Jackson Mark. Machining with Abrasives
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Machining with Abrasives
Mark J. Jackson
l
J. Paulo Davim
Editors
Machining with Abrasive s
Editors
Mark J. Jackson
Purdue University
MET, Center for Advanced Manufacturing
College of Technology
West Lafayette, IN 47907-2021
USA
jacksomj@purdue.edu
J. Paulo Davim
University of Aveiro
Department of Mechanical Engineering
3810-193 Aveiro, Portugal
pdavim@mec.ua.pt
ISBN 978-1-4419-7301-6 e-ISBN 978-1-4419-7302-3
DOI 10.1007/978-1-4419-7302-3
Springer New York Dordrecht Heidelberg London
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Preface
Machining with abrasives is a widely used process for producing intricate shapes on
components and artifacts and for providing precise tolerances that are required
especially for the manufacture of engineering components. Grinding technology is
associated with the current developments in this area and this book contains
chapters on abrasive materials, bonding systems, grinding wheel design, micro
and nanogrinding, control of grinding processes, abrasive grinding, abrasive
water jet grinding, and dressing of grinding wheels. The chapters are written by
subject matter experts from around the world and provide an authoritative text on
the current developments in machining with abrasive tools. Chapter 1 focuses on
new developments in abrasive materials and associated bonding systems ranging
from conventional abrasives to superabrasive materials. Chapter 2 provides an
interesting prose on heat treatment and the performance of vitrified bonds, while
Chap.3 takes a look at the design of grinding wheels and wheel safety. The dressing
of grinding whe els is discussed in Chap.4 and leads into a chapter on the on the
surface integrity in ground surfaces (Chap.5). The control aspect of grinding is
explained lucidly in Chap.6, while Chap.7 focuses on the exciting new area of
nanogrinding. The final chapters deal with polishing with loose abrasive particles
and an authoritative overview of impact abrasive machining.
The structure of the book is based on matter provided by many colleagues and
the author wishes to thank the contributors of this book for helping construct a
source of knowledge and information on machining with abrasives and for granting
the editors permission to use such material. The editors also acknowledge the help
and support of Inder science Publishers for allowing the chapter contributors and
editors to reproduce their work that was originally published in refereed
Inderscience journals and other refereed journals where permissions have been
acknowledged.
Dr. Mark J. Jackson
Dr. J. Paulo Davim
v
About the Editors
Dr. Mark J. Jackson
C. Eng., Engineering Council of London, U.K., 1998
M. A. Status, Natural Sciences, University
of Cambridge, U.K., 1998
Ph.D., Mechanical Engineering, Liverpool, U.K., 1995
M.Eng., Mechanical & Manufacturing Engineering,
Liverpool, U.K., 1991
O.N.D., Mechanical Engineering, Halton College,
U.K., 1986
O.N.C. Part I, Mechanical Engineering, Halton
College, U.K., 1984
Doctor Jackson began his engineering career in 1983 when he studied for his O.N.
C. part I examinations and his first-year apprenticeship-training course in mechani-
cal engineering. After gaining his Ordinary National Diploma in Engineering with
distinctions and I.C .I. prize for achievement, he read for a degree in mechanical and
manufacturing engineering at Liverpool Polytechnic and spent periods in industry
working for I.C.I. Pharmaceuticals, Unilever Industries, and Anglo Blackwells.
After graduating with a Master of Engineering (M. Eng.) degree with Distinction
under the supervision of Professor Jack Schofield, M.B.E., Doctor Jackson subse-
quently read for a Doctor of Philosophy (Ph.D.) degree at Liverpool in the field of
materials engineering focusing primarily on microstructure-property relationships
in vitreous-bonded abrasive materials under the supervision of Professor Benjamin
Mills. He was subsequently employed by Unicorn Abrasives’ Central Research &
Development Laboratory (Saint-Gobain Abrasives’ Group) as materia ls technolo-
gist, then technical manager, responsible for product and new business develop-
ment in Europe , and university liaison projects concerned with abrasive process
development. Doctor Jackson then became a research fellow at the Cavendish
Laboratory, University of Cambridge, working with Professor John Field, O.B.E.,
F.R.S., on impact fracture and friction of diamond before becoming a lec turer in
vii
engineering at the University of Liverpool in 1998. At Liverpool, Dr. Jackson
established research in the field of micromachining using mechanical tools, laser
beams, and abrasive particles. At Liverpool, he attracted a number of research
grants concerned with developing innovative manufacturing processes for which he
was jointly awarded an Innovative Manufacturing Technology Center from the
Engineering and Physical Sciences Research Council in November 2001. In 2002,
he became associate professor of mechanical engineering and faculty associate in
the Center for Manufacturing Research, and Center for Electric Power at Tennessee
Technological Univ ersity (an associated university of Oak Ridge National Labora-
tory), and a facu lty associate at Oak Ridge National Laboratory. Dr. Jackson was
the academic adviser to the Formula SAE Team at Tennessee Technological
University. In 2004 he moved to Purdue University as Professor of Mechanical
Engineering in the College of Technology.
