Modeling and simulation of the distribution of undeformed chip thicknesses in surface grinding

Zhang, Yuzhou; Fang, Congfu; Huang, Guoqin; Xu, Xipeng

doi:10.1016/j.ijmachtools.2018.01.002

Cited by 84 publications

(23 citation statements)

References 25 publications

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“…In this paper, the undeformed chip thickness is investigated based on the interference depth of the AAG tip penetration into the workpiece. And the interference depth of AAG sliding or plowing on the workpiece surface is regarded as undeformed chip thickness which is also argued by Zhang et al [10]. It is manifested clearly in Fig.1 (e-f) that the interference depth is strongly influenced by AAG protruding height and the grinding depth.…”

Section: The Shape Size and Distribution Of Chipsmentioning

confidence: 57%

“…To account for this, the Rayleigh probability function [8], [9] is presented to describe the stochastic interference depth of grains which is equal to the undeformed chip thickness, f (h) = (h/σ 2 )e −h 2 2σ 2 h ≥ 0 0 h < 0 (4) with an expected value and the variance expressed as E(h) = π 2σ (5) sd(h) = √ 0.429σ (6) where h is the undeformed chip thickness and σ is the parameter defining this function. The Rayleigh distribution touches upon strong assumptions and σ has no clear physical meaning [10]. To further conform to the real situation of abrasive grains distribution, the Monte Carlo method [11] and the vibration method [12] are utilized to randomly generate the diameter and distributed position of the grain.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of the Distribution of Undeformed Chip Thickness Based on the Real Interference Depth of the Active Abrasive Grain

2020

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Distribution of the maximum undeformed chip thickness can be approximated as the reproduction of grooves and protrusions of the grinding surface. It plays a very important role in grinding process as it has a close influence on the prediction and modeling of grinding forces, tool life, and surface quality, as well as process stability. In this study, it is investigated from the perspective of the real interference depth of the active abrasive grain to cater to the performance evaluation of the grinding surface. Firstly, image processing techniques combined with three dimensional topography tests are utilized to extract grains' essential characteristics such as the protrusion height, shape, distribution and density. Then, grains' wear is quantified by the probability assignment function and Dempster-Shafer evidence theory. Based on this, the actual interference depth of a single grain is determined. Through grain's kinematics analysis and considering the effect of contact deformation on the actual contact arc length and affective cutting edge density, the distribution of chip thickness in the current grinding area is defined and its distribution model is established. Model's correctness and rationality are verified by grinding experiments of the slider raceway. Results demonstrate the grain's interference depth highly depends on its protrusion height, wear amount and grinding depth which is a primary contributor to the size of undeformed chip thickness, and grains' density, contact deformations mainly affect its distribution. The quantified distribution model of the maximum undeformed chip thickness lays a foundation for the topography modeling and integrity research of grinding surfaces. INDEX TERMS Abrasive particles wear, active cutting edges, grinding, image processing, interference depth, protrusion height, undeformed chip thickness.

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Section: The Shape Size and Distribution Of Chipsmentioning

confidence: 57%

Section: Introductionmentioning

confidence: 99%

Modeling of the Distribution of Undeformed Chip Thickness Based on the Real Interference Depth of the Active Abrasive Grain

2020

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“…considering that the thickness of the undeformed chips in the grinding zone is not uniform, but increases gradually from zero to maximum along the contact arc length. The triangular heat source model was found to fit the measured temperature responses more accurately in many previous studies [32], and so the heat source was considered to have a triangular distribution in the present work. Considering the periodic variation of the heat source with time caused by the intermittent feed, the periodic moving heat source model with a triangular distribution at the grinding zone can be described as [14]…”

Section: Heat Source Modelmentioning

confidence: 90%

Experimental Study and Numerical Simulation of the Intermittent Feed High-Speed Grinding of TC4 Titanium Alloy

