Handbook of machining with grinding wheels:
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Elektronisch E-Book |
| Sprache: | English |
| Veröffentlicht: |
Boca Raton, FL
CRC Press
2016
|
| Ausgabe: | Second edition |
| Schlagworte: | |
| Online-Zugang: | TUM01 Volltext Inhaltsverzeichnis |
| Beschreibung: | 1 Online-Ressource Illustrationen, Diagramme |
| ISBN: | 9781482206685 9781482206708 |
Internformat
MARC
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| 035 | |a (DE-599)BVBBV043549241 | ||
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| 084 | |a FER 743f |2 stub | ||
| 100 | 1 | |a Marinescu, Ioan D. |4 aut | |
| 245 | 1 | 0 | |a Handbook of machining with grinding wheels |c Ioan D. Marinescu [and four others] |
| 250 | |a Second edition | ||
| 264 | 1 | |a Boca Raton, FL |b CRC Press |c 2016 | |
| 300 | |a 1 Online-Ressource |b Illustrationen, Diagramme | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b c |2 rdamedia | ||
| 338 | |b cr |2 rdacarrier | ||
| 650 | 0 | 7 | |a Schleifen |0 (DE-588)4128669-8 |2 gnd |9 rswk-swf |
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| 856 | 4 | 0 | |u http://www.crcnetbase.com/isbn/9781482206708 |x Verlag |z URL des Erstveröffentlichers |3 Volltext |
| 856 | 4 | 2 | |m HEBIS Datenaustausch |q application/pdf |u http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028964552&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |3 Inhaltsverzeichnis |
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Datensatz im Suchindex
| _version_ | 1804176212093829120 |
|---|---|
| adam_text | Contents
Preface to First Edition xxiii
Preface to Second Edition xxv
Section I The Basic Process of Grinding
1 Introduction 3
1 1 From Craft to Science 3
1 2 Basic Uses of Grinding 4
121 High-Accuracy Required 4
122 High Removal Rate Required 4
123 Machining of Hard Materials 4
1 3 Elements of the Grinding System 5
131 The Basic Grinding Process 5
132 Four Basic Grinding Operations 6
1 4 The Importance of the Abrasive 7
1 5 Grinding Wheels for a Purpose 8
1 6 Problem Solving 8
References 9
2 Grinding Parameters 11
2 1 Introduction 11
211 Wheel Life 11
212 Redress Life 13
213 Cycle Time 13
2 2 Process Parameters 13
221 Uncut Chip Thickness or Grain Penetration Depth 13
222 Wheel Speed 14
223 Work Speed 14
224 Depth of Cut 14
225 Equivalent Wheel Diameter 14
226 Active Grit Density 14
227 Grit Shape Factor 14
228 Force per Grit 15
229 Specific Grinding Energy 15
2 2 10 Specific Removal Rate 16
2 2 11 Grinding Power 17
2 2 12 Tangential Grinding Force 17
2 2 13 Normal Grinding Force 17
2 2 14 Coefficient of Grinding 17
2 2 15 Surface Roughness 18
2 2 16 Rt Roughness 18
2 2 17 Ra Roughness 19
v
vi Contents
2 2 18 Rz Roughness 19
2 2 19 Material or Bearing Ratio 19
2 2 20 Peak Count 19
2 2 21 Comparison of Roughness Classes 19
2 2 22 Factors That Affect Roughness Measurements 19
2 2 23 Roughness Specifications on Drawings 19
2 2 24 Stock Removal Parameter 21
2 2 25 Decay Constant x 22
2 2 26 G Ratio 22
2 2 27 P Ratio 22
2 2 28 Contact Length 22
2 2 29 Geometric Contact Length 23
2 2 30 Real Contact Length 23
