Jackson Mark. Machining with Abrasives
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Contents
1 Abrasive Tools and Bonding Systems..................................... 1
Mark J. Jackson and Michael P. Hitchiner
2 Heat Treatment and Performance of Vitrified Grinding Wheels ..... 79
Mark J. Jackson
3 Grinding Wheel Safety and Design ..................................... 131
Mark J. Jackson
4 Dressing of Grinding Wheels ............................................ 181
Taghi Tawakoli and Abdolreza Rasifard
5 Surface Integrity of Materials Induced by Grinding .................. 245
L.C. Zhang
6 Traditional and Non-traditional Control Techniques
for Grinding Processes ................................................... 269
Jian Liu, Chengying Xu, and Mark Jackson
7 Nanogrinding ............................................................. 303
Mark J. Jackson and J. Paulo Davim
8 Polishing Using Flexible Abrasive Tools and Loose Abrasives ....... 345
Han Huang, Libo Zhou,, and Ling Yin
9 Impact Abrasive Machining ............................................. 385
Yasser M. Ali and Jun Wang
Index............................................................................ 421
xi
Contributors
Yasser M. Ali
School of Mechanical and Manufacturing Engineering, The Univer sity
of New South Wales, Sydney, NSW 2052, Australia
J. Paulo Davim
Department of Mechanical Engineering, University of Aveiro, 3810-193 Aveiro,
Portugal
Michael P. Hitchiner
Saint-Gobain Abrasives, Inc., 27588 Northline Road, Romulus, MI 48174, USA
Han Huang
School of Mechanical and Mining Engineering, The University of Queensland,
Brisbane, QLD 4072, Australia
Mark J. Jackson
MET, Center for Advanced Manufacturing, Purdue University,
College of Technology, 401 North Grant Street, West Lafayette,
IN 47907-2021, USA
Jian Lu
Department of Mechanical, Materials and Aerospace Engineering,
University of Central Florida , 4000 Central Florida Blvd,
Orlando, FL 32816, USA
Abdolreza Rasifard
Competence Center of Grinding Technology and Superfinishing, Hochschule
Furtwangen University, Villingen-Schwenningen, Germany
Taghi Tawakoli
Department of Mechanical and Process Engineering, Hochschule Furtwangen
University, Villingen-Schwenningen, Germany
xiii
Jun Wang
School of Mechanical and Manufacturing Engineering, The Univer sity
of New South Wales, Sydney, NSW 2052, Australia
Chengying Xu
Department of Mechanical, Materials and Aerospace Engineering,
University of Central Florida , 4000 Central Florida Blvd,
Orlando, FL 32816, USA
Ling Yin
School of Engineering, James Cook University, Brisbane, QLD 4811, Austr alia
L.C. Zhang (Liangchi Zhang)
School of Mechanical and Manufacturing Engineering,
The University of New South Wales, Sydney, NSW 2052, Australia
Libo Zhou
Department of Intelligent Systems Engineering, Ibaraki University,
Hitachi, Japan
xiv Contributors
Chapter 1
Abrasive Tools and Bonding Systems
Mark J. Jackson and Michael P. Hitchiner
Abstract The manufacture of high performance gri nding wheels is heavily
dependent upon the selecting the correct abrasive grain in terms of cutting ability,
fracturing ability and the shape of the grain that controls metal removal rate,
dressing interval, coolant delivery to the wheel-workpiece interface and chip
evacuation. This chapter explains the recent developments in abrasive grains and
bonding systems and should allow the reader to better select the correct abrasive
grain and bonding system to economi cally machine materials.
Keywords Abrasive tools Bonding Grinding wheels
1.1 Abrasive Grain Characteristics
1.1.1 Grain Shape
Grain shape makes an enormous impact on grain strength, grinding performance,
and packing characteristics that impact wheel formulation and manufacture. Shape
will affect the r term in the undeformed chip thickness calculation t
0
¼ {[Vw/
(VsCr)](d/De)
1/2
}
1/2
where r is the ratio of undeformed chip width to chip depth.
