Handbook of Machining with Grinding Wheels

THE BASIC PROCESS OF GRINDING

Introduction

From Craft to Science

Basic Uses of Grinding

Elements of the Grinding System

The Importance of the Abrasive

Grinding Wheels for a Purpose

Problem Solving

References

Grinding Parameters

Introduction

Process Parameters

Grinding Temperatures

Appendix: Drawing Form and Profile Tolerancing

References

Material Removal Mechanisms

Significance

Grinding Wheel Topography

Determination of Grinding Wheel Topography

Kinematics of the Cutting Edge Engagement

Fundamental Removal Mechanisms

Material Removal in Grinding of Ductile Materials

Surface Formation in Grinding of Brittle-Hard Materials

Energy Transformation

References

Grinding Wheels

Introduction

Wheel Shape Specification

Wheel Balance

Design of High-Speed Wheels

Bond Life

Wheel Mount Design

Wheel Design and Chatter Suppression

References

The Nature of the Abrasive

Introduction

Silicon Carbide

Alumina (Alox)-Based Abrasives

Electrofused Alumina Abrasives

Chemical Precipitation and/or Sintering of Alumina

Diamond Abrasives

CBN

Grain Size Distributions

Future Grain Developments

Postscript

References

Specification of the Bond

Introduction

Single-Layer Wheels

Electroplated (EP) Single-Layer Wheels

Brazed Single-Layer Wheels

Vitrified Bond Wheels for Conventional Wheels

Vitrified Bonds for Diamond Wheels

Vitrified Bonds for CBN

Resin Bond Wheels

Plastic Bonds

Phenolic Resin Bonds

Polyimide Resin Bonds

Metal Bonds

Other Bond Systems

References

Dressing

Introduction

Traverse Dressing of Conventional Vitrified Wheels with Stationary Tools

Traverse Dressing of Superabrasive Wheels with Stationary Tools

Uniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond Tools

Uniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary Diamond Tools

Cross-Axis Traverse Dressing with Diamond Discs

Diamond Form-Roll Dressing

Truing and Conditioning of Superabrasive Wheels

References

Grinding Dynamics

Introduction

Forced and Regenerative Vibrations

The Effect of Workpiece Velocity

Geometrical Interference between Grinding Wheel and Workpiece

Vibration Behavior of Various Grinding Operations

Regenerative Self-Excited Vibrations

Suppression of Grinding Vibrations

Conclusions

References

Grinding Wheel Wear

Three Types of Wheel Wear

Wheel Wear Mechanisms

Wear of the Abrasive Grains

Bond Wear

Assessment of Wheel Wear

References

Coolants

Introduction

Basic Properties of Grinding Fluids

Types of Grinding Fluids

Base Materials

Additives

Application Results

Environmental Aspects

The Supply System

Grinding Fluid Nozzles

Influence of the Grinding Fluid in Grinding

References

Monitoring of Grinding Processes

The Need for Process Monitoring

Sensors for Monitoring Process Variables

Sensor for Monitoring the Grinding Wheel

Sensors for Monitoring the Workpiece

Sensors for Peripheral Systems

References

Economics of Grinding

Introduction

A Grinding Cost Comparison Based on an Available Grinding Machine

A Cost Comparison Including Capital Investment

Cost Comparison Including Tooling

Grinding as a Replacement for Other Processes

Multitasking Machines for Hard-Turning with Grinding

Summary

References

APPLICATION OF GRINDING PROCESSES

Grinding of Ductile Materials

Introduction

Cast Irons

Steels

Heat-Resistant Superalloys

References

Grinding of Ceramics

Introduction

Background on Ceramic Materials

Diamond Wheels for Grinding Ceramics

Physics of Grinding Ceramics

ELID Grinding of Ceramics

References

Grinding Machine Technology

The Machine Base

Foundations

Guideways

Slideway Configurations

Hydrostatic Slideways

Recirculating Rolling Element Slideways

Linear Axis Drives and Motion Control

Elements of AC Servodrive Ballscrew Systems

Linear Motor Drive Systems

Spindle Motors and Grinding Wheel Drives

Drive Arrangements for Large Conventional Wheels

Drive Arrangements for Small Wheel Spindle Units

Spindles for High-Speed Grinding

Miscellaneous Wheel Spindles and Drives

Rotary Dressing Systems

Power and Stiffness Requirements for Rotary Dressers

Rotary Dressing Spindle Examples

Dressing Infeed System

References

Surface Grinding

Types of Surface Grinding Process

Basics of Reciprocating Grinding

Basics of Creep Grinding

Basics of Speed-Stroke Grinding

Successful Application of Creep Feed Grinding

Face Grinding

Fine Grinding

Appendix: Lapping Kinematics

References

External Cylindrical Grinding

The Basic Process

High-Speed Grinding

Automotive Camlobe Grinding

Punch Grinding

Crankshaft Grinding

Roll Grinding

References

Internal Grinding

Introduction

The Internal Grinding Process

Abrasive Type

Process Parameters

Machine Tool Selection

Troubleshooting

References

Centerless Grinding

The Importance of Centerless Grinding

Basic Process

Basic Relationships

Feed Processes

Centerless Wheel and Dressing Geometry

The Workrest

Speed Control

Machine Structure

High Removal Rate Grinding

Economic Evaluation of Conventional and CBN Wheels

The Mechanics of Rounding

Vibration Stability

Dynamic Stability

Avoiding Critical Frequencies

Summary and Recommendations for Rounding

Process Control

References

Ultrasonic Assisted Grinding

Introduction

Ultrasonic Technology and Process Variants

Ultrasonic-Assisted Grinding with Workpiece Excitation

Peripheral Grinding with Radial Ultrasonic Assistance

Peripheral Grinding with Axial Ultrasonic Assistance

Ultrasonic-Assisted Grinding with Excitation of the Wheel

Summary

References

Glossary

Notation and Use of SI Units

Index