Abstract
This surface-grinding study investigates and quantifies the improved cutting mechanics and coolant delivery achieved using circumferentially grooved grinding wheels and compares the results with regular non-grooved grinding wheels. It was shown that, when performing shallow dry grinding experiments, a grooved grinding wheel yielded specific energies that were 30.6 % lower than a regular non-grooved wheel. This reduction in specific energy was attributed to the grooved wheel enabling an increase in the size effect. Evidence for this hypothesis was gathered using a scanning electron microscope which revealed that the grooved grinding wheel chips were approximately six to eight times wider than those from the regular non-grooved grinding wheel. It was also shown that, when performing wet grinding experiments, a grooved grinding wheel yielded specific energies that were 41.3 % lower than a regular non-grooved wheel. This additional 10.7 % reduction in specific energy was hypothesized to be due to the grooved wheel enabling more grinding fluid to enter the grinding zone leading to better lubrication and cooling. A fluid flow comparison was then carried out to validate this hypothesis, and it was observed that the grooved grinding wheel was able to deliver more than twice the amount of coolant flow into the contact zone when compared to a regular non-grooved wheel.
Similar content being viewed by others
References
Nakayama K, Takagi J, Abe T (1977) Grinding wheel with helical grooves—an attempt to improve the grinding performance. Manufacturing Technology, 27th Gen Assem. of CIRP 25(1):133–138
Verkerk J (1979) Slotted wheels to avoid cracks in precision grinding, Annual Abrasive Engineering Society Conference/Exhibition, Pittsburg, pp 75–81
Matsui S, Syoji K, Kuriyagawa T (1986) Grinding characteristics of segmental wheel –Studies on creep feed grinding, 4th report. J Jpn Soc Precis Eng 52(11):35–41
Okuyama S, Nakamura Y, Kawamura S (1993) Cooling action of grinding fluid in shallow grinding. Int J Mach Tools Manuf 33:13–23
Suto T, Waida T, Noguchi H, Inoue H (1990) High performance creep feed grinding of difficult-to-machine materials with new-type wheels. Bull Jpn Soc Precis Eng 24(1):39–44
Zhang LC, Suto T, Noguchi H, Waida T (1995) A study of creep-feed grinding of metallic and ceramic materials. J Mater Process Technol 48(1–4):267–274
Nguyen T, Zhang LC (2005) Modelling of the mist formation in a segmented grinding wheel system. Int J Mach Tools Manuf 45(1):21–28
Nguyen T, Zhang LC (2005) The coolant penetration in grinding with segmented wheels—part 1: mechanism and comparison with conventional wheels. Int J Mach Tools Manuf 45(12–13):1412–1420
Nguyen T, Zhang LC (2006) The coolant penetration in grinding with a segmented wheel—part 2: quantitative analysis. Int J Mach Tools Manuf 46(2):114–121
Nguyen T, Zhang LC (2009) Performance of a new segmented grinding wheel system. Int J Mach Tools Manuf 49(3–4):291–296
Kim J-D, Kang Y-H, Jin D-X, Lee Y-S (1997) Development of discontinuous grinding wheel with multi-porous grooves. Int J Mach Tools Manuf 37(11):1611–1624
Köklü U (2012) Grinding with helically grooved wheels. J Process Mech Eng 1–10
Tawakoli T, Westkaemper E, Rabiey M (2007) Dry grinding by special conditioning. Int J Adv Manuf Technol 33:419–424
Walter C, Komischke T, Beyer P, Wegener K (2014) A laser micro texturing technique for performance enhancement of superabrasive grinding wheels. Proceedings of the 14th euspen International Conference, Dubrovnik
Denkena B, Grove T, Göttsching T, Silva EJ, Coelho RT, Filleti R (2015) Enhanced grinding performance by means of patterned grinding wheels. Int J Adv Manuf Technol 77:1935–1941
Stepień P (2011) Deterministic and stochastic components of regular surface texture generated by a special grinding process. Wear 271(3–4):514–518
Oliveira JFG, Bottene AC, França TV (2010) A novel dressing technique for texturing of ground surfaces. CIRP Ann Manuf Technol 59:361–364
Silva EJ, Oliveira JFG, Salles BB, Cardoso RS, Reis VRA (2013) Strategies for productions of parts textured by grinding using patterned wheels. CIRP Ann Manuf Technol 62:355–358
Mohamed AL-MO, Bauer R, Warkentin A (2013) Application of shallow circumferential grooved wheels to creep-feed grinding. J Mater Process Technol 213:700–706
Davis JR, ASM International Handbook Committee (2010) ASM handbook volume 16—machining, ASM International
Mohamed AL-MO, Bauer R, Warkentin A (2014) A novel method for grooving and re-grooving aluminum oxide grinding wheels. Int J Adv Manuf Technol 73:715–725
Aslan D, Budak E (2015) Surface roughness and thermos-mechanical force modeling for grinding operations with regular and circumferentially grooved wheels. J Mater Process Technol 223:75–90
Malkin S (1989) Grinding technology and applications of machining with abrasives. SME, Dearborn
Marinescu ID, Rowe WB, Dimitrov B, Inasaki I (2004) Tribology of abrasive machining processes. William Andrew Publishing, Norwich
Engineer F, Guo C, Malkin S (1992) Experimental measurements of fluid flow through the grinding zone. Trans ASME J Eng Ind 114:61–66
Li CH, Hou YL, Ding YC, Lu BH (2009) Analysis and measurement of effective flow-rate in flood grinding. Advances in Materials Manufacturing Science and Technology XIII: Advanced Manufacturing Technology and Equipment, and Manufacturing Systems and Automation: Materials Science Forum (626–627):159–164
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Mohamed, AM.O., Bauer, R. & Warkentin, A. Uncut chip thickness and coolant delivery effects on the performance of circumferentially grooved grinding wheels. Int J Adv Manuf Technol 85, 1429–1438 (2016). https://doi.org/10.1007/s00170-015-8062-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-8062-6