The modelling and experimental verification of the grinding wheel topographical properties based on the ‘through-the-process’ method

The single-layer superabrasive wheels are made by joining all abrasive grains onto the wheel hub through electroplating or brazing processes. Recently, the attention has risen to acquire a better grinding quality through more stringent grain size control. It is found that any small deviation in the grain dimensional distribution will result in considerable difference in the grinding quality. Therefore, the understanding on correlation between the grain dimensional deviations with the wheel performances will be critical, and the primary step is to establish the correlation between the critical wheel design parameters with the wheel topographical features. In this paper, the ‘through-the-process’ grinding wheel model is developed for single-layer electroplated cubic boron nitride (CBN) wheels by simulating each wheel fabrication procedure, numerically. The efficacy of the wheel model is verified by comparing simulation results with the experimental measurement data in terms of the static grain count and grain protrusion height distribution, and further analysis of the intrinsic relationship between the grain dimensional distribution and the wheel surface topographical properties is carried out so as to provide the quantitative basis for grinding wheel quality control and optimal abrasive product design.

[1]  Fabrizia Caiazzo,et al.  The influence of working parameters on the response of a capacitive sensor used in-process for the measurement of tool wear , 1998 .

[2]  W. Rowe,et al.  Precision grinding using CBN wheels , 2002 .

[3]  G. K. Lal,et al.  A model for the topography of diamond grinding wheels , 1993 .

[4]  Ichiro Inasaki.  Grinding Process Simulation Based on the Wheel Topography Measurement , 1996 .

[5]  Xun Chen,et al.  Analysis and simulation of the grinding process. Part I: Generation of the grinding wheel surface , 1996 .

[6]  Tomasz Królikowski,et al.  Grinding Wheel Topography Modeling with Application of an Elastic Neural Network , 2009, ICIC.

[7]  Hong Jun Xu,et al.  Measurement Technique of Grinding Wheel Topography Based on Binocular Stereo Vision , 2006 .

[8]  G. K. Lal,et al.  Stochastic simulation approach to modelling diamond wheel topography , 1997 .

[9]  M. J. Jackson,et al.  High-speed grinding with CBN grinding wheels — applications and future technology , 2001 .

[10]  Jan C. Aurich,et al.  Development of a Superabrasive Grinding Wheel With Defined Grain Structure Using Kinematic Simulation , 2003 .

[11]  Günter Warnecke,et al.  Kinematic Simulation for Analyzing and Predicting High-Performance Grinding Processes , 1998 .

[12]  Katsushi Furutani,et al.  In-process measurement of topography change of grinding wheel by using hydrodynamic pressure , 2002 .

[13]  Robert Bauer,et al.  A survey of recent grinding wheel topography models , 2006 .

[14]  J. Hegeman.  Fundamentals of grinding: Surface conditions of ground materials , 2000 .

[15]  Ichiro Inasaki,et al.  Modelling and Simulation of Grinding Processes , 1992 .

[16]  S. Paul,et al.  Numerical modelling of surface topography in superabrasive grinding , 2008 .

[17]  A. A. Torrance,et al.  The relation between the traverse dressing of vitrified grinding wheels and their performance , 2000 .

[18]  D. Butler,et al.  The characterisation of grinding wheels using 3D surface measurement techniques , 2002 .

[19]  Liam Blunt,et al.  The application of three-dimensional surface measurement techniques to characterizing grinding wheel topography , 1996 .

[20]  D. Guo,et al.  A novel model for undeformed nanometer chips of soft-brittle HgCdTe films induced by ultrafine diamond grits , 2012 .

[21]  M. Stephens.  EDF Statistics for Goodness of Fit and Some Comparisons , 1974 .

[22]  Xuekun Li,et al.  The study on the influences of superabrasive grain spatial orientation for microcutting processes based on response surface methodology , 2013 .

[23]  Hans Kurt Tönshoff,et al.  Abrasive Machining in the Future , 1993 .

[24]  K. Moon,et al.  A methodology for the multi-resolution simulation of grinding wheel surface , 1997 .

[25]  Jan C. Aurich,et al.  High-performance dry grinding using a grinding wheel with a defined grain pattern , 2008 .

[26]  R. Venkata Rao,et al.  Advanced Modeling and Optimization of Manufacturing Processes , 2010 .

[27]  D. Guo,et al.  Characterization of Nanoscale Chips and a Novel Model for Face Nanogrinding on Soft-Brittle HgCdTe Films , 2012, Tribology Letters.