Objective
Preparation
Run
Evaluate
Record
Publish
Objective
First, be clear what you or others want to achieve. Some objectives may be in conflict with each other, such as aiming for
higher removal rates while, at the same time, trying to achieve better process stability. Some of the objectives may be:
1.
2.
3.
4.
5.
Preparation
If the task is an existing process, make yourself familiar with the key issues and record them. These include:
1. Material removal rate Qw or Q-prime (remember Qw = (vw x ae)/60 = (feed-rate vw in mm/min x depth of cut ae in mm,
divided by 60)
2. Wheel speed vc
3. Feed-rate vw
4. Total amount of grinding allowance and depth of cut ae and number of cuts
5. Check nozzles for damage, establish and record nozzle position
6. Measure coolant temperature (morning and evening) and check flow rates
7. Dressing parameters such as speed ratio qs, infeed, synchronous or asynchronous dress
8. Check Amp meter during grinding cycle. Record highest reading during roughing
9. Check air grinding time and length of overrun. Remember: actual grinding time is often only 20 to 30% of total cycle
time. Gains in cycle time reduction can often be achieved by reducing air grinding rather than by increasing feed-rates.
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Run
If using a vitrified bonded wheel, prior to mounting the wheel, ring it! Use plastic blotters between metal flange and vitrified
grinding wheel. Tighten the flange screws with a torque wrench. Unless any other torque values are given, use 20 footpounds or about 30 Nm for induced porosity wheels. Superabrasive wheels with metal bodies do not require plastic flanges
nor torque wrenches.
If you feel the existing parameters for a given wheel are reasonable, repeat those parameters with a new wheel specification
and compare results.
Lets assume you are running a vitrified wheel test and you have just a few hours available for the test, consider turning
down the diameter of the test wheel, halfway between new wheel and the stub wheel diameter. Often, a new wheel gives
excellent results while the performance diminishes as the diameter gets smaller. Remember 100 mm in diameter equals
314 mm in wheel circumference and hence much fewer abrasive grits have to share the same workload.
Dressing Parameters
Lets assume that you are confronted with a new grinding task for which there is no historical data. If the process allows
dressing the wheels on the machine with rotary diamond rolls, start with synchronous dressing, setting the speed ratio qd at
0.8, with a diamond roll infeed ad of 0.5 m to 1 m per revolution for conventional abrasives. If using CBN, reduce to infeed
per revolution to 0.2 m. The NaxosForce bond family also offers dressable diamond wheels.
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Grinding Parameters
To establish the feed-rate vw, use the specific material rate Qw (Q-prime) given in volume of material removed (mm3) per
mm wheel width per second (mm3/mm/sec): Qw = (feed-rate vw x depth of cut ae) / 60. The following values may help as a
starting point
Creep-feed grinding hardened steel: 5 to 10 mm/mm/s
Creep-feed-grinding aerospace nickel alloys: 10 to 20 mm3/mm/s
Flute grinding of taps with resin bonded wheels: 10 to 20 mm3/mm/s
Flute grinding solid carbide mills: 6 to 12 mm3/mm/s
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These values depend on the stiffness of the machine tool, the fixturing of the workpiece, the hardness and the
microstructure of the material to be ground.
If possible, work in down-grinding mode as it generates lower forces that, in turn, reduce the risk of burning and flexing of
the workpiece. Depending on the grinding task, the number of passes should be kept as low as possible. To reduce cycle
time, it is better to reduce the number of passes than to increase feed-rates. However, if cycle time reduction is aimed for
and one must choose between increasing the depth of cut or the feed-rate, it is better to increase the feed-rate as this
makes the grinding wheel more aggressive and more free-cutting.
Evaluate
Before making too many changes to any given process, run it for a while, ideally through the full life of one grinding wheel if
you are working with conventional abrasives.
Also, remember, good engineering is to change only one parameter at a time, observe changes, evaluate and only then
make further adjustments.
Measure components for dimensional accuracy, burr formation and grinding abuse (burning). Given that you have knocked
out any unnecessary passes, to further shorten cycle time increase the feed-rate. To reduce wheel consumption, reduce
dress infeeds. For example, in continuous dress creep-feed reduce the infeed per revolution from 0.8 micron to 0.6
micron/rev. Ideally, push the wheel to breakdown or to burning. For this purpose, particularly burning, you may require some
reject components.
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Record
Create your own spreadsheet, listing all the main parameters for each of the passes that are needed to grind a component.
The parameters that need be recorded:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Wheel speed vc
Depth of cut ad
Feed-rate vw
Material rate Qw
Average chip thickness hm
Aggressiveness of grinding wheel Fa
Dress ratio qd and amount of dress ad
Amp load in %
Cycle time: tc
Publish
Share your results with your colleagues and build a database that will give you faster results next time you have to run a
similar test.
By using a systematic approach as outlined, we can increase process stability and economics and will ensure that the full
potential of modern grinding wheels is fully utilised.
Qw (Q-prime):
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Article supplied by Walter Graf, Chief Marketing Officer, Winterthur Technology Group 2011
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