Skip to main content
SpringerLink
Log in

Formulating CAM parameters for surface patterning by grinding process based on unit pattern geometry

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

Abstract

Grinding employs an abrasive product, usually a rotating wheel, which is brought into controlled contact with a workpiece surface. The grinding patterning process can be simulated using computer programming with specific user-defined parameters. To predict the surface pattern that will result from grinding with the grooved wheel, calculating the CAM parameters is very important. The intention of this research is to formulate CAM parameters for the generation of a surface pattern on a flat nominal surface by grinding with a wheel that has been prepared in a special way. A diamond dresser having a rounded tip is applied to prepare helical grooves on the conventional wheel’s surface. With the intention of extracting CAM parameters, a mathematical model is developed for a grinding patterning process, starting from the unit pattern geometry of the workpiece plate. The models are characterized by the process parameters of grinding patterning such as unit pattern geometry, dressing parameters, wheel geometry and grinding conditions, as well as work surface geometry. A computer program with a user interface is developed using Matlab according to the proposed mathematical model to predict surface pattern. In addition, several examples of simulation results of the 3D wheel geometry model and corresponding patterned surfaces have been displayed using the proposed CAM parameters as input. Formulated CAM parameters can be used to control the actual grinding process or predict the ground surface pattern.

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. Malkin S, Guo S (2008) Grinding technology theory and applications of machining with abrasives. Ellis Horwood Limited, Chichester

    Google Scholar 

  2. Domala KV, Salisbury EJ, Moon KS, Sutherland JW (1995) A study of the three dimensional structure of a ground surface. Proc. Ist Int Machining and Grinding Conf 847-863

  3. Suto T, Sata T (1981) Simulation of grinding process based on wheel surface characteristics. Bull Japan Soc Precis Eng 15(1):27–33

    Google Scholar 

  4. Chen X, Rowe WB (1996) Analysis and simulation of the grinding process, part I: generation of the grinding wheel surface. Int J Mach Tools Manufact 36(8):871–882

    Article  Google Scholar 

  5. Bałasz B (2003) Analysis of shaping of workpiece surface topography and load of active abrasive grains in grinding process. Dissertation, Koszalin University of Technology

  6. Stepien P (2006) Three basic types of regular surface texture generated by plunge grinding with the wheel having helical grooves. Adv Manuf Sci Technol 30(3):37–54

    MathSciNet  Google Scholar 

  7. Stepien P (2007) Grinding forces in regular texture generation. Int J Mach Tools Manuf 47:2098–2110

    Article  Google Scholar 

  8. Stepien P (2008) Mechanism of grinding wheel surface reproduction in regular surface texture generation. Surf Eng 24(3):219–225

    Article  MathSciNet  Google Scholar 

  9. Li X, Rong Y (2011) Framework of grinding process modeling and simulation based on microscopic interaction analysis. Robot Comput-Integr Manuf 27:471–478

    Article  Google Scholar 

  10. Saravanan R, Sachithanandam M (2001) Genetic algorithm (GA) for multivariable surface grinding process optimisation using a multi-objective function model. Int J Adv Manuf Tech 17:330–338

    Article  Google Scholar 

  11. Saravanan R, Asokan P, Sachidanandam M (2002) A multiobjective genetic algorithm (GA) approach for optimization of surface grinding operations. Int J Mach Tools and Manuf 42:1327–1334

    Article  Google Scholar 

  12. Steffens K, Konig W (1983) Closed loop simulation of grinding. CIRP Ann Manuf Technol 32(1):255–259

    Article  Google Scholar 

  13. Brinksmeier E, Aurich JC, Govekar E, Heinzel C, Hoffmeister H-W, Klocke F, Peters J, Rentsch R, Stephenson DJ, Uhlmann E, Weinert K, Wittmann M (2006) Advances in modeling and simulation of grinding processes. Ann CIRP 55(2):667–696

    Article  Google Scholar 

  14. Stepien P (1989) Generation of regular patterns on ground surfaces. Ann CIRP 38(1):561–566

    Article  Google Scholar 

  15. Gao W, Araki T, Kiyono S, Okazaki Y, Yamanaka M (2003) Precision nanofabrication and evaluation of a large area sinusoidal grid surface for a surface encoder. Precis Eng 27:289–298

    Article  Google Scholar 

  16. Ike H (1996) Properties of metal sheets with 3-D designed surface microgeometry prepared by special rolls. J Mater Process Technol 60:363–368

    Article  Google Scholar 

  17. Ike H, Plancak M (1998) Coining process as a means of controlling surface microgeometry. J Mater Process Technol 80–81:101–107

    Article  Google Scholar 

  18. Pettersson U, Jacobson S (2006) Tribological texturing of steel surfaces with a novel diamond embossing tool technique. Tribol Int 39:695–700

    Article  Google Scholar 

  19. Fornie’s E, Zaldo C, Albella JM (2005) Control of random texture of monocrystalline silicon cells by angle-resolved optical reflectance. Sol Energy Mater Sol Cells 87:583–593

    Article  Google Scholar 

  20. Xi Z, Yang D, Que D (2003) Texturization of monocrystalline silicon with tribasic-sodium phosphate. Sol Energy Mater Sol Cells 77:255–263

