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StudyonEffectofGrindingFluidSupplyParametersonSurfaceIntegrityinQuick-pointGrindingforGreenManufacturing
Abstract.Inhighandsuper-highspeedgrindingprocess,thereisanairflowlayerwithhighspeedaroundthecircleedgeofthegrindingwheelthathindersthegrindingfluidintocontactlayer,namely,theairbarriereffect.Thespeedofairflowlayerisdirectlyproportionaltothesquareofthewheelspeed.Quick-pointgrindingisanewtypeofhighandsuper-highspeedgrindingprocesswithapointcontactzoneandlessgrindingpower.TheedgeeffectoftheairbarrierisweakenedbecausethethinCBNwheelisappliedintheprocess.Bytheanalysisofdynamicpressureandvelocitydistributionsintheairflowlayeraroundthewheeledge,themathematicmodelsoftheflowandjetpressureofgrindingfluidforeffectivesupplyintheprocesswereestablishedandtheprocessofoptimizationcalculationofthejetnozzlediameterforgreenmanufacturingwasalsoanalyzedbasedonthethermodynamicsandthetechnicalcharacterofquick-pointgrindingprocess.Thequick-pointgrindingexperimentforsurfaceintegrityinfluencedbygrindingfluidsupplyparameterswasperformed.
Introduction
Grindingisthemachiningprocessthathasheavyeffectonbothenvironmentandresource.Theheavyeffectresultsfromthegrindingpowderandgrindingfluidthatisusedingrindingprocesslargelyforcooling,washingandlubricatingfunctionsmainly.Especiallyforhighandsuper-highgrindingspeedprocess,thereistheairflowlayerwithhighrotaryspeedaroundthecircleedgeofthegrindingwheelthathindersthegrindingfluidintothecontactlayer[1],namelytheairflowbarriereffect.Soithastoincreasethegrindingfluidsupplyparameterstokeepthefluideffectduringgrindingprocess.Inrecentyears,ithasbeenthefocusofresearchinengineeringtoimprovethegrindinggreennessanddevelopthegreengrindingprocess.Quick-pointgrindingisanewtypeofhighandsuper-highspeedgrindingprocesswithsomeexcellentperformances,suchaslowgrindingforceandtemperature,goodcoolingconditions,longwheellifeandsoon.Itispossibletoachievethedrygrindingbydesigningthegrindingfluidsystemandthegrindingfluidsupplyparametersreasonably,andoptimizinggrindingprocessparametersforgreenmanufacturing.
AnalysisofPressureandVelocityofAirflowLayeraroundWheel
Grindingheatisgeneratedfromthedeformationandfrictionofmaterialsduringthegrindingprocessandmakesthegrindingtemperaturerise,whichcanresultinthethermalsurfacedamageofworkpiece.Therefore,areliablegrindingfluidsystemisnecessaryforthemostgrindingprocesstokeepcooling,washingandlubricatingfunctions.Forhighandsuper-highspeedgrindingprocess,thegrindingfluidsupplyparametersandjetwaymustbedesignedreasonablytoovercometheairflowbarriereffectonfluidsupply,increasetheratiooftheeffectivefluidandreducethesplashandwasteofthefluid.Inquick-pointgrindingprocess,itisthepointcontactbetweenwheelandworkpieceduetothepointgrindinganglesandthethinCBNwheel(Fig.1),sotheairflowlayerisverynarrowandtheairflowbarriereffectweakens,thefluideffectisimprovedgreatly,asaresult,thegrindingfluidsupplyparameterscanbelessened.
Fig.1Principleofquick-pointgrinding
Thethicknessandpressureoftheairflowlayerwithhighrotaryspeedaroundthecircleedgeofgrindingwheelisthemainfactorstoinfluencethefluideffectinhighspeedgrinding,thehigherthewheelspeed,thethickertheairflowlayerisandthehigherthepressureoftheairflowlayeris.AccordingtoBernoulliEquation[2],thedynamicpressureoftheairflowlayerisgivenby
wherevaistheairflowspeed[m/s],ρaistheairdensity[kg/m3].Ifthedynamicpressurepaoftheairflowlayerismeasuredonthedifferentwheelposition,theairflowspeedatsamepositioncanbecalculated.Table1givestheexperimentvaluesofdynamicpressureandspeedofairlayer.Ifthediameterofwheelis600mmandthewheelspeedis30m/sand60m/srespectively,themeasuredvaluesofthedynamicpressureandtheairflowspeedareshowninTable1.Itisvisiblethatthedynamicpressureoftheairflowlayerisincreasedwithincreaseofthewheelspeed.