Jiao

Zhou

Deng

2019

Metals

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This paper proposes intermittent feed high-speed grinding, which shows considerable advantages in terms of reducing grinding temperature, relieving grinding wheel blockage and improving workpiece surface integrity. In this grinding, the continuous feed mode of the workpiece is changed into the normal feed + fast retreat reciprocating feed mode by a fast linear feed worktable. By reasonably setting the normal feed distance of single grinding, the action time of the grinding wheel and workpiece is reduced, so that the grinding heat transfer process does not reach a stable state, reducing the grinding temperature during single grinding. Besides this, the surface temperature is cooled to nearly room temperature and the grinding wheel is flushed by the timely retreating of the grinding wheel to allow the grinding fluid to enter the grinding zone fully, which greatly reduces the phenomenon of heat accumulation and grinding wheel loading. An intermittent feed high-speed grinding experiment on Ti-6Al-4V (TC4) titanium alloy was systematically carried out, and the influence of the grinding parameters on grinding force and grinding temperature was deeply analyzed. The instantaneous grinding temperature field and thermal stress field of TC4 titanium alloy in intermittent feed high-speed grinding were constructed with the finite element method. The surface morphology of the grinding wheel and TC4 titanium alloy specimens after intermittent feed grinding were analyzed and were compared with those after traditional continuous grinding. It was found that the curves of the grinding force and temperature varied with time in the process of machining, consisting of many “pulse” peaks. Under the same grinding parameters, the magnitude of the grinding force is the same as that of continuous grinding. In a certain range, the grinding temperature is greatly affected by the single feed distance and the interval time. The numerical simulation results are in good agreement with the experimental results, and the error is controlled within 12%. Compared with traditional high-speed grinding, under the same process parameters, the grinding temperature is greatly reduced, the surface integrity of the workpiece is better, and the clogging of the grinding wheel is greatly reduced.

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“…The most recent research investigations into modelling the grinding process have usually been based on numerical methods because these have a greater capacity to represent reality in comparison with analytical approaches. In this case, these methods are not only focused on thermal issues [23,24], but also on the characterization of material removal mechanisms [25,26], dressing process performance [27] or methods to advance wheel surface modelling [28]. Doman et al [29] conducted a complete review of the most recent advances in grinding modelling.…”

Section: Process Modellingmentioning

confidence: 99%

Expectations and limitations of Cyber-Physical Systems (CPS) for Advanced Manufacturing: A View from the Grinding Industry

et al. 2020

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Grinding is a critical technology in the manufacturing of high added-value precision parts, accounting for approximately 20–25% of all machining costs in the industrialized world. It is a commonly used process in the finishing of parts in numerous key industrial sectors such as transport (including the aeronautical, automotive and railway industries), and energy or biomedical industries. As in the case of many other manufacturing technologies, grinding relies heavily on the experience and knowledge of the operatives. For this reason, considerable efforts have been devoted to generating a systematic and sustainable approach that reduces and eventually eliminates costly trial-and-error strategies. The main contribution of this work is that, for the first time, a complete digital twin (DT) for the grinding industry is presented. The required flow of information between numerical simulations, advanced mechanical testing and industrial practice has been defined, thus producing a virtual mirror of the real process. The structure of the DT comprises four layers, which integrate: (1) scientific knowledge of the process (advanced process modeling and numerical simulation); (2) characterization of materials through specialized mechanical testing; (3) advanced sensing techniques, to provide feedback for process models; and (4) knowledge integration in a configurable open-source industrial tool. To this end, intensive collaboration between all the involved agents (from university to industry) is essential. One of the most remarkable results is the development of new and more realistic models for predicting wheel wear, which currently can only be known in industry through costly trial-and-error strategies. Also, current work is focused on the development of an intelligent grinding wheel, which will provide on-line information about process variables such as temperature and forces. This is a critical issue in the advance towards a zero-defect grinding process.

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Modeling and simulation of the distribution of undeformed chip thicknesses in surface grinding

Cited by 84 publications

References 25 publications

Modeling of the Distribution of Undeformed Chip Thickness Based on the Real Interference Depth of the Active Abrasive Grain

Modeling of the Distribution of Undeformed Chip Thickness Based on the Real Interference Depth of the Active Abrasive Grain

Experimental Study and Numerical Simulation of the Intermittent Feed High-Speed Grinding of TC4 Titanium Alloy

Expectations and limitations of Cyber-Physical Systems (CPS) for Advanced Manufacturing: A View from the Grinding Industry

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