Handbook of Machining with Grinding Wheels / Edition 2

by Ioan D. Marinescu, Mike P. Hitchiner, Eckart Uhlmann, W. Brian Rowe, Ichiro Inasaki

Overview

Grinding is a crucial technology that employs specific abrasive processes for the fabrication of advanced products and surfaces. Handbook of Machining with Grinding Wheels, Second Edition highlights important industry developments that can lead to improved part quality, higher productivity, and lower costs. Divided into two parts, the book begins with an explanation of grinding behavior and ends with a focus on new and emerging industrial applications.

While the first edition focused on the basics of abrasive machining technology and presented a unified approach to machining with grinding wheels, the second edition ties in the continued need for traditional processes in conjunction with the latest applications. This book highlights new research topics that include: nanotechnology, alternative energy, and additive manufacturing, compares related approaches, and provides numerous references throughout the book.

New in the Second Edition:

• Contains the latest information on abrasives, bonds, and dressing
• Updates classic stability lobes for grinding
• Introduces a new method for tracking dynamic instability in centerless grinding
• Provides a section in the chapter on ultrasonic-assisted grinding, which contains recent work on modelling of the process
• Adds material on fluid cooling
• Presents experimental results for in-process feedback to the grinding process
• Includes new examples on grinding machine technology (particularly for dressing)

A single source reference covering every aspect of the grinding process, Handbook of Machining with Grinding Wheels functions as a definitive guide to grinding technology for both practicing engineers and students studying graduate-level courses (such as abrasive machining; grinding R&D; metal removal processes; machining of brittle materials; and principles of cutting).

　

　

Product Details

ISBN-13:	9781482206685
Publisher:	Taylor & Francis
Publication date:	02/08/2016
Edition description:	Revised
Pages:	750
Product dimensions:	7.00(w) x 10.00(h) x (d)

About the Author

Brian Rowe is considered the father of centerless grinding in addition to other notable research on grinding that includes thermal aspects, dynamic aspects, and fluid-film bearings. He established a laboratory and school dedicated to manufacturing processes at Liverpool John Moores University and is an Emeritus Professor.

Ichiro Inasaki is the dean of the Graduate School of Science and Technology at Keio University, Japan. He has developed a laboratory with outstanding research activities and his "intelligent grinding wheel" is featured in the Noritake Museum and represents one of his best accomplishments and contributions. He led CIRP in 2004/2005 as the president and was granted several awards.

Eckart Uhlmann is professor and director of the Institute for Machine-Tools and Management at Technical University of Berlin, Germany. Dr. Uhlmann received this chaired professorship after a very successful industrial career with Hermes Abrasive in Germany. As the head of his institute he holds the leading position in research on all aspects of abrasive machining with grinding wheels.

Dr. Mike Hitchiner is manager of precision technology at Saint Gobain Abrasives (Norton), the largest grinding wheel company in the world. Mike has devoted all his life to research, development and practical application of grinding processes. He started this activity during his D Phil at the University of Oxford in England, and was later considered "Mr. CBN Grinding" by the precision grinding industry. Today he focuses on working with machine tool builders and developing new grinding processes. He has brought an important industrial perspective to this book, as well as hundreds of applications.

Table of Contents

THE BASIC PROCESS OF GRINDING

Introduction
From Craft to Science
Basic Uses of Grinding
Elements of the Grinding System
The Importance of the Abrasive
Grinding Wheels for a Purpose
Problem Solving
References

Grinding Parameters
Introduction
Process Parameters
Grinding Temperatures
Appendix: Drawing Form and Profile Tolerancing
References

Material Removal Mechanisms
Significance
Grinding Wheel Topography
Determination of Grinding Wheel Topography
Kinematics of the Cutting-Edge Engagement
Fundamental Removal Mechanisms
Material Removal in Grinding of Ductile Materials
Surface Formation in Grinding of Brittle–Hard Materials
Energy Transformation
References

Grinding Wheels
Introduction
Wheel Shape Specification
Wheel Balance
Design of High-Speed Wheels
Bond Life
Wheel Mount Design
Wheel Design and Chatter Suppression
References

The Nature of the Abrasive
Introduction
Silicon Carbide
Alumina (Alox)-Based Abrasives
Electrofused Alumina Abrasives
Chemical Precipitation and/or Sintering of Alumina
Diamond Abrasives
Cubic Boron Nitride
Future Grain Developments
References

Specification of the Bond
Introduction
Single-Layer Wheels
Electroplated and Electroless-Plated Single-Layer Wheels
Brazed Single-Layer Wheels
Vitrified Bond Wheels for Conventional Wheels
Vitrified Bonds for Diamond Wheels
Vitrified Bonds for CBN
Resin Bond Wheels
Plastic Bonds
Phenolic Resin Bonds
Polyimide Resin Bonds
Metal Bonds
Other Bond Systems
References

