Abstract
The paper presents the results obtained for abrasive electro-discharge grinding (AEDG) of Ti6Al4V titanium alloy with the use of super hard grinding wheels of cubic boron nitride with a metal bond. The experimental investigations were focused on process monitoring for sharp and worn grinding wheels. For the evaluation of the grinding process, the grinding force amplitude and a few descriptors of the high-frequency stress waves were investigated in both time and frequency domains. The results show that during the AEDG, specific elastic waves are generated. Since these waves have characteristic amplitudes, frequencies, and other different descriptors dependent on the current grinding wheel cutting ability and discharge parameters, they can be applied to estimate a statistically significant regression function. For each measurement signal, a few statistical features are calculated and used as input for data selection and classification procedures. Registration and classification of forces and acoustic emission signals can be used to analyse the abrasive electro-discharge grinding process and allow for the determination of the machining results and the lifespan of super hard grinding wheels.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Vinay PV, Rao CS (2013) Grinding mechanics and advances—a review. J Mech Eng Technol 5(2):41–74
Li X (2014) Application of self-inhaling internal cooling wheel in vertical surface grinding. Chinese J Mech Eng 27(1):86–91. https://doi.org/10.3901/CJME.2014.01.086
Veiga C, Davim JP, Loureiro AJR (2013) Review on machinability of titanium alloys: the process perspective. Rev Adv Mater Sci 34(2):148–164
Vemula VV, Khan TA (2012) Study on grindability of Ti-6Al-4V using solid lubricants. Int J Emerg Technol 3(1):109–114
Malkin S, Guo C (2007) Thermal analysis of grinding. CIRP Ann Manuf Techn 56(2):760–782. https://doi.org/10.1016/j.cirp.2007.10.005
Sutowski P, Święcik R (2016) Badania wysokoczęstotliwościowych fal naprężeń w procesie elektroerozyjnego szlifowania stopu tytanu [the study of the high-frequency stress waves in the abrasive electrical discharge grinding of titanium alloy]. Mechanik 89(8–9):1098–1099. https://doi.org/10.17814/mechanik.2016.8-9.266
Hood R, Cooper P, Aspinwall DK, Lee DS (2015) Creep feed grinding of γ-TiAl using single layer electroplated diamond superabrasive wheels. CIRP J Manuf Sci Techol 11:36–44. https://doi.org/10.1016/j.cirpj.2015. 07.001
Zhao B, Ding WF, Xu JH, Su HH (2016) Comparative study on cutting behavior of vitrified cubic boron nitride wheel and electroplated cubic boron nitride wheel in high-speed grinding of (TiCp+TiBw)/Ti-6Al-4V composites. P I Mech Eng B-J Eng 230(3):428–438. https://doi.org/10.1177/095440541455 3457
Li Z, Ding W, Shen L, Xi X, Fu Y (2016) Comparative investigation on high-speed grinding of TiCp/Ti–6Al–4V particulate reinforced titanium matrix composites with single-layer electroplated and brazed CBN wheels. Chin J Aeronaut 29(5):1414–1424. https://doi.org/10.1016/ j.cja.2016.01.005
Xu X, Yu Y, Huang H (2003) Mechanisms of abrasive wear in the grinding of titanium (TC4) and nickel (K417) alloys. Wear 255(7–12):1421–1426. https://doi.org/10.1016/S0043-1648(03)00163-7
Hood R, Aspinwall DK, Voice W (2007) Creep feed grinding of a gamma titanium aluminide intermetallic alloy using SiC abrasives. J Mater Process Tech 191(1–3):210–214. https://doi.org/10.1016/j.jmatprotec. 2007.03.081
Zhang HX, Chen WY, Chen ZT (2007) Experimental studies on grinding of titanium alloy with SG wheels. Key Eng Mater 329:75–80. https://doi.org/10.4028/www.scientific.net/KEM.329. 75
Nadolny K, Sienicki W, Wojtewicz M (2015) The effect upon the grinding wheel active surface condition when impregnating with non-metallic elements during internal cylindrical grinding of titanium. Arch Civ Mech Eng Arch Civ Mech Eng 15(1):71–86. https://doi.org/10.1016/ j.acme.2014.03. 004
Nadolny K, Kapłonek W, Wojtewicz M, Sienicki W (2013) Effects of sulfurization of grinding wheels on internal cylindrical grinding of titanium grade 2®. Indian J Eng Mater S 20(2):108–124
Teicher U, Ghosh A, Chattopadhyay AB, Künanz K (2006) On the grindability of titanium alloy by brazed type monolayered superabrasive grinding wheels. Int J Mach Tool Manu 46(6):620–622. https://doi.org/10.1016/j.ijmachtools.2005.07.012
Li X, Chen Z, Chen W (2011) Suppression of surface burn in grinding of titanium alloy TC4 using a self-inhaling internal cooling wheel. Chin J Aeronaut 24(1):96–101. https://doi.org/10.1016/S1000-9361(11) 60012-5
