International Journal of Mechatronics and Manufacturing Systems http://www.inderscience.com/browse/index.php?journalID=239&year=2011&vol=4&issue=6 Inderscience Publishers Ltd en-uk International Journal of Mechatronics and Manufacturing Systems 1753-1039 1753-1047 © 2011 Inderscience Publishers Ltd editor@inderscience.com https://www.inderscience.com/images/files/coverImgs/ijmms_scoverijmms.jpg http://www.inderscience.com/browse/index.php?journalID=239&year=2011&vol=4&issue=6 http://www.inderscience.com/link.php?id=44091 Today, CBN grinding wheels are prevalently dressed with form rollers. Hence, the improvement of dressing with form rollers by using new methods is of particular interest. Although ultrasonic assistance has been successfully used for a long time in different machining processes, the ultrasonic assisted dressing with form rollers has not yet been realised for technical and economical reasons. The ultrasonic assisted dressing with form rollers was developed for the first time at the KSF Institute using a special dressing spindle that is introduced in this article. The results obtained through the experimental investigation depict significant improvements with utilising ultrasonic assistance in dressing with form rollers. This is realised when the dressing parameters are properly set. Ultrasonic assisted dressing of CBN grinding wheels with form rollers
Taghi Tawakoli; Abdolreza Rasifard
International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 473 - 486
Today, CBN grinding wheels are prevalently dressed with form rollers. Hence, the improvement of dressing with form rollers by using new methods is of particular interest. Although ultrasonic assistance has been successfully used for a long time in different machining processes, the ultrasonic assisted dressing with form rollers has not yet been realised for technical and economical reasons. The ultrasonic assisted dressing with form rollers was developed for the first time at the KSF Institute using a special dressing spindle that is introduced in this article. The results obtained through the experimental investigation depict significant improvements with utilising ultrasonic assistance in dressing with form rollers. This is realised when the dressing parameters are properly set.

]]> 10.1504/IJMMS.2011.044091 International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 473 - 486 Taghi Tawakoli; Abdolreza Rasifard Institute of Grinding and Precision Technology, KSF, Hochschule Furtwangen University, 78054 Villingen-Schwenningen, Germany. ' Institute of Grinding and Precision Technology, KSF, Hochschule Furtwangen University, 78054 Villingen-Schwenningen, Germany grinding wheel dressing form rollers diamond CBN grinding wheels ultrasonic spindles ultrasonic-assisted dressing. 2011-12-09T23:20:50-05:00 4 6 473 486 2011-12-09T23:20:50-05:00 http://www.inderscience.com/link.php?id=44094 In order to provide solutions to the current challenges and discussions on resource efficiency and energy savings, the manufacturing industry must present saving methods, in particular in energy intensive applications. The grinding technologies, with their high demands on precision and integrity of the boundary layer of components are one such application area which must source new and innovative solutions. Due to the ever increasing complexity of components, such as cooling lubricant systems and arrangements for maintaining temperatures of axes and guideways, the demand on machine tools to reach these high accuracies is constantly rising. In order to make a significant contribution to resource efficiency and energy savings, along with research on tool and process optimisation and innovative machining kinematics, the activities of the IWF focus on the substitution of complex machine tools with robot assisted machining strategies in order to simultaneously achieve high flexibility and productivity. Resource efficient grinding solutions and restrictions
Eckart Uhlmann; Christoph Sammler; Fiona Byrne
International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 487 - 495
In order to provide solutions to the current challenges and discussions on resource efficiency and energy savings, the manufacturing industry must present saving methods, in particular in energy intensive applications. The grinding technologies, with their high demands on precision and integrity of the boundary layer of components are one such application area which must source new and innovative solutions. Due to the ever increasing complexity of components, such as cooling lubricant systems and arrangements for maintaining temperatures of axes and guideways, the demand on machine tools to reach these high accuracies is constantly rising. In order to make a significant contribution to resource efficiency and energy savings, along with research on tool and process optimisation and innovative machining kinematics, the activities of the IWF focus on the substitution of complex machine tools with robot assisted machining strategies in order to simultaneously achieve high flexibility and productivity.