Dressing
Introduction
Traverse Dressing of Conventional Vitrified Wheels with Stationary Tools
Traverse Dressing of Superabrasive Wheels with Stationary Tools
Uniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond Tools
Uniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary Diamond Tools
Cross-Axis Traverse Dressing with Diamond Disks
Diamond Form Roll Dressing
Truing and Conditioning of Superabrasive Wheels
References

Grinding Dynamics
Introduction
Forced and Regenerative Vibrations
The Effect of Workpiece Speed
Geometrical Interference between Grinding Wheel and Workpiece
Vibration Behavior of Various Grinding Operations
Regenerative Self-Excited Vibrations
Suppression of Grinding Vibrations
Conclusions
References

Grinding Wheel Wear
Types of Wheel Wear
Wheel Wear Mechanisms
Wear of the Abrasive Grains
Bond Wear
Assessment of Wheel Wear
References

Coolants, the Coolant System, and Cooling
Introduction
Basic Properties of Grinding Fluids
Types of Grinding Fluids
Basic Properties
Additives
Application Results
Environmental Aspects
Supply System
Grinding Fluid Nozzles
Influence of the Grinding Fluid in Grinding
Reduction of Temperature by Convective Cooling
References

Monitoring of Grinding Processes
Need for Process Monitoring
Sensors for Monitoring Process Variables
Sensors for Monitoring the Grinding Wheel
Sensors for Monitoring the Workpiece
Sensors for Peripheral Systems
References

Economics of Grinding
Introduction
A Comparison Based on an Available Grinding Machine
A Cost Comparison Including Capital Investment
Cost Comparison Including Tooling
Grinding as a Replacement for Other Processes
Multitasking Machines for Hard Turning with Grinding
Summary
References

APPLICATION OF GRINDING PROCESSES

Grinding of Ductile Materials
Introduction
Cast Irons
Steels
Heat-Resistant Superalloys
References

Grinding of Ceramics
Introduction
Background on Ceramic Materials
Diamond Wheels for Grinding Ceramics
Physics of Grinding Ceramics
ELID Grinding of Ceramics
References

Grinding Machine Technology
The Machine Base
Foundations
Guideways
Slideway Configurations
Hydrostatic Slideways
Recirculating Rolling Element Slideways
Linear Axis Drives and Motion Control
Elements of AC Servo-Drive Ball Screw Systems
Linear Motor Drive Systems
Spindle Motors and Grinding Wheel Drives
Drive Arrangements for Large Conventional Wheels
Drive Arrangements for Small Wheel Spindles
High-Speed Spindles for Small Wheels
Spindles for High-Speed Grinding
Miscellaneous Wheel Spindles and Drives
Rotary Dressing Systems
Power and Stiffness Requirements for Rotary Dressers
Rotary Dressing Spindle Examples
Dressing Infeed Systems
References
Additional References

Surface Grinding
Types of Surface Grinding Process
Basics of Reciprocating Grinding
Basics of Creep Grinding
Basics of Speed-Stroke Grinding
Successful Application of CF Grinding
Face Grinding
Fine Grinding
References

External Cylindrical Grinding
The Basic Process
High-Speed Grinding
Automotive Camlobe Grinding
Punch Grinding
Crankshaft Grinding
Roll Grinding
References

Internal Grinding
Introduction
The Internal Grinding Process
Abrasive Type
Process Parameters
Machine Tool Selection
Trouble Shooting
References

Centerless Grinding
The Importance of Centerless Grinding
Basic Processes
Basic Relationships
Feed Processes
Centerless Wheels and Dressing Geometry
The Workrest
Speed Control
Machine Structure
High Removal Rate Grinding
Economic Evaluation of Conventional and CBN Wheels
The Mechanics of Rounding
Vibration Stability Theory
Dynamic Stability Limits
Avoiding Critical Frequencies
Summary and Recommendations for Rounding
Process Control
References

Ultrasonic-Assisted Grinding
Introduction
Ultrasonic Technology and Process Variants
Ultrasonic-Assisted Grinding with Workpiece Excitation
Peripheral Grinding with Radial Ultrasonic Assistance
Peripheral Grinding with Axial Ultrasonic Assistance
Ultrasonic-Assisted Grinding with Excitation of the Wheel
Summary
References

Glossary

Appendix: Notation and Use of SI Units

Editorial Reviews

"It is a comprehensive book which deals with almost all important aspects of theory and practice of different types of grinding operations and applications. It also describes in detail, grinding machines hence it becomes useful for researchers, teachers as well as practicing engineers."
—Dr. V. K. Jain, Mechanical Engineering Department, I.I.T. Kanpur, India

From the Publisher