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Characterization of vitrified alumina grinding wheel topography using 3D roughness parameters: influence of the crystalline structure of abrasive grains

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Abstract

One of the most recent trends in industrial grinding is the use of customized grinding wheels, with the need to completely characterize abrasive grains and bond behavior. Thus, the main goal of the present research work was to evaluate the influence of the crystalline structure of abrasive grains on both the topography and wear of the grinding wheel. To this end, we analyzed vitrified alumina grinding wheels with a monocrystalline, conventional, and microcrystalline grain structure. First, experimental grinding tests were conducted to analyze the wear suffered by the wheel surface. The new and worn topographies were characterized using confocal and SEM techniques in order to achieve an in-depth study of wheel topography. The analysis revealed differences in wheel topography depending on the crystalline structure, with Spk, Sk, and Svk 3D functional parameters being the most significant for detecting wheel wear. Finally, SEM and EDXA analyses showed that the topography is modified not only by wear but also by the accumulation of a third body on both abrasive grains and bond, decreasing the friction coefficient during grinding.

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Abbreviations

ae :

Depth of cut [μm]

ad :

Dressing depth [μm]

bw :

Grinding width [mm]

ec :

Specific grinding energy [J/mm2]

MA:

Monocrystalline alumina [−]

P′:

Specific power consumption during grinding [W]

Qw’:

Real specific removal rate [mm3/mm·s]

qs :

Speed ratio [−]

3SG:

Wheel composed of 30% SG abrasive grains [−]

Sk :

Core roughness depth [μm]

Spk :

Reduced peak height [μm]

Svk :

Reduced valley depth [μm]

vd :

Dresser speed [mm/min]

vs :

Wheel speed [m/s]

vw :

Workpiece speed [mm/min]

V’w :

Specific material removal [mm3/mm]

WFA:

White fused alumina, conventional alumina [−]

μ:

Force ratio [−]

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Acknowledgements

The authors also acknowledge the support provided by the Vice Rectorate for Research VRI (UPV/EHU) for the hiring of recent doctors until its integration in postdoctoral training programs at the UPV/EHU (DOKBERRI 2020-I).

Funding

The authors gratefully acknowledge the funding support received from the Spanish Ministry of Economy and Competitiveness and the FEDER operation program for funding the project “Scientific models and machine-tool advanced sensing techniques for efficient machining of precision components of Low Pressure Turbines” (DPI2017-82239-P).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering Bilbao, University of the Basque Country (UPV/EHU), Plaza Ingeniero Torres Quevedo, 1, 48013, Bilbao, Bizkaia, Spain

    Leire Godino, Iñigo Pombo, Jose Antonio Sanchez & Borja Izquierdo

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  1. Leire Godino
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  2. Iñigo Pombo
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Contributions

L.G, I.P, and J.A Sanchez contributed equally to the generation and analysis of experimental data and the development of the manuscript. Likewise, B.I has carried out the revision of the manuscript and the corrections done after reviewers’ revision.

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Correspondence to Leire Godino.

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The authors declare no conflict of interest. The founding sponsors had no role in the design of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript, and in the decision to publish the results.

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Godino, L., Pombo, I., Sanchez, J.A. et al. Characterization of vitrified alumina grinding wheel topography using 3D roughness parameters: influence of the crystalline structure of abrasive grains. Int J Adv Manuf Technol 113, 1673–1684 (2021). https://doi.org/10.1007/s00170-021-06721-3

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