]]> 10.1504/IJMMS.2011.044094 International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 487 - 495 Eckart Uhlmann; Christoph Sammler; Fiona Byrne Department Machine Tools and Manufacturing Technologies, Institute for Machine Tools and Factory Management (IWF), Technische Universität Berlin, Pascalstrasse 8-9, 10587 Berlin, Germany; Fraunhofer Institut für Produktionsanlagen und Konstruktionstechnik, Pascalstrasse 8-9, 10587 Berlin, Germany. ' Institute for Machine Tools and Factory Management (IWF), Technische Universität Berlin, Pascalstrasse 8-9, 10587 Berlin, Germany. ' Institute for Machine Tools and Factory Management (IWF), Technische Universität Berlin, Pascalstrasse 8-9, 10587 Berlin, Germany resource efficiency coolant cooling lubricants speed stroke grinding flexible robots robot machining grooved grinding wheels ceramic diamond grinding wheels energy saving machining kinematics manufacturing flexibility manufacturing productivity. 2011-12-09T23:20:50-05:00 4 6 487 495 2011-12-09T23:20:50-05:00 http://www.inderscience.com/link.php?id=44092 This paper concerns fine grinding with lapping kinematics using a novel machine concept which works with finishing foils instead of grinding wheels. The tool is separated in a way that the cutting grain on the finishing foil can determine the roughness. The pressure plate is responsible for the shape accuracy. A constant foil feed rate bringing unused grains in the cutting zone allows a constant machining behaviour. A dressing of the tool is no longer needed. The machined workpieces show low roughness and good evenness within a short period of time. Studies on the effects of machining parameters such as pressure, cutting speed, foil feed rate and cooling lubricant during finishing of hardened steel 100Cr6 and C45 are presented regarding to surface quality and tool wear. In addition, the influence of filter systems on surface roughness and material removal rate is discussed. The accomplished tests show the functional capabilities and potential of the novel machine concept. Manufacturing high quality surfaces of hardened steels: fine grinding with lapping kinematics using abrasive foil tools
Hans-Werner Hoffmeister; Wiebke-Cathérine Hahmann
International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 496 - 510
This paper concerns fine grinding with lapping kinematics using a novel machine concept which works with finishing foils instead of grinding wheels. The tool is separated in a way that the cutting grain on the finishing foil can determine the roughness. The pressure plate is responsible for the shape accuracy. A constant foil feed rate bringing unused grains in the cutting zone allows a constant machining behaviour. A dressing of the tool is no longer needed. The machined workpieces show low roughness and good evenness within a short period of time. Studies on the effects of machining parameters such as pressure, cutting speed, foil feed rate and cooling lubricant during finishing of hardened steel 100Cr6 and C45 are presented regarding to surface quality and tool wear. In addition, the influence of filter systems on surface roughness and material removal rate is discussed. The accomplished tests show the functional capabilities and potential of the novel machine concept.

]]> 10.1504/IJMMS.2011.044092 International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 496 - 510 Hans-Werner Hoffmeister; Wiebke-Cathérine Hahmann Institut für Werkzeugmaschinen und Fertigungstechnik (IWF) Institute of Machine Tools and Production Technology, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany. ' Institut für Werkzeugmaschinen und Fertigungstechnik (IWF) Institute of Machine Tools and Production Technology, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany surface manufacturing lapping kinematics fine grinding flat honing abrasive foils surface quality hardened steel surface roughness foil feed rate tool wear material removal rate MRR. 2011-12-09T23:20:50-05:00 4 6 496 510 2011-12-09T23:20:50-05:00 http://www.inderscience.com/link.php?id=44090 For a first-time assessment of the local process forces in rotational grinding, a three-component piezo sensor is integrated under a segment of a resin-bond D3 cup grinding wheel. The signals are amplified in the rotating system and telemetrically transferred to an external receiver. Industrially, common spindle speeds of up to 5,000 min<SUP align=“right”> 1</SUP> were achieved by conclusive optimisation of the tool's static-dynamic behaviour. The system can detect even minute force variations in dependence on the process parameters and the relative position of the cutting speed to the crystal main axes. 200 mm (100)-oriented Si wafers are used due to its importance for IC fabrication. The normal and tangential forces increase with an increase in feed rate and radius and decrease with cutting speed. A direction dependence of the process forces can be determined, with force maxima and minima occurring for cutting directions parallel to <110> and <100>, respectively. Areas with high and low process forces coincide well with the areas of high and low subsurface damage (SSD) depths, respectively. Measurement of local contact zone forces in rotational grinding of silicon wafers
Dietmar Pähler
International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 511 - 539
For a first-time assessment of the local process forces in rotational grinding, a three-component piezo sensor is integrated under a segment of a resin-bond D3 cup grinding wheel. The signals are amplified in the rotating system and telemetrically transferred to an external receiver. Industrially, common spindle speeds of up to 5,000 min<SUP align=“right”> 1</SUP> were achieved by conclusive optimisation of the tool's static-dynamic behaviour. The system can detect even minute force variations in dependence on the process parameters and the relative position of the cutting speed to the crystal main axes. 200 mm (100)-oriented Si wafers are used due to its importance for IC fabrication. The normal and tangential forces increase with an increase in feed rate and radius and decrease with cutting speed. A direction dependence of the process forces can be determined, with force maxima and minima occurring for cutting directions parallel to <110> and <100>, respectively. Areas with high and low process forces coincide well with the areas of high and low subsurface damage (SSD) depths, respectively.

