Contribution to cylindrical grinding of interrupted surfaces of hardened steel with medium grit wheel

  • Hamilton José de Mello
  • Diego Rafael de Mello
  • Rafael Lemes Rodriguez
  • José Claudio Lopes
  • Rosemar Batista da Silva
  • Luiz Eduardo de Angelo Sanchez
  • Rodolfo Alexandre Hildebrandt
  • Paulo Roberto Aguiar
  • Eduardo Carlos Bianchi
ORIGINAL ARTICLE
  • 51 Downloads

Abstract

Grinding is generally the first choice to provide combination of both superior surface finish and closer dimensional tolerances in a machined component. This process can be employed in manufacturing of continuous and interrupted surfaces. Crankshafts and engine piston rings are examples of ground precision mechanical components having interrupted surfaces. However, the specific literature about grinding of interrupted surfaces is still scarce. In this context, aiming to further contribute to the understanding of the behavior of surface integrity of interrupted surfaces during grinding, this paper presents an experimental investigation of interrupted surfaces ground with white aluminum oxide grinding wheel. Discs of AISI 4340 hardened steel with different number of grooves (2, 6, and 12) on the external surface were tested. Experiments with discs without interrupted surface were also carried out for comparisons. In addition to the number of grooves, three values of infeed rate (0.25, 0.50, and 0.75 mm/min) were used as input parameters. The output parameters investigated were the geometric errors (surface roughness and roundness) of the workpiece material as well as the diametric wheel wear. Analysis of variance (ANOVA) test was performed to verify any statistical difference among the output variables. Results showed that both surface finish and roundness of workpieces with interrupted surfaces were higher than those obtained for continuous surface. These parameters also increased with infeed rate up to 0.50 mm/min, whereas the grinding wheel wear was more sensitive to number of grooves and infeed rate. No thermal damages were observed on the machined workpieces under the conditions investigated.

Keywords

Cylindrical external plunge grinding Interrupted surface Number of grooves AISI 4340 steel Geometric errors Wheel wear Surface integrity 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Compliance with ethical standards

Conflict of interest

The authors declare that they have no conflict of interest.

