International Journal of Abrasive Technology (7 papers in press)

Regular Issues

• A modeling study of grinding force for axial feed machining of Si3N4-diamond grinding wheel endface based on specific chip energy  
  by Zhang Xianglei, Peng Chen, Cheng Gao, Ming Feng, Zhuojie Chen 
  Abstract: Grinding force is an essential metric for grinding mechanism research, and establishing its mathematical model is crucial. Modeling and experimental investigation of end-face grinding force without impact were conducted in this paper. A grinding force model based on specific chip energy was created due to the close relationship between specific chip energy and grinding force. The Si3N4 material grinding experiment was conducted with a bowl-shaped diamond grinding wheel, and the grinding force model was derived from the experimental results. The grinding force mathematical model was upgraded and updated. Finally, the grinding forces were measured at different grinding wheel rotation speeds and different feed rates, and the accuracy of the grinding force model established in this paper was confirmed by comparing the experimental data with the theoretical data. The construction of the grinding force model in this paper significantly contributes to the study of grinding force modeling.
  Keywords: Grinding force; End-face grinding; Specific chip energy; Si3N4 ceramics; Diamond grinding wheel.
  DOI: 10.1504/IJAT.2023.10055081
   
  
• Experimental study on plunge-cut internal cylindrical electrolysis grinding processing of bearing ring  
  by Zhanzhan Hu, Feng JIAO 
  Abstract: Bearing ring is an important part of rolling bearing. Its traditional processing technology is complex and easy to fail. As a composite processing technology, electrolytic grinding (ECG) has the advantages of low surface roughness and low tool cathode loss. Therefore, its application to the processing of bearing rings can improve the problems of traditional processing technology to a certain extent. In this study, based on the study of the polarisation characteristics of GCr15 bearing steel, the parameters such as processing voltage, duty cycle, grinding wheel speed and feed speed were selected for the plunge-cut internal ECG of bearing rings. The experimental results show that within the selected parameter range, the main factors affecting the surface roughness are the processing voltage and the feed speed, and under certain parameter conditions, the surface roughness of the workpiece decreases first and then increases with the increase of the two.
  Keywords: bearing ring; plunge-cut; internal grinding; electrolysis grinding; surface roughness.
  DOI: 10.1504/IJAT.2023.10055411
   
  
• Experimental study on the processing of sapphire with a free-abrasive assisted fixed-abrasive lapping plate  
  by Cao Jiyang, Jiayun Deng, J.B. Lu, Qiusheng Yan, Xiaowei Nie 
  Abstract: To improve the lapping efficiency of the self-made fixed-abrasive lapping plate for sapphire, free-abrasives were added to the lapping solution to improve the plate’s self-dressing performance to realize high-efficiency and high-quality processing for sapphire wafers. The effects of free-abrasive types, size and concentration on processing sapphire wafers were studied, and the processing mechanism of free-abrasive assisted fixed-abrasive lapping was also revealed. The results show that the material removal rate (MRR) of the sapphire wafer increases with increasing the free-abrasive hardness and the size, and first increases and then decreases with increasing concentration; The surface roughness Ra first decreases and then increases with increasing the free-abrasive hardness, increases with increasing the size and continually decrease with increasing the concentration; The lapping plate wear ratio first increases and then decreases with increasing the free-abrasive hardness and concentration and increases with increasing the size. When the free-abrasive, abrasive size and concentration are SiO2, 20 ?m, and 3 wt.%, a processed surface with Ra of 0.141 ?m and MRR of 4.24 ?m/min could be obtained.
  Keywords: Abrasive characteristics; processing effect; free-abrasive assisted fixed-abrasives lapping; wear ratio.
  DOI: 10.1504/IJAT.2023.10055569
   