Boswell B, Islam M, Davies IJ, Ginting YR, Ong AK (2017) A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining. Int J Adv Manuf Technol First Online: 23 February 2017. https://doi.org/10.1007/s00170-017-0142-3
Święcik R (2009) Experimental investigation of abrasive electrodischarge grinding of Ti6Al4V titanium alloy. J Achiev Mater Manuf Eng 37(2):706–711
Wang Y, Lin B, Cao X, Wang S (2014) An experimental investigation of system matching in ultrasonic vibration assisted grinding for titanium. J Mater Process Technol 214(9):1871–1878. https://doi.org/10.1016/j.jmatpro tec.2014.04.001
Razavi HA, Kurfess TR, Danyluk S (2003) Force control grinding of gamma titanium aluminide. Int J Mach Tool Manu 43(2):185–191. https://doi.org/10.1016/S0890-6955(02)00113-X
Hasçalık A, Çaydaş U (2007) A comparative study of surface integrity of Ti–6Al–4V alloy machined by EDM and AECG. J Mater Process Technol 190(1–3):173–180. https://doi.org/10.1016/ j.jmatprotec.2007.02.048
Niemczewska-Wójcik M (2011) Wpływ wybranych parametrów obróbki elektroerozyjnej na cechy powierzchni obrobionej [the influence of the chosen parameters of electric discharge machining on the surface features]. Tribologia 42(6):151–159
Amorim F, Weingaertner W (2007) The behavior of graphite and copper electrodes on the finish die-sinking electrical discharge machining (EDM) of AISI P20 tool steel. J Braz Soc Mech Sci 29(4):366–371. https://doi.org/10.1590/S1678-58782007000400004
Gatto A, Sofroniou M, Spaletta G, Bassoli E (2015) On the chaotic nature of electro-discharge machining. Int J Adv Manuf Technol 79(5):985–996. https://doi.org/10.1007/s00170-015-6894-8
Yadav SKS, Yadava V, Lakshmi Narayana V (2008) Experimental study and parameter design of electro-discharge diamond grinding. Int J Adv Manuf Technol 36(1):34–4236. https://doi.org/10.1007/s00170-006-0820-z
Kozak J (2002) Abrasive electrodischarge grinding (AEDG) of advanced materials. Arch Civ Mech Eng 2(1–2):83–95
Guo G, Liu Z, An Q, Chen M (2011) Experimental investigation on conventional grinding of Ti-6Al-4V using SiC abrasive. Int J Adv Manuf Technol 57(1):135–142. https://doi.org/10.1007/s00170-011-3272-z
Sutowski P, Sutowska M (2017) Kapłonek W (2017) The use of high-frequency acoustic emission analysis for in-process assessment of the surface quality of aluminium alloy 5251 in abrasive waterjet machining. Proc Inst Mech Eng, B J Eng Manuf Online first: April 19. https://doi.org/10.1177/0954405417703428
Sutowski P, Nadolny K, Kapłonek W (2012) Monitoring of cylindrical grinding processes by use of a non-contact AE system. Int J Precis Eng Man 13(10):1737–1743. https://doi.org/10.1007/s12541-012-0228-7
Susic E, Grabec I (2000) Characterization of the grinding process by acoustic emission. Int J Mach Tool Manu 40(2):225–238. https://doi.org/10.1016/S0890-6955(99) 00055-3
Sutowski P (2010) Oszacowanie stopnia zużycia ściernicy z wykorzystaniem sygnału emisji akustycznej i teorii zbiorów rozmytych [the evaluation of grinding wheel wear with use of acoustic emission signal and fuzzy logic system]. Archiwum Technologii Maszyn i Automatyzacji 30(4):47–56
Sutowski P (2012) Surface evaluation during the grinding process using acoustic emission signal. Journal of Machine Engineering 12(4):23–34
Kwak JS, Ha MK (2004) Neural network approach for diagnosis of grinding operation by acoustic emission and power signals. J Mater Process Technol 147(1):65–71. https://doi.org/10.1016/ j.jmatprotec.2003.11.016
Cichoń A (2009) The application of the selected time–frequency descriptors detection of the acoustic emission signals generated by multisource partial discharges. Acta Phys Pol A—Opt Acoust Methods Sci Technol 116(3):209–293. https://doi.org/10.12693/APhysPolA.116.290
ASTM F1108–14 (2014) Standard specification for titanium-6aluminum-4vanadium alloy castings for surgical implants (UNS R56406). ASTM International, West Conshohocken, PA
Campanelli SL, Casalino G, Mortello M, Angelastro A, Ludovico AD (2015) Microstructural characteristics and mechanical properties of Ti6Al4V alloy fiber laser welds. Procedia CIRP, 9th CIRP conference on intelligent computation in manufacturing engineering—CIRP ICME '14, 33:428–433. https://doi.org/10.1016/j.Procir.2015.06.098
MatWeb, LLC (2017) MatWeb—the Online Materials Information Resource. http://www.matweb.com/search/DataSheet.aspx?MatGUID=a0655d261898456b958e5f825ae85390&ckck=1. Accessed 14 January 2017
