Ultra-precision grinding of asymmetric curved surfaces by line contact with cup wheel

The wheel wear is a crucial factor affecting the shape accuracy while grinding the asymmetric curved surface components. To decrease the effects of the wheel wear and improve the machining accuracy, a novel approach of grinding with large-size and fine-grained cup wheel was suggested. This method has many advantages: a full line contact of the cup wheel against the work-piece can be realized, the wheel shape can be well maintained, and the wheel wear is uniform and can be compensated just by feeding along its axis. Moreover, a mathematical model was developed to analyze the grinding motion and the grinding principle deviation. Two hydrodynamic seal rings with wavy surfaces used in reactor coolant pumps were taken as examples to verify the practicability. It is expected to be an efficient method to manufacture more complex asymmetric curved surfaces with high shape accuracy and high surface quality.

[1]  Abbas Vafaeesefat,et al.  Penetration–elimination method for five-axis CNC machining of sculptured surfaces , 2007 .

[2]  I. Etsion,et al.  The Effect of Combined Coning and Waviness on the Separating Force in Mechanical Face Seals , 1980 .

[3]  A. O. Lebeck,et al.  The design and testing of a wavy-tilt-dam mechanical face seal , 1989 .

[4]  Han Huang,et al.  Grinding of silicon wafers using an ultrafine diamond wheel of a hybrid bond material , 2011 .

[5]  A. O. Lebeck.  Hydrodynamic Lubrication in Wavy Contacting Face Seals—A Two Dimensional Model , 1981 .

[6]  Zhijian Pei,et al.  Fine grinding of silicon wafers , 2001 .

[7]  V. C. Venkatesh.  New method of aspheric generation for manufacturing glass moulds on vertical machine centre , 2005 .

[8]  Hiroshi Mizumoto,et al.  Novel Positioning Devices for Ultraprecision Machine Tool , 2009 .

[9]  Elizabeth A. Croft,et al.  Feed optimization for five-axis CNC machine tools with drive constraints , 2008 .

[10]  J. E. Ritter,et al.  Grinding Mechanisms and Strength Degradation for Ceramics , 1989 .

[11]  Jun Shimizu,et al.  State-of-the-art technologies and kinematical analysis for one-stop finishing of φ300 mm Si wafer , 2002 .

[12]  Masanori Iye,et al.  Application of zero-expansion pore-free ceramics to a mirror of an astronomical telescope , 2008, Astronomical Telescopes + Instrumentation.

[13]  Z. Pei,et al.  Grinding of silicon wafers: A review from historical perspectives , 2008 .

[14]  I. Inasaki.  Grinding of hard and brittle materials , 1987 .

[15]  Gerry Byrne,et al.  Ultraprecision grinding technologies in silicon semiconductor processing , 2004 .

[16]  Mutsumi Touge,et al.  High-Precision Surface Grinding of Ceramics with Superfine Grain Diamond Cup Wheels , 1997 .

[17]  Peihua Gu,et al.  Recent development in CNC machining of freeform surfaces: A state-of-the-art review , 2010, Comput. Aided Des..

[18]  Renke Kang,et al.  Ultra-precision grinding of a hydrostatic mechanical sealing ring face with extremely shallow taper angle , 2011 .

[19]  Tsunemoto Kuriyagawa,et al.  A new grinding method for aspheric ceramic mirrors , 1996 .

[20]  C.T.P van Amersvoort.  Profile of a global mechanical seal company , 1995 .

[21]  S. Agarwal,et al.  Experimental investigation of surface/subsurface damage formation and material removal mechanisms in SiC grinding , 2008 .

[22]  C Sun,et al.  A method of version merging for computer-aided design files based on feature extraction , 2011 .

[23]  A. O. Lebeck,et al.  The design and testing of moving-wave mechanical face seals under variable operating conditions in water , 1986 .

[24]  A. O. Lebeck.  A Test Apparatus for Measuring the Effects of Waviness in Mechanical Face Seals , 1981 .

[25]  Yuan-Shin Lee,et al.  Rolling-ball method and contour marching approach to identifying critical regions for complex surface machining , 2000 .

[26]  Tsunemoto Kuriyagawa,et al.  Wheel curve generation error of aspheric microgrinding in parallel grinding method , 2006 .

[27]  Yoshiharu Namba,et al.  Development of Ultra-Precision Grinding Machine for Grazing Incidence X-Ray Mirrors. , 1994 .

[28]  Ekkard Brinksmeier,et al.  Ultra-precision grinding , 2010 .

[29]  J. Wei,et al.  Research on an ultrasonic NDT system for complex surface parts , 2002 .