Skip to main content
SpringerLink
Log in

An experimental and theoretical analysis of surface generation in the ultra-precision grinding of hard and brittle materials

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presents an experimental and theoretical study of surface generation in the ultra-precision grinding of hard and brittle materials. The study takes into account the material properties, the relative vibration between the grinding wheel and the workpiece, the machining parameters and the phase shift of the grinding process. The Taguchi approach is employed to study the influence of machining parameters on the surface quality and shows that the feed speed and rotational speed of the workpiece are key factors. Experiments have been conducted to study individual variables, and the results further show that the feed rate and the cross-feed distance have a significant effect on surface generation. It is found that the spirals around the central area of the workpiece are the primary mechanism for surface generation, which originates from the synchronous relative tool-work vibration. The integral part of the ratio of the rotational speed of the grinding wheel to rotational speed of the workpiece determines the number of spirals and its fractional part controls the spiral geometry. A theoretical model for predicting the single spiral generation has been developed to explain the accumulation of the phase shift and the geometry. The changeable feed speed near the end of grinding is also modelled, revealing the approximate straight lines around one circle in the central region. The simulated results indicate that the theoretical models and the ground surfaces are in close agreement. The scallop-height model is developed to calculate the influence of phase shift on surface quality, and it is found that the phase shift near the medium value can effectively improve surface quality. Finally, a comparison of different surface generation mechanisms in grinding mould steel, tungsten carbide (WC) and reaction bonded silicon carbide (RB-SiC) is made. It is interesting to note that the Spanzipfel effect contributes to the surface generation not only on ductile materials such as mould steel but also on brittle materials such as WC and RB-SiC. The Spanzipfel effect is the most significant in grinding mould steel. For WC and RB-SiC, the ground surface contains both a ductile region and a brittle region in the form of micro-fractures.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Agarwal S, Rao PV (2012) Predictive modeling of undeformed chip thickness in ceramic grinding. Int J Mach Tools Manuf 56:59–68

    Article  Google Scholar 

  2. Beaucamp A, Simon P, Charlton P, King C, Matsubara A, Wegener K (2017) Brittle-ductile transition in shape adaptive grinding (SAG) of SiC aspheric optics. Int J Mach Tools Manuf 115:29–37

    Article  Google Scholar 

  3. Jahanmir S, Ramulu M, Koshy P (1999) Machining of ceramics and composites. Marcel Dekker, New York

    Google Scholar 

  4. Zhang QL, To S, Zhao QL, Guo B, Zhang GQ (2015) Impact of material microstructure and diamond grit wear on surface finish in micro-grinding of RB-SiC/Si and WC/Co carbides. Int J Refract Met Hard Mater 51:258–263

    Article  Google Scholar 

  5. Agarwal S, Rao PV (2010) Grinding characteristics, material removal and damage formation mechanisms in high removal rate grinding of silicon carbide. Int J Mach Tools Manuf 50:1077–1087

    Article  Google Scholar 

  6. Yin L, Huang H (2008) Brittle materials in nano-abrasive fabrication of optical mirrorsurfaces. Precis Eng 32:336–341

    Article  Google Scholar 

  7. Zhang B, Zheng XL, Tokura H, Yoshikawa M (2003) Grinding induced damage in ceramics. J Mater Process Technol 132(1–3):353–364

    Article  Google Scholar 

  8. Lee SC, Ren N (1996) Behavior of elastic-plastic rough surface contacts as affected by surface topography, load, and material hardness. Tribol Trans 39(1):67–74

    Article  Google Scholar 

  9. Stark GA, Moon KS (1999) Modeling surface texture in the peripheral milling process using neural network, spline, and fractal methods with evidence of chaos. ASME J Manuf Sci Eng 121(2):251–256

    Article  Google Scholar 

  10. Huang H, Yin L, Zhou LB (2003) High speed grinding of silicon nitride with resin bond diamond wheels. J Mater Process Technol 141(3):329–336

    Article  Google Scholar 

  11. Zhang QL, To S, Zhao QL, Guo B (2016) Surface generation mechanism of WC/Co and RB-SiC/Si composites under high spindle speed grinding (HSSG). Int J Refract Met Hard Mater 56:123–131

    Article  Google Scholar 

  12. Kwak J (2005) Application of Taguchi and response surface methodologies for geometric error in surface grinding process. Int J Mach Tools Manuf 45(3):327–334

    Article  Google Scholar 

  13. AllorRL, WhalenTJ, BaerJR, KumarKV (1993)Machining of silicon nitride: experimental determination of process/property relationships Proceedings of International Conference on Machining Adv Mater223–234

  14. Oliveira JFG, Botteneand AC, França TV (2001) A novel dressing technique for texturing of ground surfaces. Annals of the CIRP—Manufacturing Technology 59:361–364

