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Wheel wear-related instability in grinding of quartz glass

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Abstract

Grinding is a popular method for producing high-quality parts made of hard and brittle materials. A lot of researchers have focused on the impact of grinding parameters on surface quality. However, only a few studies discussed the surface quality instability caused by the grinding wheel wear during a long grinding process. In this paper, through wheel state monitoring and surface quality testing of ground samples, it is found that the relationship between ground surface roughness and theoretical undeformed chip thickness is significantly affected by the grinding wheel wear state rather than maintain steady as described in most available models. By introducing the normal grinding force, a linear relationship was found among normal grinding force, undeformed chip thickness, and ground surface roughness. Besides, sensitivity analysis was conducted to guide the parameter adjustment to maintain the stability of ground surface roughness and grinding state. The mechanism of the effect of wheel wear on normal grinding force was also studied in detail. This study will help to further understand the mechanism of the influence of wheel wear on the grinding stability.

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Data Availability

The authors confirm that the data supporting the findings of this study are available within the article.

Abbreviations

a p :

Depth of cut

C :

Number of cutting points per area

d e :

Equivalent diameter of grinding wheel

D :

Diameter of the grinding wheel

E(R a ) :

Expected value of surface roughness Ra

E(t) :

Expected value of undeformed chip thickness

f :

Overlap factor

F n :

Normal grinding force

h w :

Reduction of abrasive grits protrusion height caused by grinding wheel wear

k :

Synthesized parameter of Vs, Vw and Ap

MRV 41Cr4 :

Material removal volume of 41Cr4 in the preparation of wear grinding wheel

N d :

Number of dynamic active grits

P 0 :

Constant determined by experiment

r :

Aspect ratio of the chip section

R a :

Arithmetical mean roughness of grinding surface

S w :

Tip area of the worn grit

t m :

Maximum undeformed chip thickness

v s :

Grinding wheel speed

v w :

Workpiece infeed rate

δ n ,n + 1 :

Change rate in normal grinding force between wear stage n and wear stage n + 1

ϕ :

A coefficient fitted according to experimental data

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Acknowledgements

All authors appreciate the financial support from the National Natural Science Foundation of China (51875078, 51991372, 51975094) and the Science Fund for Creative Research Groups of NSFC of China (51621064).

Funding

The National Natural Science Foundation of China (Grant nos. 51875078, 51991372, and 51975094) and the Science Fund for Creative Research Groups of NSFC of China (Grant no. 51621064).

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China

    Yonghao Wang, Ping Zhou, Yuhang Pan, Ying Yan & Dongming Guo

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  1. Yonghao Wang
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Contributions

Ping Zhou, Ying Yan, and Dongming Guo developed the idea for the study, Yonghao Wang and Yuhang Pan did the analyses, and Yonghao Wang wrote the paper.

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Correspondence to Ping Zhou.

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Wang, Y., Zhou, P., Pan, Y. et al. Wheel wear-related instability in grinding of quartz glass. Int J Adv Manuf Technol 119, 233–245 (2022). https://doi.org/10.1007/s00170-021-08189-7

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