Technical Brief

Detailed Analysis and Description of Grinding Wheel Topographies

[+] Author and Article Information
Markus Weiß

Tyrolit Schleifmittelwerke Swarovski K.G.,
Schwaz A-6122, Austria
e-mail: Markus.Weiss@Tyrolit.com

Fritz Klocke

Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Aachen D-52074, Germany
e-mail: f.klocke@wzl.rwth-aachen.de

Sebastian Barth

Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Aachen D-52074, Germany
e-mail: s.barth@wzl.rwth-aachen.de

Matthias Rasim

August Rüggeberg GmbH & Co. KG,
Marienheide D-51709, Germany
e-mail: Matthias.rasim@pferd.com

Patrick Mattfeld

Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Aachen D-52074, Germany
e-mail: p.mattfeld@wzl.rwth-aachen.de

1Corresponding author.

Manuscript received July 26, 2015; final manuscript received November 17, 2016; published online March 3, 2017. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 139(5), 054502 (Mar 03, 2017) (9 pages) Paper No: MANU-15-1373; doi: 10.1115/1.4035531 History: Received July 26, 2015; Revised November 17, 2016

In this paper, an innovative approach for the description of the functional properties of a grinding wheel surface is discussed. First, the state of the art in the description of grinding wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of grinding wheel topographies are provided. In order to analyze the functional properties of a grinding wheel's topography depending on its specification, grinding experiments were carried out. For the experimental investigations vitrified, synthetic resin bonded and electroplated grinding wheels with varied compositions were analyzed. During the experiments, the topographies of the investigated grinding wheels have been analyzed by means of the topotool in detail. The developed software tool allows a detailed description of the kinematic cutting edges depending on the grinding process parameters and the grinding wheel specification. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge, a differentiation of the cutting edge areas in normal and tangential areas of the grinding wheel's circumferential direction is implemented. Furthermore, the topotool enables to analyze the kinematic cutting edges shape by calculating the angles of the grain in different directions. This enables a detailed analysis and a quantitative comparison of grinding wheel topographies related to different grinding wheel specifications. In addition, the influence of the dressing process and wear conditions to the grinding wheel topography can be evaluated. The new approach allows a better characterization of the contact conditions between grinding wheel and workpiece. Hence, the impact of a specific topography on the grinding process behavior, the generated grinding energy distribution, and the grinding result can be revealed.

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Fig. 1

Material ratio depending on grinding wheel specification and the dressing conditions according to Ref. [10]

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Fig. 2

Extension of the two-dimensional model of Kassen and Werner to a three-dimensional approach according to Ref. [10]

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Fig. 3

Cutoff area, kinematic cutting edge count, and cutting edge area in the normal and tangential directions

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Fig. 4

Influence of cut of area on kinematic cutting edge count and specific cutting areas

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Fig. 5

Determination of the grain shape characteristics

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Fig. 6

Kinematics and parameters of the conditioning and grinding process

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Fig. 7

Topographies of resin bonded grinding wheels with different grain sizes

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Fig. 8

Characteristic topography values of three resin bonded grinding wheel specifications

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Fig. 9

Comparison of vitrified and resin bonded grinding wheel topographies

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Fig. 10

Characteristic topography values of a vitrified and resin bonded specification in different wear conditions

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Fig. 11

Comparison of grinding forces

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Fig. 12

Influence of the grain type on the relative frequency of the grain shape characteristics

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Fig. 13

The abrasive system

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Fig. 14

Modeled kinematic cutting edge count




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