Quick Stop Device to Analyze the Chip Formation Mechanisms in Face Grinding

Göttsching, T.; Wippermann, Andi; Grove, Thilo

doi:10.4028/www.scientific.net/amr.1140.221

Cited by 4 publications

(5 citation statements)

References 8 publications

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“…This enables the interruption of grinding process with cutting speeds of up to 50 m/s. This means an increase of 43% of the cutting speed which can be interrupted with this device, compared with previously used devices [44,45,49,50].…”

Section: Quick-stop Devicementioning

confidence: 84%

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Grinding of transformation-toughened mixed oxide ceramic

Denkena

Krödel

Wippermann

et al. 2020

Int J Adv Manuf Technol

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During the manufacturing of ceramic components, grinding is an important manufacturing step. It influences the workpiece quality and the operational reliability. Thermomechanical loads during grinding can influence the lifetime and operational reliability of ceramics by modifying their bending strength and subsurface properties. Therefore, it is necessary to consider the influence of the grinding forces and mechanical loads on the strength of the ceramics in order to design a suitable grinding process. In this investigation, a quick-stop device is used to interrupt the grinding process of the newly developed mixed oxide ceramic SHYTZ (strontium hexaaluminate/yttria-toughened zirconia) and the market-established ceramic ATZ (alumina-toughened zirconia). Subsequently, an analysis of the occurring material removal phenomena, the number of active abrasive grains, and the real thermomechanical loads is carried out. It was found that the number of active grains and the material removal phenomena are influenced by the tool specifications. Besides that, the experimentally determined number of active grains was found to be up to 14 times higher than predicted by an analytical model given in literature. Consequently, the calculated single grain chip thickness was found to be up to 12.1% lower than analytically predicted. The investigation of the process forces and thermal loads showed up to 52% higher loads for ATZ than for SHYTZ. The subsequent analysis of the resulting bending strength of the ceramics revealed a lower influence of the grinding process on the strength of SHYTZ than for ATZ. Furthermore, a correlation between the used tool bonding and the resulting thermomechanical loads, bending strength, and residual stresses could be observed.

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Section: Quick-stop Devicementioning

confidence: 84%

“…However, no systematic studies were carried out [48]. Recently developed quick-stop devices enable a reliable interruption of the grinding processes with cutting speeds of up to 35 m/s [44,45,49,50].…”

Section: State Of the Artmentioning

confidence: 99%

Grinding of transformation-toughened mixed oxide ceramic

Denkena

Krödel

Wippermann

et al. 2020

Int J Adv Manuf Technol

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“…Therefore the quick stop device needs to accelerate the samples above the speed of the grinding wheel v c , which ranges from about 15 m/s up to 35 m/s for conventional grinding wheels. Calculation and high speed measurements of the acceleration velocity showed that a captive bolt pistol supplies enough energy to properly interrupt a grinding process [19]. The final device was fixed into a Blohm grinding machine and is shown in Fig.…”

Section: 3mentioning

confidence: 99%

Material removal and chip formation mechanisms of UHC-steel during grinding

Denkena

Grove

Göttsching

2017

Int J Adv Manuf Technol

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The grinding process is still an important manufacturing process for the machining of automotive components. For power train components UHC-steel is a promising new innovative alloy because of its low specific density. Results from turning of UHC-steel showed that the texture of UHC-steel significantly differs from conventional steels. Furthermore extremely hard carbides, which are embedded into a soft ferrite matrix result in a UHC-steel specific machining behavior and a high tool wear rate. Therefore UHC-steel is marked as a difficult to cut material. So far there are no research results available for the grinding of UHC-steel. Therefore fundamental investigations were conducted in order to analyze the material removal and chip formation mechanisms. Scratching tests with a geometrically defined CBN cutting edge showed ductile material removal mechanisms for a single grain chip thickness variation from h cu = 1,5 µm up to 14 µm. Analysis of the contact zone by means of an innovative quick stop device confirm these results.

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“…In the same context and to obtain the chip attached to the workpiece for the investigation of chip formation processes in various machine tools, many other QSDs have been invented and employed by other researchers for various types of machining operations. For instance, in shaping, an electromagnetic QSD was fabricated by Wu et al 20 Griffiths 21 invented a QSD for deep drilling, however, in grinding readers are referred to the research works of G€ ottsching et al 22 and Ghosh et al 23 Readers are referred also to other more recent research works dealing with designing and manufacturing of new QSDs and the study of chip formation for various workpiece materials. For instance, Computer Aided Quick Stop Device (CAQSD) employing a servo motor is developed by Ozturk et al 24 for the study of dead metal zone formation in brass workpiece material.…”

Section: Introductionmentioning

confidence: 99%

“…20 Griffiths 21 invented a QSD for deep drilling, however, in grinding readers are referred to the research works of Göttsching et al. 22 and Ghosh et al. 23…”

Section: Introductionmentioning

confidence: 99%

A new quick-stop device to study the chip formation mechanism in metal cutting: Computational and experimental investigation

Mhamdi

Rajhi

Boujelbene

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Understanding the chip formation mechanisms during machining is an important factor to facilitate the choice of cutting tools and machining parameters. Despite the appearance of new sophisticated methods and advanced equipment, the technique so called quick-Stop Test (QST) remains efficient, less costly, and easier to apply in the investigation of chip formation in cutting process. In present paper a new Quick-Stop Device QSD is designed, numerically simulated, implemented, and tested. The reformed QST technique uses a QSD device which operates on the modified Charpy pendulum. Accordingly, design of new QSD is presented and deeply described, and 2D FE modeling of the new QST, including the application of the appropriate boundary conditions, has been carried out. Moreover, chip formation and morphology for different cutting conditions have been effectively simulated. Subsequently, quick stop cutting operations including metal cutting tests of high alloyed tool steel (AISI D2) using fabricated new QSD are performed. Preliminary results of quick-stop experiment from current investigation prove the effectiveness of the new designed QSD in matter of rigidity, safety, and absence of vibration, while providing a fast set up time and allowing extremely short workpiece-cutting tool separation time and guarantee the generation of chip with its root. The photomicrographs of chip root samples gathered from hard metal cutting experiments including various cutting speeds machining conditions, enables clear observation of segmented chip formation mechanisms, thereby, highly promising the new designed QSD for the purpose of investigation of the different cutting parameters influencing the chip formation and morphology.

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Quick Stop Device to Analyze the Chip Formation Mechanisms in Face Grinding

Cited by 4 publications

References 8 publications

Grinding of transformation-toughened mixed oxide ceramic

Grinding of transformation-toughened mixed oxide ceramic

Material removal and chip formation mechanisms of UHC-steel during grinding

A new quick-stop device to study the chip formation mechanism in metal cutting: Computational and experimental investigation

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