Table1Measuredvaluesofdynamicpressureandspeedofairflowlayer
Fig.2showsthedistributionofthespeedofairflowlayerwiththedistancetbetweentheairflowlayerandthewheeledge[3].Theairflowspeedisdecreasedwiththeincreaseofthedistancebetweentheairflowlayerandthewheel,andincreasedwiththeincreaseofwheelspeed.Themaximumspeedofairflowisgeneratedonthecircleofthewheeledgeandapproachesthemaximumperipheralwheelspeed.Buttherearethesharpergradsoftheairflowspeedalongtheradialdirectionofthewheel.Therefore,therotaryairflowlayerwithhighpressurekeepsthegrindingzoneoffgrindingfluidandlowerstheworkpieceintegrityandthewheellifeduetothefailinthefluideffect.Inquick-pointgrindingprocess,itisthepointcontactbetweenwheelandworkpieceintheorybecausetheaxesofthewheelandtheworkpieceareunparalleleachother(Fig.1)whichisdifferentfromtheconventionalcylindricalgrinding,sothecoolingconditionisbetter.BecausethethinCBNwheelisusedintheprocess,inaddition,theairflowlayerbarriereffectongrindingfluidisweakened.
CalculationofGrindingFluidFlow
Ingeneral,theworkof85%~90%tobeabsorbedfordeformationandfrictionofmaterialsconvertsintoheatenergyatnormaltemperature[4,5],namelythethermaleffect.Forgrindingprocess,thedeformationandfrictionofmaterialsasthemainworkisgeneratedthroughthewholeprocess.Therefore,itcanbeconcludedthatthemostnon-elasticityworkconvertintoheatingrindingprocess.Basedontheheat-workbalanceequation,theflowofgrindingfluidisgivenby
whereρisthefluiddensity[kg/m3],Nisthegrindingpower[kW],cisthespecificheat[J/kg·K],Gisthecoolingcoefficientthatrestswiththecontactareabetweenwheelandworkpieceandtheratiooftheeffectivefluidtoentergrindingzone,generally,Gisselectedinrangeof1.0~2.0,Δtistheincrementoftemperatureandselectedinrangeof5~15℃.Forthegrindingfluidsupplysystem(Fig.3)inquick-pointgrinding,thelargerGcanbeselectedduetothebettercoolingconditionsandthelesscontactarea.
AnalysisofFluidJetPressure
Toovercometheairflowbarriereffectandmakethefluidentercontactzone,thegrindingfluidjetpressuremustfitforthefollowinginequation
wherev0isthefluidjetspeed[m/s].Giventhediameterofthefluidjetnozzle,thefluidflowQisincreasedwiththeincreaseofthefluidjetpressure.Ontheotherhand,thehigherthejetpressureoffluid,theheavierthesplashandsprayofthefluidare,andthemoretheconsumedpoweris.Therefore,thejetpressureisusually0.3~3MPainhighandsuper-highspeedgrindingprocess.Inquick-pointgrindingprocess,itisthepointcontactbetweenthewheelandtheworkpieceintheorybecausetheaxesofthewheelandtheworkpieceareunparalleleachother(Fig.1)whichisdifferentfromtheconventionalcylindricalgrinding,sothelesscontactarealowersthegrindingheatandforcegreatly,andimprovesthecoolingperformanceandthegrindingfluideffect.Inaddition,thethinCBNwheelmakestheairflowbarriereffectweaken.Therefore,giventhefluidjetpressure,theflowcanbelessenedbyreducingthediameterofthejetnozzletoweakentheinfluenceofgrindingfluidonenvironmentandimprovethegreennessofthegrindingprocess.
CalculationofJetNozzleDiameter
Thefluidfluxthroughthejetnozzleiscalculatedby
whered0isthejetnozzlediameter[mm].CombinedEq.3withEq.4,themaximumdiameterofjetnozzleisgivenby
Forimprovingthefluideffect,doublenozzlesareappliedinquick-pointgrindingprocess(Fig.3).Giventhefluidflux,themaximumdiameteroftheprimaryandsecondaryjetnozzleiscalculatedby
Inquick-pointgrindingprocess,providedthatthelocalareanearthecontactpointwasconsideredonlyandthecurvatureeffectofthecontactarcontheworkpiecewasomitted,therealcontactlengthmaybelessthan0.5mm[6],thereforethelargerGcanbeselectedduetothebettercoolingconditions.