Gołąbczak A, Święcik R, Gołąbczak M, Stańczyk B (2014) Badania porównawcze temperatury warstwy wierzchniej w procesie elektroerozyjnego szlifowania (AEDG) materiałów trudnoobrabialnych [comparative studies of the surface layer temperature during abrasive electrodischarge grinding process (AEDG) of hard machinable materials]. Mechanik 87(8–9):134–137
Gołąbczak A, Gołąbczak M, Konstantynowicz A, Święcik R, Galant M (2015) Modeling and experimental investigations of the surface layer temperature of titanium alloys during AEDG processing. Defect Diffus Forum 365:63–70. https://doi.org/10.4028/www.scientific.net/DDF.365.63
Gołąbczak A, Gołąbczak M, Święcik R, Stańczyk B, Kaczmarek D (2015) Dwuparametrowa ocena zdolności skrawnych ściernic supertwardych ze spoiwem metalowym [the two-parameter cutting ability evaluation of superhard grinding wheels with metal bonded]. Mechanik 88(8–9):112–116. https://doi.org/10.17814/mechanik.2015.8-9.353
Gołąbczak A, Gołąbczak M, Konstantynowicz A, Święcik R (2016) Modeling and research of temperature distribution in surface layer of titanium alloy workpiece during AEDG and conventional grinding. Contin Mech Thermodyn 28(6):1781–1789. https://doi.org/10.1007/ s00161-016-0509-y
Pragłowska–Ryłko N, Sułowicz M (2015) Zastosowanie ruchomej wartości skutecznej prądu do diagnostyki silników indukcyjnych klatkowych [Application of moving RMS current value in diagnostics of squirrel cage induction motors]. Maszyny Elektryczne - Zeszyty Problemowe 106(2):141–146
Bin Hasan MMA (2012) Model-free drive system current monitoring: faults detection and diagnosis through statistical features extraction and support vector machines classification. Current based condition monitoring of electromechanical systems. Thesis (Ph.D.). School of Engineering Design and Technology, University of Bradford. URI: http://hdl.handle.net/10454/5732
Igba J, Alemzadeh K, Durugbo C, Eiriksson ET (2016) Analysing RMS and peak values of vibration signals for condition monitoring of wind turbine gearboxes. Renew Energy 91:90–106. https://doi.org/10.1016/j.renene.2016.01.006
Gołąbczak A, Gołąbczak M, Święcik R, Kaczmarek D (2016) Ocena zdolności skrawnych ściernic supertwardych po obciąganiu wybranymi sposobami elektroerozyjnymi [the assessment of cutting ability of superhard grinding wheels after selected electrodischarge dressing methods]. Mechanik 10:1356–1357. https://doi.org/10.17814/mechanik.2016.10.359
Tom M, Komatsu T, Kunieda M (2002) Measurement of process reaction force in EDM using Hopkinson bar method. J Jpn Soc Precis Eng 68(6):822–826. https://doi.org/10.2493/jjspe.68.822
Zhang Y, Liu Y, Yang S, Ji R, Li Z, Zheng C (2014) Investigation on the influence of the dielectrics on the material removal characteristics of EDM. J Mater Process Technol 214(5):1052–1061. https://doi.org/10.1016/j.jmatprotec.2013.12.012
Korolev SV, Krylov VV (1988) Efficient excitation of Rayleigh waves by a strong shock wave initiated by a spark in air. Sov Tech Phys Lett 14(11):843–845
Krylov VV (1992) On the theory of surface acoustic wave generation by electric spark discharge. J Phys D Appl Phys 25(2):155–161. https://doi.org/10.1088/0022-3727/25/2/004
Marinescu ID, Hitchiner M, Uhlmann E, Rowe WB, Inasaki I (2007) Handbook of machining with grinding wheels. CRC Press, Taylor & Francis Group ISBN: 978-1-57444-671-5
Nisal, TV (2014) Monitoring of surface grinding process using acoustic emission (AE) with emphasis on cutting fluid selection. University of Toledo. Theses and Dissertations. 1800. http://utdr.utoledo.edu/theses-dissertations/1800
Breiman L (2001) Random forests. Mach Learn 45(1):5–32. https://doi.org/10.1023/a: 1010933404324
Fawcett T (2006) An introduction to ROC analysis. In: pattern recognition letters—special issue: ROC analysis in pattern recognition. Elsevier science Inc., New York, NY, USA, 27(8):861–874, ISSN: 0167-8655. https://doi.org/10.1016/j.patrec.2005.10.010
The MathWorks, Inc. (2016) Statistics and machine learning toolbox™. User’s guide
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Research involving human participants and/or animals
For this type of study, the statement is not applicable.
Informed consent
For this type of study, the statement is not applicable.
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Sutowski, P., Święcik, R. The estimation of machining results and efficiency of the abrasive electro-discharge grinding process of Ti6Al4V titanium alloy using the high-frequency acoustic emission and force signals. Int J Adv Manuf Technol 94, 1263–1282 (2018). https://doi.org/10.1007/s00170-017-1011-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-1011-9