    Article  Google Scholar 

  21. Bulatov VP, Krasny VA, Schneider YG (1997) Basic of machining methods to yield wear- and fretting-resistive surfaces, having regular roughness patterns. Wear 208:132–137

    Article  Google Scholar 

  22. Arola D, McCain ML, Kunaporn S, Ramulu M (2002) Waterjet and abrasive waterjet surface treatment of titanium: a comparison of surface texture and residual stress. Wear 249:943–950

    Article  Google Scholar 

  23. Ramasawmy H, Blunt L (2004) Effect of EDM process parameters on 3D surface topography. J Mater Process Technol 148:155–164

    Article  Google Scholar 

  24. Cheng X, Yang XH, Huang YM, Zheng GM, Li L (2014) Helical surface creation by wire electrical discharge machining for micro tools. Robot Comput Integr Manuf 30:287–294

    Article  MATH  Google Scholar 

  25. Kovalchenko A, Ajayi O, Erdemir A, Fenske G, Etsion I (2005) The effect of laser surface texturing on transitions in lubrication regimes during unidirectional sliding contact. Tribol Int 38:219–225

    Article  Google Scholar 

  26. Choo KL, Ogawa Y, Kanbargi G, Otra V, Raff LM, Komanduri R (2004) Micromachining of silicon by short-pulse laser ablation in air and under water. Mater Sci Eng, A 372:145–162

    Article  Google Scholar 

  27. Du D, He YF, Sui B, Xiong LJ, Zhang H (2005) Laser texturing of rollers by pulsed Nd:YAG laser. J Mater Process Technol 161:456–461

    Article  Google Scholar 

  28. Hong MH, Huang SM, Luk’yanchuk BS, Chong TC (2003) Laser assisted surface nanopatterning. Sens Actuators, A 108:69–74

    Article  Google Scholar 

  29. Lee Y-C, Chen C-M, Wu C-Y (2005) A new excimer laser micromachining method for axially symmetric 3D microstructures with continuous surface profiles. Sens Actuators, A 117:349–355

    Article  Google Scholar 

  30. Man HC, Zhang S, Cheng FT, Guo X (2005) Laser fabrication of porous surface layer on NiTi shape memory alloy. Mater Sci Eng, A 404:173–178

    Article  Google Scholar 

  31. Chamorro LP, Arndt REA, Sotiropoulos F (2013) Drag reduction of large wind turbine blades through riblets: evaluation of riblet geometry and application strategies. Renew Energy 50:1095–1105

    Article  Google Scholar 

  32. Denkena B, Köhler J, Wang B (2010) Manufacturing of functional riblet structures by profile grinding. CIRP J Manuf Sci Technol 3:14–26

    Article  Google Scholar 

  33. Andersson P, Koskinen J, Varjus S, Gerbig Y, Haefke H, Georgiou S, Zhmud B, Buss W (2007) Micro-lubrication effect by laser-textured steel surfaces. Wear 262:369–379

    Article  Google Scholar 

  34. Chakrabarti S, Paul S (2008) Numerical modeling of surface topography in superabrasive grinding. Int J Adv Manuf Technol 39:29–38

    Article  Google Scholar 

  35. Kim H-C, Lee S-G (2012) Development of machining technology for micropatterns with large surface area. Int J Adv Manuf Technol 58:1261–1270. doi:10.1007/s00170-011-3544-7

    Article  Google Scholar 

  36. Cao Y, Guan J, Li B, Chen X, Yang J, Gan C (2012) Modeling and simulation of grinding surface topography considering wheel vibration. Int J Adv Manuf Technol DOI. doi:10.1007/s00170-012-4378-7

    Google Scholar 

  37. Kim HC, Ko TJ (2012) Parametric modeling of a screw fabricated by turning. J Korean Soc Manuf Process Eng 11(6):62–68

    Google Scholar 

  38. Islam MM, Kim H, Ko T, Geometry modeling of screwed wheel dressed by rounded tool. Accepted to the Journal of the Chinese Society of Mechanical Engineers.

  39. Kim H, Ko TJ (2014) Simulation of micro-patterns engraved by grinding process with screw shaped wheel. Simul Model Pract Theory 49:277–286

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Manufacturing Information Laboratory, Department of Mechanical and Automotive Engineering, Andong National University, 1375 Gyeongdong-ro, Andong, Gyeongbuk, 760-749, South Korea

    Md. Mofizul Islam

  2. Department of Mechanical and Automotive Engineering, Andong National University, 1375, Gyeongdong-ro, Andong, Gyeongbuk, 760-749, South Korea

    Hochan Kim

  3. School of Mechanical Engineering, Yeungnam University, 214-1 Daedong, Gyoungsan, Kyoungbuk, 712-449, South Korea

    Taejo Ko

Authors
  1. Md. Mofizul Islam
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hochan Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Taejo Ko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hochan Kim.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Islam, M.M., Kim, H. & Ko, T. Formulating CAM parameters for surface patterning by grinding process based on unit pattern geometry. Int J Adv Manuf Technol 83, 595–609 (2016). https://doi.org/10.1007/s00170-015-7296-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7296-7

Keywords

Search

Navigation