International Journal of Abrasive Technology (5 papers in press)

Regular Issues

• Polishing investigation on zirconia ceramics using magnetic compound fluid (MCF) slurry  
  by Feng Ming, Wang Youliang, Bitou Teruo, Nomura Mitsuyoshi, Fujii Tatsuya, Wu Yongbo 
  Abstract: Zirconia ceramics have wide applications in the fields of aerospace, defense industry, new energy, automotive, electronics and biomedical. Although the conventional methods can fabricate zirconia ceramics products efficiently, the induced scratches, micro-cracks and sub-damage are inevitable. Therefore, the post-polishing processing should be employed. The magnetic-assisted polishing with MCF slurry is considered as a friendly polishing method which can not only achieve smooth surface but also reduce the defects remained at the work-piece surface. However, the investigations on the high precision polishing of zirconia ceramics by using the MCF slurry were not conducted so far. In this work, the polishing method by using magnetic compound fluid (MCF) slurry under the rotary magnetic field was proposed for the zirconia ceramics polishing. The principle and the constructed experimental setup were presented at first. Then, the spot polishing was conducted. Finally, the effect of parameters, including working gap h, MCF carrier revolution speed nc, abrasive particles (APs) size, the concentration of carbon iron particles (CIP) and concentration of ?-cellulose on the finishing of work surface was investigated. The polishing results show that surface roughness Ra 5 nm was obtained at the surface of zirconia ceramics with 0.5 mm of h, 400 rpm of nc, ?1.25 ?m of abrasive particle, 45 wt.% of CIP concentration and 3 wt.% of ?-cellulose concentration.
  Keywords: MCF slurry; Rotary magnetic field; Zirconia ceramics; Polishing; Precision.
  
  
• A New Method of Real Time Monitoring of Cutting Tool Status bases on HHT  
  by Qzheng Liu, Guoqiang Guo, Zichao Lin 
  Abstract: The machine tool is the main execution unit in the Cyber-Physical system (CPS system), which can improve the product quality by dynamic monitoring and real-time perception of its wear status. In order to realize the on-line signal acquisition and monitoring of tool wear status, the spindle power signal acquisition system was implemented. The cutting force signal is used as contrast analysis. The HHT method and wavelet transform method are introduced to construct the tool wear coefficients, which are corresponding to the tool wear status. Compared with the wavelet transform, it is proved that Hilbert-Huang transform can restrain the noise signal effectively and improve the accuracy of the monitoring. Finally, the new tool wear monitoring method is applied to drilling 45# steel and titanium alloy TC4 to catch the tool wear state, and the power signal is used to carry out comprehensive online tool state monitoring. It is accurate and practical in the drilling test, which shows prospective usage in the near future.
  Keywords: Cyber-Physical System; Power Signal; Hilbert-Huang Transform; Tool Wear Coefficient; Wavelet Transform.
  
  
• Study on the Specific Grinding Energy of Cemented Carbide (YG8) Grinding with a Vitrified Diamond Wheel in High Speed Regime  
  by Youji Zhan, Xiao Tian, Yongchao Xu, Minzhong Jia 
  Abstract: Based on the chip geometry, a new mathematical model is established to correlate specific grinding energy with the maximum undeformed chip thickness, the cutting length, and grinding parameters. This work investigates the energy of cemented carbide (YG8) grinding with a vitrified diamond wheel in high speed regime (the grinding speed of up to 120m/s). Effects of the maximum undeformed chip thickness, the cutting length and the various grinding parameters on the specific grinding energy were investigated. A regression model was then developed to connect the specific energy with the maximum undeformed chip thickness and the cutting length, by fitting the experimental data of high speed grinding with least square method. The results indicate that the specific grinding energy increases with the rise of the cutting length, while decreases with the increase in the maximum undeformed chip thickness. The distribution mechanism of the grinding energy shows that the grinding energy is mainly expended for sliding and ductile plowing. A nearly proportional relationship is obtained between the consumed power per unit width (Pm) and the plowed surface areas generated by all cutting points per unit width (Sw). Compared to conventional grinding, it is found that specific grinding energy requirement is increased for high speed grinding of cemented carbide.
  Keywords: Specific grinding energy; Vitrified diamond wheel; High speed grinding; Cemented carbide.
  
  
• Investigation of Principal Factor Decision Support System Using Data-Mining Methodology for Surface Grinding Wheel  
  by Hiroyuki Kodama, Itaru Uotani, Takao Mendori, Kazuhito Ohashi 
  Abstract: The five factors of the three main elements of a grinding wheel are important parameters affecting surface quality and grinding efficiency, however it is difficult to determine an optimal combination of grinding conditions for workpiece material. In previous research, we constructed a support system for effectively selecting an appropriate grinding wheel using decision tree technique. We also proposed a visualization process to show how grinding wheel elements and factors correspond to the materials characteristics of the workpiece material. In this research, to evaluate the usefulness of prepared visualization maps and their effectiveness in deciding grinding wheel elements, we performed comparison experiments applying the surface grinding technique to JIS SUS310S material using PA abrasive grain as recommended by the grain-type visualization map and WA and GC abrasive grains for comparison purposes. We found that visualization maps enable quick selection of a grinding wheel even for the grinding of difficult-to-cut materials for which grinding wheel selection is usually difficult.
  Keywords: Data-mining; Supervised learning; Decision tree; Grinding wheel; surface grinding.
  
  
• APPLICATION OF NSGA- II FOR OPTIMIZATION OF CYLINDRICAL PLUNGE GRINDING PROCESS PARAMETERS  
  by Sanjay Patil, Yogesh Bhalerao 
  Abstract: Cylindrical grinding (finishing) operation is widely used for obtaining accurate surface finish on components in automobile sectors. Present industries are facing a challenge of producing high quality components with low power consumption and low manufacturing cost due to increased competition. In this paper, optimum process parameters values are obtained for dressing depth of cut, dressing cross feed rate and grinding feed rate of cylindrical plunge grinding operation.Experiments were performed as per L9 Orthogonal Array with replica on Computer Numerical Control Angular Head grinding machine. Mathematical model has been developed using ResponsernSurface Methodology for determining grinding responses. The results of RSM are further used to obtain pareto front optimal solutions using NSGA II approach. A novel method is developed to obtain grinding ratio. The established results are helpful to decide optimal grinding parameters.
  Keywords: cylindrical grinding; grinding ratio; NSGA II; power; surface roughness.