Effects of various helically angled grinding wheels on the surface roughness and roundness in grinding cylindrical surfaces

Creating textures on abrasive wheels is a strategy that allows a significant improvement in grinding operations. The reduction of the internal stresses in the workpiece and the temperature during the grinding operation generates an increase in the dimensional accuracy of the workpiece and a longer tool life. Textured abrasive wheels can be produced in many different ways. Depending on the processing method, the dimensional accuracy of the tool and its applicability is changed. Some methods can produce tools with three-dimensional grooves; there are also methods that are employed for the re-texturing of grooves after the grooved zone wears out. In the literature, the benefits of textured grinding wheels over traditional wheels have been extensively discussed. However, information on the particularities of texturing methods is still lacking. To clarify the advantages, limitations, and main advances regarding each of the groove production methods, the authors of this article carried out a systematic review. The objective of this work is to establish the factors that are affected by groove production methods and the technological advances in this area. The benefits and drawbacks of various grooving techniques are then reviewed, and potential study areas are indicated.

show abstract

“…Gavas et al, (2015) [35] The influence of different helically angled grinding wheels on surface roughness and roundness in diverse workpieces.…”

Section: Mohamed Et Al (2014) [34]mentioning

confidence: 99%

Texturing Methods of Abrasive Grinding Wheels: A Systematic Review

et al. 2022

View full text Add to dashboard Cite

show abstract

“…They all produced a variety of texture geometries on abrasive tool surface, such as white noise texture, triangular wave texture, linear texture, and cross linear texture. Moreover, Gavas et al [29] provided more in-depth understanding of the effects of texture geometry on the grinding performances. The SAT with helical grooves having the angles of 30° resulted in the high machined surface quality and geometrical accuracy for low-hardness metals such as AISI 1040, while 45° for high-hardness steel such as AISI 52100.…”

Section: Introductionmentioning

confidence: 99%

On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model

Wang

Liu

Zhao

et al. 2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Structured Abrasive Tools (SATs) are considered as one of the nextgeneration abrasive tool solutions due to their superior ability to transport cutting fluids into grinding zones to lower grinding temperature and therefore enable high-quality machined surfaces. There are several SAT fabrication methods including mechanical, electroplating, brazing and laser-based methods.Mechanical methods can not produce SATs with small-sized structures due to significant contact forces, while electroplating has poor controllability of abrasive grain allocations. Brazing requires special machines with high-precision motion control while laser-based methods need significant efforts on laser parameter selection and optimisation. With this, here we present a Multiple-Pass Rotary Wire Electrical Discharge Machining (MPRWEDM) method to address the aforementioned limitations. We also develop a theorical model of the created kerf profile during the MPRWEDM so as to enable controllable fabrication of SATs.The model was experimentally validated, showing a decent relative error of Page 2 of 39 9.8%. The non-linear multiple-pass effect was studied both analytically and experimentally. Based on MPRWEDM, not only the SAT with designed grooves but also the structured surface (having an array of pyramid geometries) generated by the SAT were successfully created, proving the great potential of MPRWEDM in controllable production of even more advanced tools.

show abstract

“…Grooved wheels were found to generate lower grinding forces and improved surface roughness for a specific speed ratio [28,29]. A helically grooved wheel was reported to increase the performance of the flat grinding process by lowering spindle power and forces .The findings show that utilizing a helically grooved wheel reduces roundness error and surface roughness, improving the quality of machined components [30]. The performance study of non-grooved and grooved wheels was compared in a wear study.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the effect of wheel grooves on surface grinding performance in EN18 Steel

Jeyakumar,

Krishnamoorthy

2023

Preprint

View full text Add to dashboard Cite

The grooved grinding wheels are utilized to enhance the coolant supply to the grinding zone and reduce the heat throughout grinding, thus making the grinding performance more efficient. In the present study, Al2O3 grinding wheels of axial, circumferential and helical grooved wheels were used to grind the EN18 steel. The input parameters chosen for experiments were types of grooved grinding wheels, depth of cut with three different coolant techniques (Dry, Flood and MQL) and experiments were conducted as per L9 Taguchi orthogonal matrix. Output parameters measured for each experiment were grinding ratio (GR), material removal rate (MRR), grinding efficiency (GE), surface roughness (Ra), specific energy (SE), temperature and noise during surface grinding. The grinding performance of non-grooved grinding wheels was compared with a grooved wheel. The results showed that using grooved grinding wheels increases all the grinding performances when compared to the non-grooved grinding wheel. The helical grooved wheel with MQL combinations reduced the temperature, sound, surface roughness and specific energy from 35.8 to 32.1 °C, 86.9 to 80.7 dB, 1.584 to 0.258 µm and 0.173 to 0.054 kJ/mm2 respectively. At the same time, the MRR, HRC, GR and GE were improved using grooved grinding wheels along with MQL from 0.432 to 1.37 mm3/s, 58.5 to 61.5 HRC, 1.77 to 4.567 and 10.26 to 43.9% respectively. Finally, the optimum grinding parameter combination was identified from a helical grooved wheel in all grinding performances. Finally, the performance of the helical grooved wheel was compared with non-grooved wheels. SEM images were taken to understand the surface finish and defects on the ground surfaces for the different wheels with coolants.

show abstract

Effects of various helically angled grinding wheels on the surface roughness and roundness in grinding cylindrical surfaces

Cited by 4 publications

References 17 publications

Texturing Methods of Abrasive Grinding Wheels: A Systematic Review

Texturing Methods of Abrasive Grinding Wheels: A Systematic Review

On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model

Investigation of the effect of wheel grooves on surface grinding performance in EN18 Steel

Contact Info

Product

Resources

About