Title: Wheel lift-off in creep-feed grinding: thermal damage, power surge, chip thickness and optimisation

Authors: Radovan Drazumeric; Jeffrey A. Badger; Peter Krajnik

Addresses: Faculty of Mechanical Engineering, University of Ljubljana, Askerceva 6, 1000 Ljubljana, Slovenia; The International Grinding Institute, 422 Mission St., San Antonio, TX, 78210, USA ' The Grinding Doc, 422, Mission St., San Antonio, TX, 78210, USA; The International Grinding Institute, 422, Mission St., San Antonio, TX 78210, USA ' Department of Industrial and Materials Science, Chalmers University of Technology, Hörsalsvägen 7B, SE-412 96 Gothenburg, Sweden

Abstract: An investigation is made into the phenomenon of early lift-off in creep-feed grinding, where the wheel lifts away from the workpiece before reaching the end of cut. In single-pass operations, early lift-off can result in thermal damage. In multi-pass operations, there is a surge in material-removal rate just before lift-off, which can result in thermal damage and excess wheel wear. This study examines the current inadequate methods of dealing with lift-off. It then develops a geometric and kinematic model for analysing the lift-off phenomenon. It finally proposes a thermal-model-based optimisation method for achieving a constant maximum surface temperature, resulting in shorter cycle times and less risk of thermal damage. The power-surge model is validated experimentally in diamond grinding of tungsten-carbide rotary tools.

Keywords: grinding; tooling; thermal damage; optimisation.

DOI: 10.1504/IJAT.2017.089287

International Journal of Abrasive Technology, 2017 Vol.8 No.2, pp.97 - 120

Received: 02 May 2017
Accepted: 18 Jul 2017

Published online: 14 Jan 2018 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article