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Grinding and Finishing: Illegitimi Non Carborundum
Grinding and Finishing: Illegitimi Non Carborundum
Overview
Processes
Analysis
Horizontal Grinding
Horizontal grinding
Vertical grinding
Centered grinding
Centerless grinding
10
11
12
Grinding Wheels
13
Grinding Wheels
14
15
16
17
18
19
Grinding Chips
20
D
q
t
l
v
21
Chip geometry
As with rolling contact length, the chip length,
l
D = wheel diameter, d = depth of cut
l Dd
Material removal rate, MRR
v = workpiece velocity, d = depth of cut, b = width
of cut
MRR v d b
23
w
r 10 to 20
t
1 1
1
Volchip w t l wtl
2 2
4
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
24
Chips
The number of chips removed per unit time
(n), where c = number of cutting edges
(grains) per unit area (typ. 0.1 to 10 per mm2,
and V = peripheral wheel velocity
n V bc
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
25
Combining
MRR v d b n Volchip
1
v d b Vbc wtl
4
w r t
l Dd
1
vd b V cb r t t Dd
4
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
26
Chip thickness
4v d
t
V cr Dd
2
or
4v
t
V cr
d
D
27
28
Power u MRR
Fgrinding V u v d b
v d b
Fgrinding u
V
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
29
1
u
t
or
1
u K1
t
substituting
1 v d b
Fgrinding K1
t V
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
30
v d b
Fgrinding K1
V
4v
d
V cr D
1
rearranging
d cr v
Fgrinding K1 b
Dd
4V
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
31
ME 6222: Manufacturing Processes and
Singh/Melkote/Colton
Systems Prof. J.S. Colton GIT 2006
Force on a grain
The force per grain can be calculated
Fgrain u Area
1
Fgrain u wt
2
w rt
and
1
u K1
t
1 1
Fgrain K1 r t t
t 2
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
32
Force on a grain
substituting for t, and rearranging
K1
4v
Fgrain r
2
V cr
d
D
vr d
Fgrain K1
V c D
Grinding temperature
Temperature rise goes with energy delivered
per unit area
Energy input
T K2
area
u bl d
1
T K2
K2 K1 d
bl
t
T K1 K2 d
1
4v d
Vcr D
34
Grinding temperature
Rearranging
=
3
1 2 4
35
36
Power u MRR u v d b
2
W s
m
min
6 mm
2000 W 35
1.5
d 25 mm 10
3
2
min
60 sec
mm
m
d 91.4 106 m
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
37
91
.
4
10
mm 25 mm
W s
min
Fgrinding 35
m
mm3 3600 rev 150 mm
min
rev 1000 mm
Fgrinding 70.7 N
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
38
1
Fgrain u wt
2
and
w rt
1
Fgrain u r t t
2
we need t
t
4v
V cr
mm
d
91.4 103 mm
min
mm grains
D
150 mm
3600 150
5
10
min
mm2
4 1500
t 1.32 103 mm
39
1
1
3 2
Fgrain u r t t 35 10 1.32 10
2
2
4
Fgrain 3.05 10 J / mm
40
1
1 1
1
Fgrain u r t t K1 r t t K1 r t
2
t 2
2
1
3.0510 N K1 10 1.32106 m
2
3 N
K1 46.2 10
m
1
41
K m
N
1
6
46.2
91
.
4
10
m 640K
6
N
m 1.32 10 m
42
Schematic
illustrations of the
superfinishing
process for a
cylindrical part.
(a) Cylindrical
mircohoning, (b)
Centerless
microhoning.
Lapping
(a) Schematic illustration of the lapping process. (b)
Production lapping on flat surfaces. (c) Production lapping
on cylindrical surfaces.
Abrasive-Flow Machining
Schematic illustration of
abrasive flow machining to
deburr a turbine impeller.
The arrows indicate
movement of the abrasive
media. Note the special
fixture, which is usually
different for each part
design. Source: Extrude
Hone Corp.
Robotic Deburring
A deburring operation on a robot-held die-cast
part for an outboard motor housing, using a
grinding wheel. Abrasive belts or flexible
abrasive radial-wheel brushes can also be used
for such operations. Source: Courtesy of
Acme Manufacturing Company and
Manufacturing Engineering Magazine,
Society of Manufacturing Engineers.
Challenges
Optics
Conformal Hydrodynamic
Nanopolishing Process and Machine
Process Description
Conformal contact has a rotating soft tool which conforms to the shape
of the cavity
Axis of this tool is inclined at 45 and the workpiece is rotated inside a
slurry filled tank which ensures non-zero relative motion between tool
and workpiece at every location in the cavity
The entire cavity can be polished at once which will be much cheaper
and faster than programming the tool path
Alternative to expensive Diamond Turning
Can finish wide range of materials ceramics (sapphire, glass) and
hardened steels
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Technology Outcomes
Superfinished surfaces in
steels (< 3nm 3D surface
roughness)
Crack-free surface of < 100
nm 3D surface roughness in
single
crystal
sapphire
cavity
Process
knowhow
and
machine
transferred
to
Precision
Engineering
Division, BARC for strategic
applications in a nuclear
device
The superfinished obtained
at a fraction of cost of
Diamond turning
It can also be used by gem
polishers
which
could
reduce the health hazard by
reducing the dust inhalation
and automation is possible
Summary
Overview of processes
Analysis of process
Example problem
54