Handbook of Machining with Grinding Wheels: 2nd Edition (Hardback) book cover

Handbook of Machining with Grinding Wheels

2nd Edition

By Ioan D. Marinescu, Mike P. Hitchiner, Eckart Uhlmann, W. Brian Rowe, Ichiro Inasaki

CRC Press

724 pages | 558 B/W Illus.

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Description

Grinding is a crucial technology that employs specific abrasive processes for the fabrication of advanced products and surfaces. Handbook of Machining with Grinding Wheels, Second Edition highlights important industry developments that can lead to improved part quality, higher productivity, and lower costs. Divided into two parts, the book begins with an explanation of grinding behavior and ends with a focus on new and emerging industrial applications.

While the first edition focused on the basics of abrasive machining technology and presented a unified approach to machining with grinding wheels, the second editionties in the continued need for traditional processes in conjunction with the latest applications. This bookhighlights new research topics that include: nanotechnology, alternative energy, and additive manufacturing, compares related approaches, and provides numerous references throughout the book.

New in the Second Edition:

  • Contains the latest information on abrasives, bonds, and dressing
  • Updates classic stability lobes for grinding
  • Introduces a new method for tracking dynamic instability in centerless grinding
  • Provides a section in the chapter on ultrasonic-assisted grinding, which contains recent work on modelling of the process
  • Adds material on fluid cooling
  • Presents experimental results for in-process feedback to the grinding process
  • Includes new examples on grinding machine technology (particularly for dressing)

A single source reference covering every aspect of the grinding process, Handbook of Machining with Grinding Wheels functions as a definitive guide to grinding technology for both practicing engineers and students studying graduate-level courses (such as abrasive machining; grinding R&D; metal removal processes; machining of brittle materials; and principles of cutting).

 

 

Reviews

"It is a comprehensive book which deals with almost all important aspects of theory and practice of different types of grinding operations and applications. It also describes in detail, grinding machines hence it becomes useful for researchers, teachers as well as practicing engineers."

—Dr. V. K. Jain, Mechanical Engineering Department, I.I.T. Kanpur, India

Table of Contents

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

Cubic Boron Nitride

Future Grain Developments

References

Specification of the Bond

Introduction

Single-Layer Wheels

Electroplated and Electroless-Plated 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 Disks

Diamond Form Roll Dressing

Truing and Conditioning of Superabrasive Wheels

References

Grinding Dynamics

Introduction

Forced and Regenerative Vibrations

The Effect of Workpiece Speed

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

Types of Wheel Wear

Wheel Wear Mechanisms

Wear of the Abrasive Grains

Bond Wear

Assessment of Wheel Wear

References

Coolants, the Coolant System, and Cooling

Introduction

Basic Properties of Grinding Fluids

Types of Grinding Fluids

Basic Properties

Additives

Application Results

Environmental Aspects

Supply System

Grinding Fluid Nozzles

Influence of the Grinding Fluid in Grinding

Reduction of Temperature by Convective Cooling

References

Monitoring of Grinding Processes

Need for Process Monitoring

Sensors for Monitoring Process Variables

Sensors for Monitoring the Grinding Wheel

Sensors for Monitoring the Workpiece

Sensors for Peripheral Systems

References

Economics of Grinding

Introduction

A 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 Servo-Drive Ball Screw Systems

Linear Motor Drive Systems

Spindle Motors and Grinding Wheel Drives

Drive Arrangements for Large Conventional Wheels

Drive Arrangements for Small Wheel Spindles

High-Speed Spindles for Small Wheels

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 Systems

References

Additional References

Surface Grinding

Types of Surface Grinding Process

Basics of Reciprocating Grinding

Basics of Creep Grinding

Basics of Speed-Stroke Grinding

Successful Application of CF Grinding

Face Grinding

Fine Grinding

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

Trouble Shooting

References

Centerless Grinding

The Importance of Centerless Grinding

Basic Processes

Basic Relationships

Feed Processes

Centerless Wheels 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 Theory

Dynamic Stability Limits

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

Appendix: Notation and Use of SI Units

About the Authors

Brian Rowe is considered the father of centerless grinding in addition to other notable research on grinding that includes thermal aspects, dynamic aspects, and fluid-film bearings. He established a laboratory and school dedicated to manufacturing processes at Liverpool John Moores University and is an Emeritus Professor.

Ichiro Inasaki is the dean of the Graduate School of Science and Technology at Keio University, Japan. He has developed a laboratory with outstanding research activities and his "intelligent grinding wheel" is featured in the Noritake Museum and represents one of his best accomplishments and contributions. He led CIRP in 2004/2005 as the president and was granted several awards.

Eckart Uhlmann is professor and director of the Institute for Machine-Tools and Management at Technical University of Berlin, Germany. Dr. Uhlmann received this chaired professorship after a very successful industrial career with Hermes Abrasive in Germany. As the head of his institute he holds the leading position in research on all aspects of abrasive machining with grinding wheels.

Dr. Mike Hitchiner is manager of precision technology at Saint Gobain Abrasives (Norton), the largest grinding wheel company in the world. Mike has devoted all his life to research, development and practical application of grinding processes. He started this activity during his D Phil at the University of Oxford in England, and was later considered "Mr. CBN Grinding" by the precision grinding industry. Today he focuses on working with machine tool builders and developing new grinding processes. He has brought an important industrial perspective to this book, as well as hundreds of applications.

Subject Categories

BISAC Subject Codes/Headings:
SCI041000
SCIENCE / Mechanics / General
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing
TEC021000
TECHNOLOGY & ENGINEERING / Material Science