Principles of Modern Grinding Technology

Principles of Modern Grinding Technology

2nd Edition - November 7, 2013

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  • Author: W. Brian Rowe
  • eBook ISBN: 9780323297981
  • Hardcover ISBN: 9780323242714

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Description

Principles of Modern Grinding Technology, Second Edition, provides insights into modern grinding technology based on the author’s 40 years of research and experience in the field. It provides a concise treatment of the principles involved and shows how grinding precision and quality of results can be improved and costs reduced. Every aspect of the grinding process--techniques, machines and machine design, process control, and productivity optimization aspects--come under the searchlight. The new edition is an extensive revision and expansion of the first edition covering all the latest developments, including center-less grinding and ultra-precision grinding. Analyses of factors that influence grinding behavior are provided and applications are presented assisted by numerical examples for illustration. The new edition of this well-proven reference is an indispensible source for technicians, engineers, researchers, teachers, and students who are involved with grinding processes.

Key Features

  • Well-proven source revised and expanded by undisputed authority in the field of grinding processes
  • Coverage of the latest developments, such as ultra-precision grinding machine developments and trends in high-speed grinding
  • Numerically worked examples give scale to essential process parameters
  • The book as a whole and in particular the treatment of center-less grinding is considered to be unchallenged by other books

Readership

Application engineers, manufacturing engineers, technicians, researchers and teachers in manufacturing engineering

Table of Contents

  • Dedication

    Preface

    Acknowledgements

    About the Author

    List of Abbreviations

    Notation for Grinding Parameters

    Commonly Used Suffixes and Affixes Which Modify a General Symbol Depending on the Context in Which It Is Used