References

  1. 1.
    Klocke F, Brinksmeier E, Weinert K (2005) Capability profile of hard cutting and grinding processes. CIRP Ann Manuf Technol 54(2):22–45.  https://doi.org/10.1016/S0007-8506(07)60018-3 CrossRefGoogle Scholar
  2. 2.
    Lopez-Arraiza A, Castillo G, Dhakal HN, Alberdi R (2013) High performance composite nozzle for the improvement of cooling in grinding machine tools. Compos Part B 54:313–318.  https://doi.org/10.1016/j.compositesb.2013.05.029 CrossRefGoogle Scholar
  3. 3.
    Inasaki I, Karpuschewski B, Lee HS (2001) Grinding chatter–origin and suppression. CIRP Ann Manuf Technol 50(2):515–534.  https://doi.org/10.1016/S0007-8506(07)62992-8 CrossRefGoogle Scholar
  4. 4.
    Karaguzel U, Bakkal M, Budak E (2016) Modeling and measurement of cutting temperatures in milling. Procedia CIRP 46:173–176.  https://doi.org/10.1016/j.procir.2016.03.182 CrossRefGoogle Scholar
  5. 5.
    Diniz AE, Gomes DM, Braghini A (2005) Turning of hardened steel with interrupted and semi-interrupted cutting. J Mater Process Technol 159(2):240–248.  https://doi.org/10.1016/j.jmatprotec.2004.05.011 CrossRefGoogle Scholar
  6. 6.
    De Godoy VAA, Diniz AE (2011) Turning of interrupted and continuous hardened steel surfaces using ceramic and CBN cutting tools. J Mater Process Technol 211(6):1014–1025.  https://doi.org/10.1016/j.jmatprotec.2011.01.002 CrossRefGoogle Scholar
  7. 7.
    Malkin S, Guo C (2008) Grinding technology: theory and applications of machining with abrasives, New York: Industrial Press, 2nd. Edition, p. 372, 2008Google Scholar
  8. 8.
    Al-Zaharnah IT (2006) Suppressing vibrations of machining processes in both feed and radial directions using an optimal control strategy: the case of interrupted cutting. J Mater Process Technol 172(2):305–310.  https://doi.org/10.1016/j.jmatprotec.2005.10.008 CrossRefGoogle Scholar
  9. 9.
    Urbikain G, De Lacalle LN, López FA (2014) Regenerative vibration avoidance due to tool tangential dynamics in interrupted turning operations. J Sound Vib 333(17):3996–4006.  https://doi.org/10.1016/j.jsv.2014.03.028 CrossRefGoogle Scholar
  10. 10.
    Kountanya R (2008) Cutting tool temperatures in interrupted cutting—the effect of feed-direction modulation. J Manuf Process 10(2):47–55.  https://doi.org/10.1016/j.jmapro.2009.04.001 CrossRefGoogle Scholar
  11. 11.
    Rowe WB (2010) Modern grinding techniques, Wiley, Hoboken, NJ; Scrivener Publishing LLC, Salem, MA, p. 49Google Scholar
  12. 12.
    Malkin S, Guo C (2007) Thermal analysis of grinding, CIRP Ann. Manuf. Technol., 56(2), pp. 760–782. p. 47-55, 2008Google Scholar
  13. 13.
    Marinescu ID, Rowe WB, Dimitrov B, Inasaki I. (2013) Tribology of abrasive machining processes. 2ªed. Norwich, William Andrew Inc.Google Scholar
  14. 14.
    Klocke F (2009) Manufacturing processes 2—grinding, honing, lapping. Springer, Berlin, p 433CrossRefGoogle Scholar
  15. 15.
    Kwak JS, Ha MK (2001) Force modeling and machining characteristics of the intermittent grinding wheels. KSME Int J 15(3):351–356.  https://doi.org/10.1007/BF03185218 CrossRefGoogle Scholar
  16. 16.
    Pérez J, Hoyas S, Skuratov DL, Ratis YL, Selezneva IA, Fernández De Córdoba P, Urchueguía JF (2008) Heat transfer analysis of intermittent grinding processes. Int J Heat Mass Transf 51(15):4132–4138.  https://doi.org/10.1016/j.ijheatmasstransfer.2007.11.043 CrossRefMATHGoogle Scholar
  17. 17.
    Oliveira DJ, Guermandi LG, Bianchi EC, Diniz AE, Aguiar PR, Canarim RC (2012) Improving minimum quantity lubrication in CBN grinding using compressed air wheel cleaning. J Mater Process Technol 212(12):2559–2568.  https://doi.org/10.1016/j.jmatprotec.2012.05.019 CrossRefGoogle Scholar
  18. 18.
    Alves LOBS, Ruzzi RS, Silva RS, Jackson M J, Tarrento GE, Mello HJ, Aguiar PR, Bianchi EC (2017) Performance evaluation of the minimum quantity of lubricant technique with auxiliary cleaning of the grinding wheel in cylindrical grinding of N2711 steel. Journal of Manufacturing Science and Engineering, V 139Google Scholar
  19. 19.
    Ruzzi RS, Belentani RM, De Mello HJ, Canarim RC, D’Addona DM, Diniz AE, De Aguiar PR, Bianchi EC (2016) MQL with water in cylindrical plunge grinding of hardened steels using CBN wheels, with and without wheel cleaning by compressed air. Int J Adv Manuf Technol 90(1–4):329–338Google Scholar
  20. 20.
    Sohal N, Sandhu CS, Panda BK (2014) Analyzing the effect of grinding parameters on MRR and surface roughness of EN24 and EN353 steel. Mech Confab 3:1–6Google Scholar
  21. 21.
    Chen X, Öpöz TT (2016) Effect of different parameters on grinding efficiency and its monitoring by acoustic emission. Prod Manuf Res 4(1):190–208p.  https://doi.org/10.1080/21693277.2016.1255159 Google Scholar
  22. 22.
    Xu W, Wu Y, Sato T, Lin W (2010) Effects of process parameters on workpiece roundness in tangential-feed centerless grinding using a surface grinder. J Mater Process Technol 210(5):759–766.  https://doi.org/10.1016/j.jmatprotec.2010.01.003 CrossRefGoogle Scholar
  23. 23.
    Shaw MC (1996) Energy conversion in cutting and grinding. CIRP Ann Manuf Technol 45(1):101–104.  https://doi.org/10.1016/S0007-8506(07)63025-X CrossRefGoogle Scholar
  24. 24.
    Kurt M, Köklü U (2012) Minimization of the shape error in the interrupted grinding process by using Taguchi method. Mechanika 18(6):677–682.  https://doi.org/10.5755/j01.mech.18.6.3163 Google Scholar
  25. 25.
    Lei X, Zhang C, Xue Y, Li J (2011) Roundness error evaluation algorithm based on polar coordinate transform. Measurement 44(2):345–350.  https://doi.org/10.1016/j.measurement.2010.10.007 CrossRefGoogle Scholar
  26. 26.
    Marinescu ID, Hitchiner M, Uhlmann E, Rowe WB, Inasaki I (2007) Handbook of machining with grinding wheels, CRC Press, Taylor & Francis Group, USA, 596Google Scholar
  27. 27.
    Choi TJ, Subrahmanya N, Li H, Shin YC (2008) Generalized practical models of cylindrical plunge grinding processes. Int J Mach Tools Manuf 48(1):61–72.  https://doi.org/10.1016/j.ijmachtools.2007.07.010 CrossRefGoogle Scholar
  28. 28.
    Liao TW, Li K, Mcspadden SB (2000) Wear mechanisms of diamond abrasives during transition and steady stages in creep-feed grinding of structural ceramics. Wear 242(1):28–37.  https://doi.org/10.1016/S0043-1648(00)00366-5 CrossRefGoogle Scholar
  29. 29.
    Wang Z, WIllett P, De Aguiar PR, Webster J (2001) Neural network detection of grinding burn from acoustic emission. Int J Mach Tools Manuf 41(2):283–309.  https://doi.org/10.1016/S0890-6955(00)00057-2 CrossRefGoogle Scholar
  30. 30.
    Kwak J, Ha M (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 CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Hamilton José de Mello
    • 1
  • Diego Rafael de Mello
    • 1
  • Rafael Lemes Rodriguez
    • 1
  • José Claudio Lopes
    • 1
  • Rosemar Batista da Silva
    • 2
  • Luiz Eduardo de Angelo Sanchez
    • 1
  • Rodolfo Alexandre Hildebrandt
    • 1
  • Paulo Roberto Aguiar
    • 1
  • Eduardo Carlos Bianchi
    • 1
  1. 1.Bauru campus, Department of Mechanical EngineeringSão Paulo State University “Júlio de Mesquita Filho”BauruBrazil
  2. 2.School of Mechanical EngineeringFederal University of Uberlandia (UFU)UberlandiaBrazil

Personalised recommendations