2 3 Grinding Temperatures 23
231 Surface Temperature, T 23
232 Maximum Workpiece Surface Temperature 24
233 The Cmax Factor 24
234 The Thermal Property for Moving Pleat Sources ßw 24
235 Workpiece Partition Ratio Rw 24
236 Effect of Grinding Variables on Temperature 25
237 Heat Convection by Coolant and Chips 25
238 Control of Thermal Damage 26
Appendix: Drawing Form and Profile Tolerancing 26
References 27
3 Material Removal Mechanisms 29
3 1 Significance 29
311 Introduction 29
312 Defining Basic Behavior 29
3 2 Grinding Wheel Topography 30
321 Introduction 30
322 Specification of Single Cutting Edges 31
3 3 Determination of Grinding Wheel Topography 31
331 Characterization Methods 31
332 Measurement Technologies for Grinding Wheel Topography 33
3321 Roughness Measures 33
3322 Qualitative Assessment 35
3323 Counting Methods 35
3324 Piezo and Thermoelectric Measurements 36
3325 Photoelectric Method 36
3326 Mirror Workpiece Method 36
33 2 7 Workpiece Penetration Method 36
3 4 Kinematics of the Cutting-Edge Engagement 37
3 5 Fundamental Removal Mechanisms 39
3 6 Material Removal in Grinding of Ductile Materials 40
3 7 Surface Formation in Grinding of Brittle-Hard Materials 42
371 Indentation Tests 42
372 Scratch and Grinding Behavior of Brittle-Hard Materials 44
7,1 * *
Contents
Vll
1 3 72 1 Fine-Grained Materials
3 72 2 Coarse-Grained Materials
3 8 Energy Transformation
References
45
45
50
52
Grinding Wheels
4 1
4 2
4 3
4 4
4 5
4 6
4 7
55
Introduction 55
411 Developments in Productivity 55
412 System Development 55
413 Conventional and Superabrasive Wheel Design 55
Wheel Shape Specification 56
421 Basic Shapes 56
422 Hole Tolerances 56
423 Side and Diameter Tolerances 59
Wheel Balance 60
431 Introduction to Wheel Balance 60
Static and Dynamic Unbalance 61
Automatic Wheel Balancers 62
Dynamic Balancing in Two Planes 63
Coolant Unbalance 63
Design of High-Speed Wheels 64
441 Trend Toward Higher Speeds 64
How Wheels Fail 64
Hoop Stress and Radial Stress 65
Reinforced Wheels 65
Segmented Wheels 66
Segment Design 67
Abrasive Layer Depth 67
Recent Development of High-Speed Conventional Wheels 68
Safety of Segmented Wheel Designs 68
Speed Rating of Grinding Wheels 71
Bond Life 72
Wheel Mount Design 73
461A Conventional Wheel Mount 73
Use of Blotters 73
Clamping Forces 74
High-Speed Wheel Mounts 75
The Single-Piece Wheel Hub 75
Direct Mounting on the Spindle 76
CFRP Wheel Hubs 77
Electroplated Wheels 78
Aluminum Hubs 78
Junker Bayonet-Style Mounts 80
HSK Hollow Taper Mount 80
Titanium Hub Design 82
Wheel Design and Chatter Suppression 83
471 The Role of Damping 83
472 Forced and Self-Excited Vibrations 83
4 3 2
4 3 3
4 3 4
4 3 5
4 4 2
4 4 3
4 4 4
4 4 5
4 4 6
4 4 7
4 4 8
4 4 9
4 4 10
4 6 2
4 6 3
4 6 4
4 6 5
4 6 6
4 6 7
4 6 8
4 6 9
4 6 10
4 6 11
4 6 12
viii Contents
473 Damped Wheel Designs and Wheel Compliance 84
474 Wheel Frequency and Chatter 85
475 Summary 85
References 85
5 The Nature of the Abrasive 87
5 1 Introduction 87
5 2 Silicon Carbide 93
521 Development of SiC 93
522 Manufacture of SiC 94
523 Hardness of SiC 94
5 3 Alumina (Alox)-Based Abrasives 95
5 4 Electrofused Alumina Abrasives 95