This in turn impacts grinding power, finish and force/grit. Shape and size are
interlinked especially for particles of indeterminate shape i.e. not perfectly
spherical, cubic, etc. For synthetic diamond particles, for example, there exists an
M.J. Jackson and J.P. Davim (eds.), Machining with Abrasives,
DOI 10.1007/978-1-4419-7302-3_1,
#
Springer Science+Business Media, LLC 2011
1
M.J. Jackson (*)
MET, College of Technology, Purdue University, 401 North Grant Street, West Lafayette,
IN 47907, USA
e-mail: jacksomj@purdue.edu
infinite combination of particle shapes derived from the transition between octahe-
dral and cubic forms, as shown in Fig. 1.1 . Moreover, crystal imperfections, and
polycrystalline particles, further add to the variety of diamond forms.
A blocky round grain will in general be far stronger than an angular, sharp-cornered
grain. Quantifying exactly what “blocky” and “angular” mean, and defining the
characteristics key to shape have been the sources of considerable study both for
grinding performance and batch to batch quality control of wheel manufacture. A
variety of parameters for describing the shape of particle projections, classified accord-
ing to the salient feature of the measurement, is shown in Table 1.1. The boxed
parameters are those considered to be of most interest in a study by De Pellegrin
et al. [1, 2], whereby the shape characteristics of diamond grain were studied in relation
to grinding performance using optical microscopy and image analysis.
Two key diametrical dimensions are the major and minor diameters, d
a
and d
b
respectively as illustrated in Fig. 1.2, provide a fundamental measure of particle
size. It may be noted that, depending on the orientation of the caliper lines relative
to the given projection, many different diameters may be obtained. Although size is
an important feature, it is shape that governs particle abrasiveness. Algebraic
combinations of linear dimensions provide measures of shape.
Fig. 1.1 Diamond particle shape map
2 M.J. Jackson and M.P. Hitchiner
Table 1.1 Classification of parameters for measuring particle shape
Span Area Perimeter Ratio Average Composite
Silhouette perimeter Average radius Spike parameter
Area moment Perimeter moment Average diameter Fractal dimension
Minimum diameter Hull area Hull perimeter Circularity Mean angle
Feret diameter Equivalent radius
(circle area
based)
Equivalent radius
(circle perimeter
based)
Shape factor Average curvature Fourier/Radance
Equivalent ellipse Ellipticity Roughness
Angularity
1 Abrasive Tools and Bonding Systems 3
Examples of such calculated values from this projection include:
(a) Aspect ratio, the ratio of the major to minor diameter d
a
/d
b
. A useful parameter
to describe grain elongation.
(b) Projection area, the area enclosed by the boundary of its projection. It is an
indirect measure of size and bulk of the particle. It is important as part of the
calculation of grain convexity.
(c) Convexity is a characteristic that strongly relates to the strength of the grain
and its abrasive potential. A grain is convex if an idealized elastic membrane
stretched across its projection leaves no space between itself and the grain’s
surface. The degree of convexity correlates with lower mechanical integrity but
higher abrasive aggressiveness with the grain being, on average, less blocky.
Convexity also correlates with the notion of grain irregularity.
Convexity C as a parameter is defined as
C ¼
A
f
A
p
A
p
where A
p
is the projected area of the grain, A
f
is the fill area between the
grain projection and the idealized elastic membrane stretched across the pro-
jection (Fig. 1.3).
(d) Grain “sharpness” is a parameter that has been developed specifically for the
characterization of abrasive grains based on chip formation modeling whereby
the abrasive rate is governed by the degree of penetration into the workpiece, as
illustrated in Fig. 1.4.
The functional relat ionship between the two orthogonal areas, O and L, is known as
the “groove function”, see Fig. 1.5. Averaging applied to numerous particle
Fig. 1.2 Dimensional definitions for a grain 2D projection
4 M.J. Jackson and M.P. Hitchiner