    Article  Google Scholar 

  15. Ohbuchi Y, Obikawa T (2006) Surface generation model in grinding with effect of grain shape and cutting speed. JSME Int J Ser C Mech Syst Mach Elem Manuf 49(1):114–120

    Article  Google Scholar 

  16. Agarwal S, Rao PV (2005) A new surface roughness prediction model for ceramic grinding. Proc Inst Mech Eng B J Eng Manuf 219(11):811–819

    Article  Google Scholar 

  17. Warnecke G, Zitt U (1998) Kinematic simulation for analyzing and predicting high-performance grinding processes. Ann CIRP 47(1):265–270

    Article  Google Scholar 

  18. Cao YL, Guan JY, Li B, Chen XL, Yang JG, Gan CB (2013) Modeling and simulation of grinding surface topography considering wheel vibration. Int J Adv Manuf Technol 66(5):937–945

    Article  Google Scholar 

  19. Jiang XH, Guo MX, Li BZ (2018) Active control of high-frequency tool-workpiece vibration in micro-grinding. Int J Adv Manuf Technol 94(1):1429–1439

    Article  Google Scholar 

  20. Yan Y, Xu J, Wiercigroch M (2016) Regenerative chatter in self-interrupted plunge grinding. Meccanica 51(12):3185–3202

    Article  MathSciNet  Google Scholar 

  21. Hassui A, Diniz AE (2003) Correlating surface roughness and vibration on plunge cylindrical grinding of steel. Int J Mach Tools Manuf 43(8):855–862

    Article  Google Scholar 

  22. Yoshihara N, Kuriyagawa T, Syoji K (2003) Formation of vertical striped pattern on the ground surface in high-reciprocation profile grinding (in Japanese). Journal of the Japan Society for Precision Engineering 67(8):1316–1320

    Google Scholar 

  23. Cao HR, Dörgeloh T, Riemer O, Brinksmeier E (2017) Adaptive separation of unbalance vibration in air bearing spindles. Procedia CIRP 62:357–362

    Article  Google Scholar 

  24. Marinescu I, Rowe W, Dimitrov B, Ohmori H (2013) Tribology of abrasive machining processes, 2nd edn. Elsevier, Amsterdam

    Google Scholar 

  25. Chen JB, Fang QH, Li P (2015) Effect of grinding wheel spindle vibration on surface roughness and subsurface damage in brittle material grinding. Int J Mach Tools Manuf 91:12–23

    Article  Google Scholar 

  26. Kuriyagawa T, Yoshihara N, Saeki M, Syoji K (2003) Nano-topography characterization of axisymmetric aspherical ground surfaces. Key Eng Mater 238-239:125–130

    Article  Google Scholar 

  27. Yoshihara N, Yan JW, Kuriyagawa T (2008) Control of nano-topography on an axisymmetric ground surface. Key Eng Mater 389-390:96–101

    Article  Google Scholar 

  28. Whitehouse DJ (1994) Handbook of surface metrology. Institute of Physics Pub, Bristol

    Google Scholar 

  29. Gill R (1986) An investigation into the effect of the ratio of grinding wheel speed to workpiece speed in the centreless grinding process. In: Coventry. Lanchester) Polytechnic, PhD thesis

    Google Scholar 

  30. Horvath M, Kundrak J, Mamalis A, Gyani K (2002) On the precision grinding of advanced ceramics. Int J Adv Manuf Technol 20(4):255–258

    Article  Google Scholar 

  31. Pandit SM, Sathyanarayanan G (1984) Data-dependent systems approach to surface generation in grinding. ASME J Eng Ind 106(3):205–212

    Article  Google Scholar 

  32. Pandit SM, Revach SS (1981) A data dependent systems approach to dynamics of surface generation in turning. ASME J Eng Ind 103(4):437–445

    Article  Google Scholar 

Download references

Funding

The work was supported by a PhD studentship (project account code: RU3K) from The Hong Kong Polytechnic University. This research work was also supported by the State Key Basic Research and Development Program, China (973 program, Grant No. 2011CB 013202), and Guangdong Provincial Department of Science and Technology, Guangdong, P.R. China, for The Introduction of Innovative R&D Team Program of Guangdong Province (project no.: 201001G0104781202).

Author information

Authors and Affiliations

  1. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Shan Shan Chen & Fei Hu Zhang

  2. Partner State Key Laboratory of Ultraprecision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong

    Shan Shan Chen & Chi Fai Cheung

Authors
  1. Shan Shan Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Chi Fai Cheung
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Fei Hu Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Shan Shan Chen.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chen, S.S., Cheung, C.F. & Zhang, F.H. An experimental and theoretical analysis of surface generation in the ultra-precision grinding of hard and brittle materials. Int J Adv Manuf Technol 97, 2715–2729 (2018). https://doi.org/10.1007/s00170-018-2121-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2121-8

Keywords

Search

Navigation