  
• Investigation on Workpiece Microstructure and Wheel Performance on Grinding Titanium Metal Matrix Composites  
  by Cécile Escaich, Zhongde Shi, Luc Baron, Marek Balazinski 
  Abstract: An experimental study is reported on the grinding of a titanium metal matrix composite (TiMMC) using electroplated diamond wheels. Flat surface grinding experiments were performed at a fixed wheel speed vs = 20 m/s, various depths of cut a = 0.030.08 mm, and workspeeds vw = 10100 mm/s. Additional tests were also conducted on titanium alloy (Ti alloy) for comparisons. The wheel wear and its effects on grinding forces, power, surface roughness, and workpiece microstructures are presented. The process limits were also investigated. It was revealed that steady state wheel wear on TiMMC was slightly slower than on Ti alloy. Low specific energy ranging from 1634 J/mm3 was obtained for both materials. It was found that surface roughness decreases for TiMMC, but increases for Ti alloy, with increasing workspeeds. Plastic deformation leads to microstructural changes in the form of twinning below ground surfaces.
  Keywords: grinding; titanium metal matrix composite; TiMMC; electroplated diamond wheel; wheel wear; surface integrity.
  DOI: 10.1504/IJAT.2023.10056894
   
  
• Modelling of Material Removal in Unidirectional Abrasive Flow Machining process using Classical Indentation Model  
  by Jai Kishan, Harlal Mali, Ram Dayal 
  Abstract: Abrasive flow machining (AFM) process is a non-traditional finishing process, that enables finishing of complex inaccessible internal surfaces by rubbing abrasive grains mixed in visco-elastic carrier medium over the surface that is to be finished. In this work mechanism of material removal (MR) during finishing of internal surfaces using unidirectional AFM process is modelled and simulated numerically. The numerical model is validated by performing experiments on unidirectional AFM setup. Design of experiments is used to investigate the influence of extrusion pressure, finishing time and viscosity of the flow medium on the performance measure parameter. It is found that MR rate depends strongly on extrusion pressure, finishing time and viscosity of medium.
  Keywords: abrasive flow machining; AFM; viscosity; active grain density; extrusion pressure; material removal; MR.
  DOI: 10.1504/IJAT.2023.10057114
   
  
• Experimental investigation and mathematical modeling of friction characteristics of a novel block-on-disk test rig under high loads with sandy abrasive  
  by The Y. Doan  
  Abstract: It is well known that an intermediate layer of abrasive particles exists in many tribological systems. The resulting wear and friction phenomena are therefore affected. In this work, we carried out various experiments in several scenarios on a specially built test-rig to investigate the dependency of friction on several parameters. Thus, samples of steel and aluminium are pressed on a rotating disc, and a layer of quart sand is filled between them. The disc is set up to rotate with different speeds and distances, the samples with different initial roughness are applied onto the particle layers. Besides, varying normal forces are applied onto the samples. The friction phenomena are thereby observed and analysed. Moreover, the dependency of the friction on the parameters is realised by function expressions of them. These expressions are necessary to build up a simulation for the overall wear process.
  Keywords: friction characteristics; three-body contact; experimental investigation; triboelements.
  DOI: 10.1504/IJAT.2024.10057469
   
  
• Study on the instantaneous cutting forces in bone oscillating sawing  
  by Han Wang, Urara Satake, Toshiyuki Enomoto 
  Abstract: Surgical oscillating saws often induce significant cutting forces when cutting bones, which reduce the accuracy and effectiveness of the surgery. Thus, keeping cutting forces steady and modest during bone sawing is vital. However, the influence of the periodic velocity variation and cut depth on the generated forces is unclear. In this study, a cutting mechanism of oscillating sawing was proposed to describe the cutting force variation at different depths per oscillation cycle. A single-tooth blade was used to investigate the instantaneous cutting forces at varying oscillation frequencies and depths of cut. The experiments show that linear velocity less affects cutting force after reaching a threshold. Furthermore, the cutting force has a linear relation with the depth of cut and maintains good consistency when the depth of cut is relatively large. In contrast, when the depth of cut is relatively low, the cutting forces vary at the same depth of cut.
  Keywords: bone cutting; surgical oscillating saw; cortical bone; instantaneous cutting force; ploughing force.
  DOI: 10.1504/IJAT.2024.10059185