Doctor Jackson is active in research work concerned with understanding the
properties of materials in the field of microscale metal cutting, micro- and nanoab-
rasive machining, and laser micro machining. He is also involved in developing
next generation manufacturing processes. Doctor Jackson has directed, co-directed,
and managed research grants funded by the Medical Research Council, Engineering
and Physical Sciences Research Council, The Royal Society of London, The Royal
Academy of Engineering (London), European Union, Ministry of Defense (Lon-
don), Atomic Weapons Research Establishment, National Science Foundation, N.
A.S.A., U. S. Department of Energy (through Oak Ridge National Laboratory), Y12
National Security Complex at Oak Ridge, Tennessee, and Industrial Companies,
which has generated research income in excess of $15 million. Dr. Jackson has
organized many conferences and served as General Chairman of the International
Surface Engineering Congress and is Deputy President of the World Academy of
Materials and Manufacturing Engineering. He has authored and co-authored over
250 publications in arch ived journals and refereed conference proceedings, has
written a book on “micro and nanomanufacturing”, is guest editor to a number of
refereed journals, and has edited a book on “commercializing micro- and nanotech-
nology products”. He is the co-editor of the “Journal of Manufacturing Technology
Research”, associate editor of the “International Journal of Molecular Engineer-
ing”, and is on the editorial board s of the “International Journal of Machining and
Machinability of Materials”, “International Journal of Computational Materials
Science and Surface Engineering”, “International Journal of Nanomanufacturing”,
“International Journal of Nan o and Biomaterials”, and the “International Journal
of Manufacturing Research”.
viii About the Editors
Dr. J. Paulo Davim
Aggregation, Mechanical Engineering, University
of Coimbra, Portugal, 2005
Ph.D., Mechanical Engineering, University of Porto,
Portugal, 1997
M.Sc., Mechanical Engineering (Materials
& Manufacturing Processes), University
of Porto, Portugal, 1991
Graduation (5 years), Mechanical Engineering,
University of Porto, Portugal, 1986
Doctor J. Paulo Davim received his Ph.D. degree in Mechanical Engineering from
the University of Porto in 1997 and the Aggregation from the University of
Coimbra in 2005. Between, 1986/96, he was lecturer in University of Porto.
Currently, he is an Aggregate Professor at the Department of Mechanical Engineer-
ing of the University of Aveiro and the Head of MACTRIB - Machining and
Tribology Research Group. He has more 24 years of teaching and research experi-
ence in manufacturing, materials and mechanical engineering. His main research
interests are the machining and tribology and more recen tly the application of
computational and statistical methods in manufacturing as well as all aspects of
sustainable manufac turing. He was coordinator of several research projects and
supervisor of 2 Ph.D. thesis and 10 M.Sc. thesis. He is Guest Editor of journals,
book Series Editor and Scientific Advisory for many international journals and
conferences. Presently, he is an Editorial Board member of 15 international journals
and acts as reviewer for than 45 prestigious ISI web Science journals. He has also
published more than 20 book chapt ers and 300 articles in journals and conferences
(more 150 articles in ISI Web Science, h-index 15).
He is the Editor of the “International Journal of Machining and Machinability of
Materials”, “International Journal of Manufacturing, Materials and Mechanical
Engineering”, “Journal of Machining and Forming Technologies”, “Journal of
Modern Manufacturing Technology” and Co Editor of the “International Journal
of Surface Science and Engineering”, “International Journal of Mechatronics and
Manufacturing Systems”, “International Journal of Materials Engineering Innova-
tion”, and the “Journal of Manufacturing Technology Research”.
About the Editors ix