., Mechanical Engineering, Halton College, U.K., 1986 O.N.C. Part I, Mechanical Engineering, Halton College, U.K., 1984 Doctor Jackson began his engineering career in 1983 when he studied for his O.N. C. part I examinations and his first-year apprenticeship-training course in mechani- cal engineering. After gaining his Ordinary National Diploma in Engineering with distinctions and I.C.I. prize for achievement, he read for a degree in mechanical and manufacturing engineering at Liverpool Polytechnic and spent periods in industry working for I.C.I. Pharmaceuticals, Unilever Industries, and Anglo Blackwells. After graduating with a Master of Engineering (M. Eng.) degree with Distinction under the supervision of Professor Jack Schofield, M.B.E., Doctor Jackson subse- quently read for a Doctor of Philosophy (Ph.D.) degree at Liverpool in the field of materials engineering focusing primarily on microstructure-property relationships in vitreous-bonded abrasive materials under the supervision of Professor Benjamin Mills. He was subsequently employed by Unicorn Abrasives’ Central Research & Development Laboratory (Saint-Gobain Abrasives’ Group) as materials technolo- gist, then technical manager, responsible for product and new business develop- ment in Europe, and university liaison projects concerned with abrasive process development. Doctor Jackson then became a research fellow at the Cavendish Laboratory, University of Cambridge, working with Professor John Field, O.B.E., F.R.S., on impact fracture and friction of diamond before becoming a lecturer in vii viii About the Editors engineering at the University of Liverpool in 1998. At Liverpool, Dr. Jackson established research in the field of micromachining using mechanical tools, laser beams, and abrasive particles. At Liverpool, he attracted a number of research grants concerned with developing innovative manufacturing processes for which he was jointly awarded an Innovative Manufacturing Technology Center from the Engineering and Physical Sciences Research Council in November 2001. In 2002, he became associate professor of mechanical engineering and faculty associate in the Center for Manufacturing Research, and Center for Electric Power at Tennessee Technological University (an associated university of Oak Ridge National Labora- tory), and a faculty associate at Oak Ridge National Laboratory. Dr. Jackson was the academic adviser to the Formula SAE Team at Tennessee Technological University. In 2004 he moved to Purdue University as Professor of Mechanical Engineering in the College of Technology. Doctor Jackson is active in research work concerned with understanding the properties of materials in the field of microscale metal cutting, micro- and nanoab- rasive machining, and laser micro machining. He is also involved in developing next generation manufacturing processes. Doctor Jackson has directed, co-directed, and managed research grants funded by the Medical Research Council, Engineering and Physical Sciences Research Council, The Royal Society of London, The Royal Academy of Engineering (London), European Union, Ministry of Defense (Lon- don), Atomic Weapons Research Establishment, National Science Foundation, N. A.S.A., U. S. Department of Energy (through Oak Ridge National Laboratory), Y12 National Security Complex at Oak Ridge, Tennessee, and Industrial Companies, which has generated research income in excess of $15 million. Dr. Jackson has organized many conferences and served as General Chairman of the International Surface Engineering Congress and is Deputy President of the World Academy of Materials and Manufacturing Engineering. He has authored and co-authored over 250 publications in archived journals and refereed conference proceedings, has written a book on “micro and nanomanufacturing”, is guest editor to a number of refereed journals, and has edited a book on “commercializing micro- and nanotech- nology products”. He is the co-editor of the “Journal of Manufacturing Technology Research”, associate editor of the “International Journal of Molecular Engineer- ing”, and is on the editorial boards of the “International Journal of Machining and Machinability of Materials”, “International Journal of Computational Materials Science and Surface Engineering”, “International Journal of Nanomanufacturing”, “International Journal of Nano and Biomaterials”, and the “International Journal of Manufacturing Research”. About the Editors ix Dr. J. Paulo Davim Aggregation, Mechanical Engineering, University of Coimbra, Portugal, 2005 Ph.D., Mechanical Engineering, University of Porto, Portugal, 1997 M.Sc., Mechanical Engineering (Materials & Manufacturing Processes), University of Porto, Portugal, 1991 Graduation (5 years), Mechanical Engineering, University of Porto, Portugal, 1986 Doctor J. Paulo Davim received his Ph.D. degree in Mechanical Engineering from the University of Porto in 1997 and the Aggregation from the University of Coimbra in 2005. Between, 1986/96, he was lecturer in University of Porto. Currently, he is an Aggregate Professor at the Department of Mechanical Engineer- ing of the University of Aveiro and the Head of MACTRIB - Machining and Tribology Research Group. He has more 24 years of teaching and research experi- ence in manufacturing, materials and mechanical engineering. His main research interests are the machining and tribology and more recently the application of computational and statistical methods in manufacturing as well as all aspects of sustainable manufacturing. He was coordinator of several research projects and supervisor of 2 Ph.D. thesis and 10 M.Sc. thesis. He is Guest Editor of journals, book Series Editor and Scientific Advisory for many international journals and conferences. Presently, he is an Editorial Board member of 15 international journals and acts as reviewer for than 45 prestigious ISI web Science journals. He has also