Abstract:In order to lower temperature, abrasive tools with passive-grinding, e.g. textured, areas (PGA) have been suggested. However, most of the reported PGA geometries (e.g. slots, holes) have been determined based on the engineering intuition (i.e. trial and error) rather than in-depth phenomenological analysis. To fill this gap, this paper proposes a method to design the PGA geometry according to the desired temperature, i.e. the inverse design method. In the method, the analytical model of grinding temperature fo… Show more
“…As shown in Figure 2 a, a thermocouple was inserted into the narrow slot on the workpiece to measure the grinding temperature. This method was generally used to record temperature variation with good accuracy [ 14 , 15 ]. The thermocouple sensing tips were located close to the grinding surface, and the narrow slots were sealed with waterproof and heat-resistant glue, which could prevent the cooling liquid from affecting the measurement results.…”
Section: Experimental Setup and Proceduresmentioning
Grinding burn is an undesired defect in gear machining, and a white layer is an indication of severe burn that is detrimental to gear surface performance. In this work, the influence of grinding parameters on the thickness of the white layer during form grinding of quenched transmission gear was investigated, and the microstructure evolution and mechanism of severe burn formation were analyzed. The grinding temperature increased with the grinding depth and grinding speed, with the highest level of ~290 °C. The thickness of the white layer exceeded 100 μm when the grinding depth was 0.03 mm, and the top layer was a plastic deformation layer followed by a fine-grained martensite layer. Coarse-grained acicular martensite was found at the interface between the white layer and softened dark layer. The mechanical effect and thermal softening mainly contributed to the formation of white layer stratification. The ground surface topography showed several scratches and typical grooves; when grinding depth increased to 0.03 mm, the grinding surface roughness Sa was relatively high and reached up to ~0.60 μm, mainly owing to severe plastic deformation under grinding wheel extrusion and the thermal effect.
“…As shown in Figure 2 a, a thermocouple was inserted into the narrow slot on the workpiece to measure the grinding temperature. This method was generally used to record temperature variation with good accuracy [ 14 , 15 ]. The thermocouple sensing tips were located close to the grinding surface, and the narrow slots were sealed with waterproof and heat-resistant glue, which could prevent the cooling liquid from affecting the measurement results.…”
Section: Experimental Setup and Proceduresmentioning
Grinding burn is an undesired defect in gear machining, and a white layer is an indication of severe burn that is detrimental to gear surface performance. In this work, the influence of grinding parameters on the thickness of the white layer during form grinding of quenched transmission gear was investigated, and the microstructure evolution and mechanism of severe burn formation were analyzed. The grinding temperature increased with the grinding depth and grinding speed, with the highest level of ~290 °C. The thickness of the white layer exceeded 100 μm when the grinding depth was 0.03 mm, and the top layer was a plastic deformation layer followed by a fine-grained martensite layer. Coarse-grained acicular martensite was found at the interface between the white layer and softened dark layer. The mechanical effect and thermal softening mainly contributed to the formation of white layer stratification. The ground surface topography showed several scratches and typical grooves; when grinding depth increased to 0.03 mm, the grinding surface roughness Sa was relatively high and reached up to ~0.60 μm, mainly owing to severe plastic deformation under grinding wheel extrusion and the thermal effect.
“…The simulation and experimental results were compared, and it was concluded that different design parameters of the wheel affect the ground components at different rates. Figure 18. Comparison of conventional, segmented and textured grinding wheels. 166 …”
Grinding is a manufacturing process which significantly contributes in producing high precision and durable components required in numerous applications such as aerospace, defence and automobiles. This review article is focused to uncover history, witness the present and predict the future of the grinding process. While going through the literature, it has been observed that minimal work has been done in explaining the history, present status and future scopes of the grinding process. In this era of information and environmental awareness, sustainability aspects have become a primary concern of almost every research field. In the grinding process too, the research work includes ecological elements such as reducing the consumption of cutting fluids through minimum quantity lubrication, utilizing cryogenics, hybrid lubrication and cooling techniques that are still required to be explored critically. Further, some significant findings of the prevailing research in grinding include modification in grinding wheel surface, merging different grinding principles such as usages of the textured grinding wheel, ultrasonic grinding, 3D printing of grinding wheel and artificial intelligence in grinding are also presented. Another unascertained problem is the management of grinding swarf, which is being attended to by recycling it to fabricate composites which is expected to be another prominent domain of research. Further, the advancements taking place exhibit the potential of the grinding process, suggesting that its future is bright and ever-growing.
“…The results of theoretical and experimental studies of thermal processes during intermittent gear grinding should be considered as scientific prerequisites for solving this problem [1,2]. On their basis, practical recommendations were developed for determining the geometric characteristics of intermittent abrasive wheels and the parameters of grinding modes according to the temperature criterion [3,4]. Works [5,6] also provided practical recommendations for selecting the parameters of gear grinding modes under various processing conditions.…”
The aim of this work is to develop a mathematical model of the gear grinding process using the method of high-performance profile copying and determine the optimal parameters of grinding modes according to the temperature criterion. It is shown that in order to ensure defect-free machining of gears under deep grinding conditions, it is necessary to significantly reduce the rate of the feed speed of the grinding wheel along the tooth of the gear wheel. For a grinding depth of 0.4 mm, it should be equal to 2.27 m/min. In this case, the machining productivity can be increased up to 5 times with the simultaneous elimination of the formation of sticking, microcracks and other temperature defects on the machined gear surfaces. This processing effect is achieved by using a modern HOFLER RAPID 1250 gear grinding machine and highly porous abrasive wheels, which are characterized by high cutting capacity. Thanks to the improved quality of gear processing, the quality and performance of manufactured mine conveyor drives (planetary gearboxes with a power of more than 200 kW) have been improved, and the number of repairs required in harsh mine conditions has been significantly reduced.
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