Grinding Energy Modeling Based on Friction, Plowing, and Shearing

Linke, Barbara; Garretson, Ian C.; Torner, François M.; Seewig, Joerg

doi:10.1115/1.4037239

Cited by 26 publications

(13 citation statements)

References 31 publications

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“…6 show that the sliding energy does not participate in the material removal process and is merely a rubbing or friction energy. For this reason, sliding power per unit of cutting area was used by Zhang et al [46] and Linke et al [47]. The highest value of the sliding power per unit cutting area for intermetallic Fe-Al(40%) was due to its brittle nature at normal temperatures.…”

Section: Resultsmentioning

confidence: 99%

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

et al. 2021

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Specific energy consumption is an important indicator for a better understanding of the machinability of materials. The present study aims to estimate the specific energy consumption for abrasive metal cutting with ultra-thin discs at comparatively low and medium feed rates. Using an experimental technique, the cutting power was measured at four predefined feed rates for S235JR, intermetallic Fe-Al(40%), and C45K with different thermal treatments. The variation in the specific energy consumption with the material removal rate was analyzed through an empirical model, which enabled us to distinguish three phenomena of energy dissipation during material removal. The thermal treatment and mechanical properties of materials have a significant impact on the energy consumption pattern, its corresponding components, and cutting power. Ductile materials consume more specific cutting energy than brittle materials. The specific cutting energy is the minimum energy required to remove the material, and plowing energy is found to be the most significant phenomenon of energy dissipation.

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Section: Resultsmentioning

confidence: 99%

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

et al. 2021

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“…Linke et al proposed a simplified distributed grain model, incorporating the three phases of material removal depending on engagement depth [3]. The calculation of energy of each of the three phases was performed based on analytical models and literature studies.…”

Section: Classical Energy Modelsmentioning

confidence: 99%

“…The calculation of energy of each of the three phases was performed based on analytical models and literature studies. The model developed by Linke et al is comparable to other models from the literature, with the advantage of being able to be applied to grinding processes with different kinematics [3]. Due to these two characteristics, simplicity and flexibility to different process kinematics, the model proposed by Linke et al will be further analyzed in the current The first chip formation mechanism refers to the energy required to overcome friction between grain and workpiece.…”

Section: Classical Energy Modelsmentioning

confidence: 99%

“…The generated heat is distributed mainly into four regions: Environment, tool (grinding worm), chip, and workpiece, middle of Figure 1. Depending on the process condition, a fraction of 60-90% of the generated heat can flow into the workpiece [3]. This fraction of generated heat leads to high temperatures in the contact zone, which can cause thermal damages in the workpiece such as metallurgical phase transformations and undesirable residual stress profiles [4,5].…”

Section: Introductionmentioning

confidence: 99%

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Investigation of Mechanical Loads Distribution for the Process of Generating Gear Grinding

Teixeira

Brimmers

Bergs

2021

JMMP

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In grinding, interaction between the workpiece material and rotating abrasive tool generates high thermo-mechanical loads in the contact zone. If these loads reach critically high values, workpiece material properties deteriorate. To prevent the material deterioration, several models for thermomechanical analysis of grinding processes have been developed. In these models, the source of heat flux is usually considered as uniform in the temperature distribution calculation. However, it is known that heat flux in grinding is generated from frictional heating as well as plastic deformation during the interaction between workpiece material and each grain from the tool. To consider these factors in a future coupled thermomechanical model specifically for the process of gear generating grinding, an investigation of the mechanical load distribution during interaction between grain and workpiece material considering the process kinematics is first required. This work aims to investigate the influence of process parameters as well as grain shape on the distribution of the mechanical loads along a single-grain in gear generating grinding. For this investigation, an adaptation of a single-grain energy model considering the chip formation mechanisms is proposed. The grinding energy as well as normal force can be determined either supported by measurements or solely based on prediction models.

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“…During the grinding and polishing process, the interacting force between the tool and surface plays a key role in achieving the surface finish. Generally, this force can be divided into two components, which are tangential force component (F T ) and normal force component (F N ) [21][22][23] as shown in Figure 4a. The direction of the F T is parallel to the direction of the feed and affects the power consumption and tool life, whereas the direction of F N is perpendicular to the surface plane and it has more influence on surface roughness and deformation of the workpiece [21].…”

Section: Force Control In Surface Polishingmentioning

confidence: 99%

Path Planning under Force Control in Robotic Polishing of the Complex Curved Surfaces

Mohsin

et al. 2019

Applied Sciences

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Surface polishing is required in many manufacturing sectors. Currently, it demands a large amount of manual work, which is time-consuming, error-prone, and costly. Additionally, it creates hazards for the workers as it may result in many deadly respiratory diseases. Robotic polishing is the solution to these problems. It can improve productivity, eliminate the defects, and provides consistent product quality. In this paper, an effective approach is presented for the robotic polishing of the complex curved surfaces. The key part of the presented method is the tool path planning with controlled force and polishing parameters optimization evaluated using design of experiments (DOE). The tool path planning is aimed at improving the surface quality and the contact area per path. The constraints of joint limits and productivity are also considered. Moreover, its jerk avoidance strategy allows the robot to move swiftly while ensuring a smooth trajectory. The presented method is verified for the polishing of an eyeglass frame. A considerable improvement of 90% on the average roughness is achieved with the maximum acceptable roughness set at 0.02 µm. The polishing operation takes just 79 secs and the average glossiness of 76 G is achieved on the final product along with the successful elimination of scratches on the surface.

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Grinding Energy Modeling Based on Friction, Plowing, and Shearing

Abstract: A c c e p t e d M a n u s c r i p t N o t C o p y e d i t e d

Cited by 26 publications

References 31 publications

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

Experimental technique to analyze the influence of cutting conditions on specific energy consumption during abrasive metal cutting with thin discs

Investigation of Mechanical Loads Distribution for the Process of Generating Gear Grinding

Path Planning under Force Control in Robotic Polishing of the Complex Curved Surfaces

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