ExperimentforEffectofGrindingFluidonSurfaceIntegrity
ExperimentConditions.TheexperimentconditionsareshowninTable2.
ThegrindingwheelandfluidsystemareshowninFig.4andgroundworkpieceisshowninFig.5。ThehardnessismeasuredwithTH550RockwellHardnessTesteratthedepth0.1mmfromthesurface.
AnalysisofExperimentResults.Giventhefluidjetpressure2MPa,thegroundsurfaceroughnesspresentsadeclinetrendappreciablywithincreaseoffluidflowattherangeof0~20L/min,butthedeclineextentisveryless.Sothegrindingfluidfluxisnotamainfactortoinfluencethesurfaceroughnessundercertainfluidjetpressure.Giventhefluidjetpressure2MPa,thegroundsurfacehardnesspresentsadeclinetrendappreciablywithdecreaseofthefluidfluxattherangeof0~20L/min.Especiallyindrygrinding,thesurfacehardnessdropsobservably,whichshowsthatthethermaldamageisgeneratedatacertainextent.Consequently,althoughthedrygrindingcanbeappliedinquick-pointgrindingprocesssometimeforhighgreenness,itisnecessarytodesignthepropergrindingfluidsupplyparametersagainstthethermaldamagesingrindingsomequenchedsteels.
Conclusions
(1)Inhighandsuper-highgrindingspeedprocess,thereistheairflowlayerwithhighrotaryspeedaroundthecircleedgeofgrindingwheelthathindersthegrindingfluidintocontactlayer.Thepressureoftheairflowlayerincreaseswithraiseoftherotaryspeedofgrindingwheel.Therearethesharperspeedgradsintheairflowlayeralongtheradialdirectionofthewheel.
(2)Thelesscontactareainquick-pointgrindingmakesthegrindingheatandforcelowerobservably,andthecoolingperformanceandthegrindingfluideffectincrease.DuetothethinCBNwheelused,theairflowbarriereffectisweakened.Therefore,itispossibletolowerthefluidsupplyparametersinquick-pointgrindingprocessforweakeningtheinfluenceofgrindingfluidonenvironmentandimprovingthegreennessofthegrindingprocess.
(3)Thegrindingfluidflowisnotmainfactortoaffectthesurfaceroughnessundercertainfluidjetpressure.Althoughthedrygrindingcanbeappliedinquick-pointgrindingprocessforhighgreenness,itisnecessarytodesignthepropergrindingfluidparametersagainstthethermaldamagesingrindingsomequenchedsteels.
Acknowledgments
ThisresearchwasfinanciallysupportedbytheScienceandTechnologyFoundationofLiaoningProvinceofChinaundergrantedNo.20072030andtheNationalNaturalScienceFoundationofChinaundergrantedNo.50775032.
References
[1]E.Brinksmeier,M.Heinzel.AnnalsoftheCIRP,1999,Vol.2:48(1999),p.581-598
[2]M.T.Tan:MicrocosmicInvestigationonMetalCutting(ShanghaiScienceandTechnologyPress,China1988)
[3]G.L.Song:BasicStudyonSuper-highSpeedGrindingTechnology.(Ph.D.NortheasternUniversity,Shenyang,1997)
[4]S.C.Chen,Q.R.Ye:PrincipleofPlasticityProcessforMetal.(TsinghuaUniversityPress,Beijing,1991)
[5]J.X.Ren,andD.A.Hua:GrindingPrinciple.(NorthwestTechnicalUniversityPress,Xian,1988),p.234-238
[6]S.C.Xiu,G.Q.CaiandY.D.Gong.DiamondandAbrasivesEngineering,No.4(2005),p.33-35
GrindingatVeryLowSpeed
Abstract.
Grindingisaverycomplexmachiningprocess.Singlegraingrindingmethodsareusefultostudycomplexgrindingaction.Verylowspeedsingle-graingrindingtestswerecarriedoutfor45steeland20Cralloywith14#ZAgrain.Thegrindinggroovewidthanddepth,thegrindingforceratio,specificgrindingforces,andgrainwearandfracturearestudied.Theplowingdecreaseswiththegrindingsectionareaorgrindingdepthincrease.Theaveragetangentialforceatgrainfractureintheexperimentsis54.4N;theaveragenormalforceatgrainfractureis949.6N.Theratiooftangential-to-normalforcevariessuddenlywhengrainfracture.
