Manufacturing Processes

The book series on manufacturing processes for engineers by Klocke is a reference for scientific and industrial experts. The compendium presents an overall picture of the most common machining and non-machining manufacturing processes.This volume on Grinding, Honing and Lapping starts from the basics of cutting edge engagement during grinding including chip formation, forces involved and energy distribution, as well as the wear of grinding grits. The characteristics of abrasive tools, their design and manufacturing are described, followed by the fundamentals of grinding fluids. Grinding of different materials (steel, cast iron, hard and brittle materials, nickel and titanium) is treated in-depth. Different grinding processes and their kinematic characteristics are then presented in detail. The parameters of different grinding procedures, references to process implementations as well as typical industrial applications are likewise specified. Besides honing and lapping, practical insights into polishing are provided. Special abrasive processes are presented including ultrasound assisted grinding and cutting with geometrically undefined cutting edges. Finally, monitoring systems for process control are discussed considering their increasing relevance and application in industrial manufacturing.The book is a comprehensive treatment of abrasive processes. It appears in the RWTH Edition Series as part of a 4 volume reference work.

Professor Dr.-Ing. Dr.-Ing. E.h. Fritz Klocke has been Professor of Manufacturing Engineering Technology, director of the WZL Laboratory for Machine Tools & Production Engineering at the RWTH Aachen, and head of the Fraunhofer Institute for Production Technology IPT in Aachen since 1995. A doctorate of honoris causa GÇPDr. E.h." was bestowed upon him by the University of Hannover in 2006. Professor Klocke was CIRP President from 2007 - 2008.

