Title: Manufacturing high quality surfaces of hardened steels: fine grinding with lapping kinematics using abrasive foil tools

Authors: Hans-Werner Hoffmeister; Wiebke-Cathérine Hahmann

Addresses: 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

Abstract: 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.

Keywords: 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.

DOI: 10.1504/IJMMS.2011.044092

International Journal of Mechatronics and Manufacturing Systems, 2011 Vol.4 No.6, pp.496 - 510

Available online: 09 Dec 2011 *

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