    Basic Units and Conversion Factors

    1. Introduction

    1.1 The Role of Grinding in Manufacture

    1.2 Basic Grinding Processes

    1.3 Specification of the Grinding System Elements

    1.4 The Book and Its Contents

    References

    2. Basic Material Removal

    2.1 The Material Removal Process

    2.2 Depth of Material Removed

    2.3 Equivalent Chip Thickness

    2.4 Removal Rate, Contact Width and Contact Area

    2.5 Specific Energy and Grindability

    2.6 Forces and Power

    2.7 Maximizing Removal Rate

    References

    3. Grinding Wheel Developments

    3.1 Introduction

    3.2 Abrasives

    3.3 Wheel Bonds

    3.4 Grinding Wheel Shapes

    3.5 Grinding Wheel Specification

    3.6 Wheel Design and Application

    3.7 High-Speed Wheels

    3.8 Wheel Elasticity and Vibrations

    References

    4. Grinding Wheel Dressing

    4.1 Introduction

    4.2 Stationary Dressing Tools

    4.3 Rotary Dressing Tools

    4.4 Grinding Performance

    4.5 Touch Dressing for CBN Wheels

    4.6 Continuous Dressing

    4.7 Electrolytic In-Process Dressing

    4.8 Electro-Discharge Dressing

    4.9 Laser Dressing

    References

    5. Wheel Contact and Wear Effects

    5.1 The Abrasive Surface

    5.2 Grain Wear

    5.3 Wheel–Workpiece Conformity

    5.4 Contact Length

    5.5 Contact Width and Peel Grinding

    References

    6. High-Speed Grinding

    6.1 Introduction

    6.2 Trends in High-Speed Grinding

    6.3 High-Speed Domains

    6.4 High-Efficiency Grinding

    6.5 Creep-Feed Grinding

    6.6 HEDG and Peel Grinding

    6.7 High Work Speed Grinding

    6.8 Temperature Effects and Temperature Analysis

    References

    7. Thermal Damage

    7.1 Introduction

    7.2 The Iron–Carbon Diagram

    7.3 Burn and Temper Damage

    7.4 Re-hardening Damage

    7.5 Residual Stresses

    7.6 Grind Hardening

    7.7 Process Monitoring

    References

    8. Application of Fluids

    8.1 Introduction

    8.2 Water-Based Fluids

    8.3 Neat Oils

    8.4 MQL and Gas-Jet Cooling

    8.5 The Pumping System

    8.6 Fluid Delivery

    8.7 Nozzle Design Calculations

    8.8 Nozzle Flow Requirements

    8.9 Power Required to Accelerate the Fluid

    8.10 Convective Contact Zone Cooling

    References

    9. Cost Reduction

    9.1 Introduction

    9.2 Analysis of Cost per Part

    9.3 Cost Reduction Trials

    9.4 Cost Comparisons for AISI 52100

    9.5 Cost Comparisons for Inconel 718

    References

    10. Grinding Machine Developments

    10.1 Machine Requirements

    10.2 Grinding Machine Elements

    10.3 Machine Layout and Deflections

    10.4 Design Principles for Machine Layout

    10.5 Spindle Assemblies and Wheel-Heads

    10.6 Plain Hydrodynamic Spindle Bearings

    10.7 Rolling Bearings

    10.8 Hydrostatic and Hybrid Bearings

    10.9 Air Bearing Spindles

    10.10 The Machine Base

    10.11 Column Deflections and Thermal Effects

    10.12 Joints, Slide-Ways and Feed-Drives

    10.13 Trends in Grinding Machine Development

    10.14 Ultra-Precision Grinders

    References

    11. Grinding Process Control

    11.1 Grinding Process Variability

    11.2 Classes of Machine Control

    11.3 Intelligent Control of Grinding

    11.4 Knowledge-Based Intelligent Control Systems

    References

    12. Vibration Problem-Solving in Grinding

    12.1 Introduction

    12.2 Dynamic Relationships for Grinding

    12.3 Grinding Wheel Contact Length Filtering

    12.4 Machine Stiffness Characteristics

    12.5 Stiffness, Damping and Resonance Parameters

    12.6 Chatter Conditions

    12.7 Practical Problem-Solving

    References

    13. Centreless Grinding

    13.1 Introduction

    13.2 Centreless Grinding Processes

    13.3 Set-Up Geometry and Removal Parameters

    13.4 Work Feed

    13.5 Wheel Dressing

    13.6 Machine Design, Roundness and Productivity

    13.7 Convenient Waviness Conditions

    13.8 Simulation of the Rounding Action

    13.9 The Shape Formation Dynamic System

    13.10 Stability of the Rounding Process

    13.11 Effect of Machine Deflections on Stability

    13.12 Summary and Avoiding Roundness Problems

    References

    14. Material Removal by Grains

    14.1 Introduction

    14.2 Equivalent Chip Thickness

    14.3 Cutting Edges

    14.4 Grain, Wheel and Point Contact Times

    14.5 The ‘Uncut Chip’

    14.6 Chip Length

    14.7 Chip Volume

    14.8 Chip Cross-Section Area

    14.9 Chip Width

    14.10 Mean Chip Thickness

    14.11 Maximum Chip Thickness

    14.12 Surface Roughness

    14.13 Appendix: Maximum Chip Thickness – Derivation from Geometry

    References

    15. Real Contact in Grinding

    15.1 Real and Apparent Contact Area

    15.2 Real Contact Length

    15.3 Smooth Wheel Analysis

    15.4 Rough Wheel Analysis

    15.5 Calibration of the Roughness Factor Rr

    References

    16. Grinding Energy

    16.1 Energy Required to Remove Material

    16.2 Measured Grinding Energy

    16.3 Predicting the Grinding Energy Requirement

    16.4 Effect of the Threshold Force

    16.5 Effect of New Surface Area Created

    16.6 Effect of Grain Shape and Sharpness

    16.7 Rubbing, Ploughing and Cutting

    References

    17. Mechanics of Abrasion and Wear

    17.1 Introduction

    17.2 Primary, Secondary and Tertiary Shear Zones

    17.3 Rubbing Contact

    17.4 Ploughing Contact

    17.5 Indentation Analysis

    17.6 Indentation With Sliding

    17.7 Basic Challen and Oxley Models

    17.8 Oblique Cutting

    17.9 Brittle Material Removal

    17.10 Wear Processes

    References

    18. Energy Partition and Temperatures

    18.1 Introduction

    18.2 Background and Essential Principles

    18.3 Heat Input and Heat Dissipation

    18.4 Workpiece Surface Temperatures

    18.5 Workpiece Sub-surface Temperatures

    18.6 Temperature Measurement

    18.7 Measured Temperatures

    18.8 Selection of Shallow-Cut or Deep-Cut Grinding

    18.9 Appendix A: General Solution for Workpiece Temperatures

    18.10 Appendix B: Derivation of Work-Wheel Fraction

    18.11 Appendix C: Flash Temperature Estimation

    18.12 Appendix D: Design Examples

    References

    Index

Product details

  • No. of pages: 480
  • Language: English
  • Copyright: © William Andrew 2013
  • Published: November 7, 2013
  • Imprint: William Andrew
  • eBook ISBN: 9780323297981
  • Hardcover ISBN: 9780323242714

About the Author

W. Brian Rowe

W. Brian Rowe is Consulting Director and Emeritus Professor of Mechanical Engineering at Liverpool John Moores University (UK). He is also former Director of the Advanced Manufacturing Technology and Tribology Research Laboratory.

Affiliations and Expertise

Consulting Director and Emeritus Professor of Mechanical Engineering, Liverpool John Moores University, Liverpool, UK

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