]]> 10.1504/IJMMS.2011.044090 International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 511 - 539 Dietmar Pähler European Grinding Technology Centre, Saint-Gobain Diamantwerkzeuge GmbH Co. KG, Schützenwall 13-17 22844 Norderstedt, Germany rotational grinding silicon wafers wafer fabrication grinding forces local forces local contact zone crystal anisotropy sub-surface damage piezo sensors. 2011-12-09T23:20:50-05:00 4 6 511 539 2011-12-09T23:20:50-05:00 http://www.inderscience.com/link.php?id=44093 Increasing the accuracy and productivity of grinding machines depends on many influencing factors. In this article, some effects in the area of thermal behaviour, control, geometrical and kinematic deviations are considered. Thermal effects have been investigated in several research projects in the past. Despite this fact, there are uncertainties which are not known and lead to bad quality of the workpieces (e.g., geometric dimensions, surface quality). They occur mainly by the fact that the complexity of the machine tool structures is not controlled. Other influences like geometric and kinematic inaccuracies, imbalance and runout of grinding wheels are also discussed. Control units of the machines have been significantly improved in the past. They can influence the quality of the workpieces strongly. Together with the machining strategy, which is given by the CAM-software, the accuracy can be improved. Decoupling of physical effects and machine accuracy are the overall goal. Significant improvements in different fields are presented. At last it is shown how the quality of cutting tools can be measured inside the machine. Starting with measurement results and taking into account grinding technological parameters good quality is achieved. Increasing the accuracy in grinding process
Paul Helmut Nebeling
International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 540 - 552
Increasing the accuracy and productivity of grinding machines depends on many influencing factors. In this article, some effects in the area of thermal behaviour, control, geometrical and kinematic deviations are considered. Thermal effects have been investigated in several research projects in the past. Despite this fact, there are uncertainties which are not known and lead to bad quality of the workpieces (e.g., geometric dimensions, surface quality). They occur mainly by the fact that the complexity of the machine tool structures is not controlled. Other influences like geometric and kinematic inaccuracies, imbalance and runout of grinding wheels are also discussed. Control units of the machines have been significantly improved in the past. They can influence the quality of the workpieces strongly. Together with the machining strategy, which is given by the CAM-software, the accuracy can be improved. Decoupling of physical effects and machine accuracy are the overall goal. Significant improvements in different fields are presented. At last it is shown how the quality of cutting tools can be measured inside the machine. Starting with measurement results and taking into account grinding technological parameters good quality is achieved.

]]> 10.1504/IJMMS.2011.044093 International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 540 - 552 Paul Helmut Nebeling Reutlingen University, 72762 Reutlingen, Germany grinding machines grinding accuracy thermal behaviour control influence kinematic deviations geometric deviations imbalance runout grinding wheels. 2011-12-09T23:20:50-05:00 4 6 540 552 2011-12-09T23:20:50-05:00 http://www.inderscience.com/link.php?id=44105 Electrolytic in-process dressing (ELID) is a grinding technology which enables to manufacture surfaces in a quality that is close to polished on advanced, brittle-hard materials such as used in optics. ELID grinding requires exactly aligned machining parameters of the grinding process. Sapphire is, due to its crystal structure, difficult to machine. There is a request for thin, i.e., below 0.2 mm thickness, sub-surface damage free wafers. To grind sapphire, the material's behaviour is to be considered. Studies on the necessary oxide layer on the ELID grinding wheel and influences on its build-up process will be presented. In-feed and grinding velocity are varied and the results on wear, removal rate and surface quality are shown. The influence of the coolant and the stiffness of the machine, the grinding forces and pressure are evaluated. The ELID grinding is compared to conventional grinding. The achieved excellent surface roughness on sapphire is discussed. Use of ELID-grinding on brittle-hard materials
Rolf Rascher; Igor Makarenko
International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 553 - 568
Electrolytic in-process dressing (ELID) is a grinding technology which enables to manufacture surfaces in a quality that is close to polished on advanced, brittle-hard materials such as used in optics. ELID grinding requires exactly aligned machining parameters of the grinding process. Sapphire is, due to its crystal structure, difficult to machine. There is a request for thin, i.e., below 0.2 mm thickness, sub-surface damage free wafers. To grind sapphire, the material's behaviour is to be considered. Studies on the necessary oxide layer on the ELID grinding wheel and influences on its build-up process will be presented. In-feed and grinding velocity are varied and the results on wear, removal rate and surface quality are shown. The influence of the coolant and the stiffness of the machine, the grinding forces and pressure are evaluated. The ELID grinding is compared to conventional grinding. The achieved excellent surface roughness on sapphire is discussed.

]]> 10.1504/IJMMS.2011.044105 International Journal of Mechatronics and Manufacturing Systems, Vol. 4, No. 6 (2011) pp. 553 - 568 Rolf Rascher; Igor Makarenko University of Applied Sciences Deggendorf, Edlmairstrasse 6+8, D-94469 Deggendorf, Germany. ' Hermann-Gmeiner-Weg 5, D-94327 Bogen, Germany electrolytic in-process dressing ELID grinding surface roughness thin wafers sapphire grinding sintered silicon carbide coolant surface quality optics brittle materials oxide layers tool wear material removal rate MRR machine stiffness grinding forces pressure. 2011-12-09T23:20:50-05:00 4 6 553 568 2011-12-09T23:20:50-05:00