Skip to main content
SpringerLink
Log in

An experimental investigation into resonance dry grinding of hardened steel and nickel alloys with element of MQL

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

Abstract

Current policies on environmental issues put extra pressures on manufacturing processes to be resource efficient and eco-friendly. However, in grinding processes, large amounts of cutting fluids are used. These fluids are not environmental friendly thus require proper management before disposal with associated cost. Hence, this work sets to explore low-frequency vibration in grinding in order to improve coolant application in conventional grinding at the first stage with the aim to introduce this into high efficiency deep grinding (HEDG) at latter stage. An attempt is made to grind nickel alloys with minimum quantity lubricant (MQL) as oppose to flood cooling. To achieve this with minimum alterations to the machine tool, a piezo-driven workpiece holder was developed for surface grinding. This simple innovative workpiece holder allowed oscillating during actual grinding process. However, this paper presents the results of low-frequency oscillatory grinding in dry and near-dry conditions. The response of the machine tool spindle unit is presented alongside with the workpiece holder response. In this investigation, hardened steels and nickel alloys were ground with vibration assistance. The grinding forces are illustrated together with the surface finish. The wheel performance is given in terms of grinding ratio.

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. Bespalova LV (1957) The theory of vibro-impact mechanisms. Izvestiya ANSSR, OTN, Moscow (in Russian)

    Google Scholar 

  2. Blekhman II (1979) Vibration of nonlinear mechanical systems, 2nd edn. Vibration in Engineering, Moscow, in Russian

    Google Scholar 

  3. Kumabe J (1985) Vibrating Cutting. Mashinostroenie, Russian translation, Moscow, original in Japanese, 1979

    Google Scholar 

  4. Jiang YX, Tang WX, Zhang GL, Song QH, Li BB, Du B (2007) An experiment investigation for dynamic characteristics of grinding machine. Key Eng Mater 329:767–772

    Article  Google Scholar 

  5. Rowe WB, Mills B, Black SCE (1996) Temperature control in CBN grinding. Int J Adv Manuf Technol 12:387–392

    Article  Google Scholar 

  6. Orynski F, Pawlowski W (2002) The mathematical description of dynamics of the cylindrical grinder. Int J Mach Tool Manuf 42:773–780

    Article  Google Scholar 

  7. Kirpitchenko I, Zhang N, Tchernykh S, Liu D K (2002) Dynamics and control of grinding machines. 6th Int Conf Motion Vib Control Part 2 1039–1044

  8. Zhang B, Hu Z, Luo H, Deng Z (2006) Vibration-assisted grinding—piezotable design and fabrication. Nanotechnol Precis Eng 4:282–290

    Google Scholar 

  9. Zhong ZW, Yang HB (2004) Development of a vibration device for grinding with microvibration. Mater Manuf Process 19(6):1121–1132

    Article  Google Scholar 

  10. Zhong ZW, Rui ZY (2005) Grinding of single-crystal silicon using a microvibration device. Mater Manuf Process 20:687–696

    Article  Google Scholar 

  11. Mahaddalkar PM, Miller MH (2014) Force and thermal effects in vibration-assisted grinding. Int J Adv Manuf 71:1117–1122

    Article  Google Scholar 

  12. Tawakoli T, Azarhoushang B (2008) Influence of ultrasonic vibrations on dry grinding of soft steel. Int J Mach Tool Manuf 48:1585–1591

    Article  Google Scholar 

  13. Babitsky VI, Kalashnikov AN, Meadows A, Wijesundarac AAHP (2003) Ultrasonically assisted turning of aviation materials. J Mater Process Technol 132:157–167

    Article  Google Scholar 

  14. Kozlov A, Deryabin M (2011) Pulsed processes when cutting heat-resistant alloys. Proceedings of the 6th International Congress of Precision Machining, Liverpool UK 13–15 September, Liverpool, pp 47–52

    Google Scholar 

  15. Liang Z, Wu Y, Wanga X, Zhao W (2010) A new two-dimensional ultrasonic assisted grinding (2D-UAG) method and its fundamental performance in monocrystal silicon machining. Int J Mach Tool Manuf 50(8):728–736

    Article  Google Scholar 

  16. Mitrofanov AV, Babitsky VI, Silberschmidt VV (2003) Finite element simulations of ultrasonically assisted turning. Comput Mater Sci 28:645–653

    Article  Google Scholar 

  17. Moriwaki T, Shamoto E (1991) Ultraprecision diamond turning of stainless steel by applying ultrasonic vibration. Kobe University Japan vol.40 No.1

  18. Spur G, Holl S E (1997) Material removal mechanisms during ultrasonic assisted grinding. Prod Eng, IV/2 pp.9-14

  19. Spur G, Holl SE (1996) Ultrasonic assisted grinding of ceramics. J Mater Process Technol 62:287–293

    Article  Google Scholar 

  20. Uhlmann E (1998) Surface formation in creep feed grinding of advanced ceramics with and without ultrasonic assistance. Institute for Machine Tools and Factory Management, Berlin

    Google Scholar 

  21. Mishra VK, Salonitis K (2013) Empirical estimation of grinding specific forces and energy based on a modified Werner grinding model. Procedia CIRP 8:287–292

    Article  Google Scholar 

  22. Salonitis K, Stavropoulos P, Kolios A (2014) External grind-hardening forces modelling and experimentation. Int J Adv Manuf Technol 70:523–530

    Article  Google Scholar 

  23. Filiz S, Cheng CH, Powell KB, Schmitz TL, Ozdoganlar OB (2009) An improved tool-holder model for RCSA tool-point frequency response prediction. Precis Eng 33(1):26–36

    Article  Google Scholar 

  24. Schmitz T, Ziegert J (1999) Examination of surface location error due to phasing of cutter vibrations. Precis Eng 23(1):55–62

    Article  Google Scholar 

  25. Altinas Y, Montgomery D, Budak E (1992) Dynamic peripheral milling of flexible structures. J Eng Ind Trans ASME 114(2):137–145

    Article  Google Scholar 

  26. Erturk A, Ozguven HN, Budak E (2006) Analytical modelling of spindle-tool dynamics on machine tools using Timoshenko beam model and receptance coupling for the prediction of tool point FRF. Int J Mach Tool Manuf 46:1901–1912

    Article  Google Scholar 

  27. Kirpitchenko I, Zhang N, Tchernykh S, Liu DK (2002) Dynamics and control of grinding machines. 6th International Conference on Motion and Vibration Control’ Part 2, pp 1039–1044

  28. Thomsen JJ (2003) Vibrations and stability: advanced theory, analysis and tools, 2nd edn. Springer complexity series, New York

    Book  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. General Engineering Research Institute, Liverpool John Moores University, Byrom Street, L3 3AF, Liverpool, UK

    Andre D. L. Batako & Vaios Tsiakoumis

Authors
  1. Andre D. L. Batako
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Vaios Tsiakoumis
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Andre D. L. Batako.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Batako, A.D.L., Tsiakoumis, V. An experimental investigation into resonance dry grinding of hardened steel and nickel alloys with element of MQL. Int J Adv Manuf Technol 77, 27–41 (2015). https://doi.org/10.1007/s00170-014-6380-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6380-8

Keywords

Search

Navigation