Grinding Technology : Theory and Applications of Machining with Abrasives

by Stephen Malkin, Changsheng Guo

• ISBN13: 9780831132477
• ISBN10: 0831132477
• Edition: 2nd
• Format: Hardcover
• Copyright: 2008-05-15
• Publisher: INDUSTRIAL PRESS

Summary

Presenting a comprehensive and consistent treatment of grinding theory and its practical utilization, this new edition focuses on grinding as a machining process using bonded abrasive grinding wheels as the cutting medium. Logically organized, this self-contained resource starts with a description of abrasives and bonded abrasive cutting tools; then moves on to thermal analyses of the grinding process for conventional, creep feed, and superabrasive grinding; and ends with methods for enhancing and optimizing of grinding operations, simulation of grinding processes, and computer control of grinding machines. The perfect reference for practicing engineers involved in the grinding process, it will also be useful for researchers working in the field. * Features a unified and self-contained presentation about what is known about grinding processes and how this information can be practically applied.

Table of Contents

Preface	p. vii
Preface to the First Edition	p. ix
Introduction	p. 1
The Grinding Process	p. 1
Historical Development of the Grinding Process	p. 3
Contents of this Book	p. 7
Grinding Wheels: Composition and Properties	p. 11
Introduction	p. 11
Grinding Wheel Specification: Conventional Abrasives	p. 12
Grinding Wheel Specification: Superabrasives	p. 17
Conventional Abrasive Materials	p. 19
Superabrasive Materials	p. 25
Bond Materials	p. 26
Vitrified Wheel Composition and Phase Diagrams	p. 31
Grinding Wheel Testing	p. 34
Grinding Geometry and Kinematics	p. 43
Introduction	p. 43
Geometrical Wheel-Workpiece Contact Length	p. 44
Cutting Path	p. 47
Maximum Cutting Depth (Undeformed Chip Thickness)	p. 54
Undeformed Chip Thickness-Continuity Analysis	p. 59
Non-Uniform Wheel Topography	p. 60
Traverse Grinding	p. 65
Profile (Form), Angle, and Helical-Groove Grinding	p. 67
Grinding Operations with Total Conformity	p. 74
Wheel Truing, Dressing, and Topography	p. 81
Introduction	p. 81
Dressing of Conventional Wheels	p. 82
Truing and Dressing of Superabrasive Wheels	p. 84
Generation of Wheel Topography-Conventional Wheels	p. 88
Generation of Wheel Topography - Superabrasives	p. 95
Measurement of Wheel Topography	p. 98
Profilometry methods	p. 98
Imprint methods	p. 100
Scratch methods	p. 102
Dynamometer and thermocouple methods	p. 104
Microscopic methods	p. 105
Grinding Mechanisms	p. 115
Introduction	p. 115
Grinding Debris (Swarf)	p. 116
Grinding Forces, Power, and Specific Energy	p. 118
Grinding Mechanisms: Conventional Abrasives	p. 120
Size effect and energy considerations	p. 120
Sliding forces and energy	p. 121
Plowing and chip-formation energies	p. 127
Grinding Mechanisms: CBN Wheels	p. 134
Creep-Feed Grinding	p. 141
Controlled-Force Grinding	p. 142
Heavy-Duty Grinding	p. 147
Empirical Relationships	p. 152
Thermal Aspects: Conventional Grinding	p. 157
Introduction	p. 157
Heat Transfer Analysis: Plunge Grinding	p. 159
Thermal Damage	p. 169
Workpiece burn	p. 170
Tempering and Rehardening	p. 173
Residual stresses	p. 176
Face Grinding	p. 179
Abrasive Cut-Off	p. 181
Thermal Aspects: Creep-Feed Grinding	p. 189
Introduction	p. 189
Workpiece Temperature and Burnout	p. 192
Energy Partition: Simple Model for Creep-Feed Grinding	p. 194
Energy Partition: Variation along the Grinding Zone	p. 196
Energy Partition: Single Grain Model	p. 201
Transient Temperature	p. 203
Thermal Comparison: Regular and Creep-Feed Grinding	p. 209
Thermal Aspects: Grinding with CBN Abrasives	p. 215
Introduction	p. 215
Vitrified CBN Wheels	p. 216
Electroplated CBN Wheels	p. 219
High Efficiency Deep Grinding (HEDG)	p. 224
Fluid Flow in Grinding	p. 231
Introduction	p. 231
Fluid Flow through Grinding Zone: Flood Application	p. 232
Fluid Flow through the Grinding Zone: Creep-Feed Grinding	p. 236
Analysis of Useful Flow Rate through the Grinding Zone	p. 238
Measurement of Hydrodynamic Forces	p. 242
Analysis of Hydrodynamic Forces	p. 248
Surface Roughness	p. 257
Introduction	p. 257
Ground Surface Morphology	p. 258
Surface Texture and Tolerance	p. 260
Ideal Surface Roughness	p. 265
Empirical Roughness Behavior	p. 272
Wheel Wear and Lubrication	p. 285
Introduction	p. 285
Quantifying Wheel Wear	p. 286
Wheel-Wear Mechanisms	p. 289
Analysis of Wheel Wear	p. 294
Attritious Wear and Grinding Chemistry	p. 301
Grinding Fluids and Lubrication	p. 304
Evaluating Wheel Performance	p. 308
Grinding Deflections: Grinding Cycles, Inaccuracies, and Vibrations	p. 315
Introduction	p. 315
Continuous Infeed Analysis	p. 315
Grinding Cycle Behavior	p. 319
Discrete Infeed Analysis	p. 321
Inaccuracies and Elastic Deflections	p. 326
Accelerated Spark-In and Spark-Out	p. 327
Grinding Vibrations	p. 331
Vibration Suppression	p. 335
Simulation, Optimization, and Intelligent Control	p. 339
Introduction	p. 339
Original Simulation Software for Cylindrical Grinding	p. 340
GrindSim: Simulation, Calibration, and Optimization of Cylindrical Grinding	p. 345
Simulation of Creep-Feed Form Grinding	p. 353
Simulation	p. 356
Calibration	p. 358
Optimization and Process Monitoring	p. 359
Machine Tool Control	p. 361
Index	p. 369
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