Introduction
Grindingisamachiningprocesswhichutilizesagrindingwheelconsistingofabrasivegrains.Itisaverycomplexprocesswithmanyvariations.Inscientificresearch,complexphenomenaareusuallyabstractedtosimplemodels.Thesinglegraingrindingisanimportantmethodtostudycomplexgrindingaction[1-6].Singlegraingrindingexperimentsareusefulbecausewiththeapplicationofalargeload,theextentofdamagecanbeamplifiedforinterpretationwhileunaffectedbyinteractions
withthedamageinsurroundinglocationsundergoingsimilarprocesses.Themethodprovidesthemostdetailedpictureofthecross-sectionalshapeofagrindingpoint.Manyscholars,studiedthegrainwearandcrash,thechipformationandthegrindingforceswithanidealshapeofgrain,andobtainedsomeusefulconclusions.Inthispaper,singlegraingrindingtestsfor45carbonsteeland20Cralloywith14#ZAgrain(aluminumoxide,10~15%ZrO2)havebeenconducted.Grindingforceratio,grainwearandfracturearediscussed.
ExperimentalConditionandProcedure
TheexperimentshavebeendoneonamachinetoolinNortheasternUniversity.Asinglegrainisadheredtoabolt.Theboltisinstalledonthedynamometerdevice.ThedeviceisshowninFig.1.ThetangentialandnormalgrindingforcesaremeasuredbyY82-7piezoelectricitycrystalloidforce-sensor(sensitivedegree:4.08pc/N,intrinsicfrequency:30KHZ)andFDH-2Telectricityamplifier.ThesignalisoutputtoCS2092dynamictestinginstrumenttonoteanddealwiththedataafteramplified.Inordertoreducenoiseandimproveaccuracy,thesensorsareprestressed.Thedynamometercanbeinbetterconditionbecauseoftheforceprestressed.Thecalibrationisdoneafterthedynamometerdeviceisfixed.
Thegrainusedintheexperimentsis14#ZAAluminumOxide(10~15%ZrO2).Thematerialsofworkis45steel(HVhardness,222kg/mm2)and20Cralloy(HVhardness,162kg/mm2).TheexperimentalconditionsofsinglegraingrindingisshowninTable1.Theexperimentswerecarriedoutinatmosphericconditionofroomtemperature20℃;relativehumidity,40-60%.
Fig.1Configurationofsinglegraingrindingtest
Table1Conditionsoftest
ResultsandDiscussion
GrindingGrooveMorphology.ThegroovecrosssectionisshowninFig.2.wisgroovewidth,anddgroovedepth.TherelationshipsbetweengroovewidthanddepthunderdifferentconditionsareshowninFig.3.Thoserelationsreflectconditionsofgrainscuttingbladeandelasticcomebackofgroove.
Fig.2Crosssectionofgrindinggroove
ForceRatioε.Forceratiocanbedefinedasε=Ft/Fn,whereFtistangentialforce,Fnnormalforce.Forceratioεisveryusefultostudythefrictionbetweengrainandwork,toevaluategraincuttingconditions.Forsharpgrains,tangentialforceFtismainlyusedtoformchips,Forceratioεislargerthanthatforbluntgrain.TherelationshipbetweenforceratioεandgroovecrosssectionareaisshowninFig.4.AsshowninFig.4,forceratioεincreasewithgroovecrosssectionarea.Thisdemonstratesthattheplowingdecreaseswithgrindingsectionareaincrease.Itindicatesthattheslidingdecreaseswiththegrindingsectionareaorgrindingdepthincrease.
Fig.3Schemeofthegrindwidthversusthegrinddepthofgrooves
Fig.4Relationbetweenratiooftangential-to-normalforceandgroovesectionarea
SpecificGrindingForce.Specificgrindingforcedefiniteasσ’=Fgt/A.Specificgrindingforceσ’mayreflectcharacteristicofworkmaterialandgraintartnessdegree.Specificgrindingforcehasthesimilarphysicsmeaningandthesamedimensionwithspecificenergy.Thespecificmeltingenergyofsteelsis10.35J/mm3.Thespecificforceforsinglegraingrinding45carbonsteeland20Cralloyisabout12×103N/mm2atv=2.8cm/swiththecrosssectionareaofundeformedchipincrease.Thatvalueishigherthanthespecificmeltingenergyofsteels.
FractureofGrain.Theactualcuttingpointsonabrasivegrainsatwheelsurfacearemicro-cuttingtoolswhichinteractwiththeworkmaterial.Thegrainfracturecanproducenewabradeonthegrain.Thatisthefoundationofthecharacteristicofwheelself-sharpen.Theratiooftangential-to-normalforceεvariesalongthegroovei
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