Symbols and Abbreviations	p. XIII
Introduction	p. 1
Principles of Cutting Edge Engagement	p. 3
Cutting Edge Form	p. 4
Cutting Edge Engagement	p. 7
Distribution of Force and Energy in the Grinding Process	p. 11
Grit and Bond Wear	p. 14
Structure and Composition of Grinding Wheels	p. 17
Grit Material	p. 17
Natural Grit Materials	p. 17
Synthetic Grit Materials	p. 19
Bonds	p. 37
Resin Bonds	p. 38
Vitrified Bonds	p. 39
Metallic Bonds	p. 40
Other bonds	p. 40
Fillers and Additives	p. 41
Tool Structure and Designation	p. 42
Composition of Conventional Grinding Wheels	p. 43
The Designation of Conventional Tools	p. 45
Composition of Superabrasive Grinding Wheels	p. 50
The Designation of Superabrasive Grinding Wheels	p. 51
Tool Manufacture	p. 54
The Manufacture of Tools with Conventional Abrasives	p. 54
The Manufacture of Superabrasive Grinding Wheels	p. 58
Tools Testing	p. 61
Hardness Testing	p. 62
Investigations in Grit Break-out	p. 64
Abrasive Belts (Coated Abrasives)	p. 66
Composition of Abrasive Belts	p. 66
The Manufacture and Structure of Abrasive Belts	p. 66
The Machinability of Various Materials	p. 73
The Concept of "Machinability" in the Grinding Process	p. 73
Influencing the Material Properties of Steels	p. 74
Material Properties as a Function of Carbon Content	p. 74
The Influence of Alloying Elements on Material Properties	p. 77
Material Properties as a Function of Heat Treatment	p. 79
The Structure of Various Steel Materials	p. 83
Case-Hardened Steels	p. 83
Heat-Treated Steels	p. 84
Nitrided Steels	p. 86
Roller Bearing Steels	p. 87
Tool Steels	p. 88
Non-Corrosion, Fireproof and High-Temperature Steels	p. 89
Grinding Various Structural Components in Steels	p. 91
Grinding Iron-Casting Materials	p. 92
Grinding Nickel-Based Materials	p. 94
Construction and Structure	p. 94
Properties and Uses	p. 96
Grinding Behaviour - Influences on the Grinding Process	p. 96
Grinding Titanium Materials	p. 99
Construction and Structure	p. 99
Properties and Uses	p. 102
Grinding Behaviour - Influences on the Grinding Process	p. 103
Grinding Brittle Materials	p. 105
The Machining Behaviour of Brittle Materials	p. 106
Machining High-Performance Ceramics	p. 107
Glass Machining	p. 108
Silicon	p. 110
Cooling Lubricants	p. 113
Principles of Cooling Lubricants in the Grinding Process	p. 113
General Functions	p. 113
The Tribological System of Grinding	p. 114
Requirements of Cooling Lubricants in the Grinding Process	p. 114
Classification, Structure and Properties	p. 116
Oils	p. 116
Emulsions	p. 117
Aqueous Solutions	p. 119
Use of Additives	p. 119
The Influence of Cooling Lubrication on the Grinding Process	p. 120
Cooling Lubricant Type	p. 120
Cooling Lubricant Supply	p. 123
Supervision, Maintenance and Disposal	p. 129
Grinding	p. 135
Preparation	p. 135
Dressing Kinematics	p. 136
Sharpening	p. 142
Further Dressing Methods - Special Methods	p. 146
Cleaning	p. 152
Dressing Variables and Effective Mechanisms - The Influence of Tool Preparation on the Grinding Process	p. 153
Parameters	p. 161
Methodological Variants according to DIN 8589	p. 177
Introduction	p. 177
External Cylindrical Grinding	p. 182
Internal Cylindrical Grinding	p. 210
Surface Grinding	p. 212
Coated Abrasives	p. 215
Other Variants	p. 227
Gear Grinding	p. 227
Gear Honing	p. 248
Process Design	p. 251
The Influence of Variables and Parameters on the Result	p. 251
The Influence of the Grinding Tool on the Output	p. 269
Multistage Processes	p. 273
Disturbances	p. 280
Application Examples	p. 287
External Cylindrical Peripheral Plunge Grinding	p. 287
External Form Grinding	p. 290
Internal Cylindrical Peripheral Plunge Grinding	p. 293
Centreless Plunge Grinding	p. 296
Surface Peripheral Plunge Grinding	p. 299
Honing	p. 302
Kinematic Principles	p. 303
Honing Tools and their Preparation	p. 309
Honing Stones with Corundum or Silicon Carbide	p. 309
Honing Stones with Boron Nitride and Diamond	p. 309
Influences on the Process and the Work Result	p. 310
Input Variables	p. 310
Tool Shape and Specifications	p. 321
Workplace Structure	p. 329
Additives	p. 331
Examples of Application	p. 333
Plateau Honing	p. 333
Gear Honing of Externally Toothed Spur Gears with an Internally Toothed Tool	p. 334
Laser Honing	p. 337
Lapping and Polishing	p. 338
Lapping	p. 338
Fundamentals	p. 339
Composition of Tools and Operational Materials	p. 347
Accessories	p. 350
Parameters	p. 351
Applications	p. 354
Polishing	p. 356
Principles	p. 357
Tool Construction and Composition	p. 364
Accessories	p. 367
Parameters	p. 368
Special Methods	p. 370
Abrasive Blast Cutting	p. 370
Operating Principle, Initial Process Parameters and Blast Parameters	p. 370
Method Variations and Applications	p. 371
Free Abrasive Grinding	p. 375
Operating Principle	p. 375
Method Variations and Applications	p. 376
The Influence of Input Process Parameters on the Result	p. 379
Cutting with Geometrically Undefined Cutting Edges	p. 380
Abrasive Cutting	p. 380
Multi-Wire Slicing (MWS)	p. 383
Inner Diameter Slicing	p. 387
Process Monitoring	p. 390
The Necessity of Process Monitoring	p. 390
Sensors for Process Monitoring	p. 392
Force Sensors	p. 392
Current Sensors	p. 393
AE-Sensors	p. 394
First Contact Control	p. 397
Collision Monitoring	p. 400
Dressing Monitoring	p. 401
Service Life Monitoring while Grinding Using AE	p. 403
Monitoring Grinding Wheel Wear with the AE Effective Value	p. 403
Detecting Chattering	p. 404
Process Step Recognition as an Element of Reliable Monitoring	p. 405
Control of Workpiece Properties	p. 406
Reliability of Process Monitoring	p. 408
Literature	p. 410
Index	p. 431
Table of Contents provided by Ingram. All Rights Reserved.

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