541 Manufacture 95
542 Brown-Fused Alumina 96
543 White-Fused Alumina 96
544 Alloying Additives 98
545 Pink Alumina 98
546 Ruby Alumina 99
547 Single-Crystal White Alumina 99
548 Postfusion Processing Methods 99
549 Postfusion Heat Treatment 99
5 4 10 Postfusion Coatings 99
5 4 11 Zirconia-Alumina 99
5 5 Chemical Precipitation and/or Sintering of Alumina 101
551 Importance of Crystal Size 101
552 Microcrystalline Grits 101
553 Seeded Gel Abrasive 102
554 Sol-Gel Abrasives 103
555 Agglomerated Grain Vortex™ 104
556 Extruded SG Abrasive 104
557 Future Trends for Conventional Abrasives 107
5 6 Diamond Abrasives 108
561 Natural and Synthetic Diamonds 108
562 Origin of Diamond 108
563 Production Costs 108
564 Three Forms of Carbon 108
565 The Shape and Structure of Diamond 109
566 Production of Synthetic Diamond 109
567 Controlling Stone Morphology 110
568 Diamond Quality Measures 110
569 Diamond Coatings Ill
5 6 10 Polycrystalline Diamond Ill
5 6 11 Diamond Produced by Chemical Vapor Deposition Ill
5 6 12 Structure of CVD Diamond 113
5 6 13 Development of Large Synthetic Diamond Crystals 113
5 6 14 Novel Diamond Abrasive Grain 115
5 6 15 Demand for Natural Diamond 115
5 6 16 Forms of Natural Diamond 118
Contents ix
5 6 17 Hardness of Diamond 118
5 6 18 Wear Resistance of Diamond 118
5 6 19 Strength of Diamond 118
5 6 20 Chemical Properties of Diamond 119
5 6 21 Thermal Stability of Diamond 120
5 6 22 Chemical Affinity of Diamond 120
5 6 23 Effects of Chemical Affinity in Manufacture 120
5 6 24 Effects of Chemical Affinity in Grinding 120
5 6 25 Grinding Steels and Cast Irons with Diamond 120
5 6 26 Thermal Properties 121
5 7 Cubic Boron Nitride 121
571 Development of CBN 121
572 Shape and Structure of CBN 123
573 Types of CBN Grains 123
574 Microcrystalline CBN 124
575 Sources and Costs of CBN 125
576 Wurtzitic Boron Nitride 125
577 Hardness of CBN 125
578 Wear Resistance of CBN 125
579 Thermal and Chemical Stability of CBN 126
5 7 10 Effect of Coolant on CBN 126
5 7 11 Effect of Reactivity with Workpiece Constituents 127
5 7 12 Thermal Properties of CBN 127
5 8 Future Grain Developments 127
References 128
6 Specification of the Bond 131
6 1 Introduction 131
6 2 Single-Layer Wheels 131
6 3 Electroplated and Electroless-Plated Single-Layer Wheels 131
631 Structure of an Electroless-Plated Layer 131
632 Product Accuracy 132
633 Wear Resistance of the Bond 133
634 Grit Size and Form Accuracy 133
635 Wheel Wear Effects in Grinding 134
636 Grit Size and Form-Holding Capability 135
637 Wheel Break-In Period 135
638 Summary of Variables Affecting Wheel Performance 137
639 Effect of Coolant on Plated Wheels 137
6 3 10 Reuse of Plated Wheels 138
6 4 Brazed Single-Layer Wheels 138
641 Controlled Grain Spacing 138
6 5 Vitrified Bond Wheels for Conventional Wheels 140
651 Application of Vitrified Bonds 140
652 Fabrication of Vitrified Bonds 141
653 Structure and Grade of Conventional Vitrified Wheels 141
654 Mixture Proportions 141
655 Structure Number 143
656 Grade of Conventional Vitrified Wheels 143
X
Contents
657 Fracture Wear Mode of Vitrified Wheels 144
658 High-Porosity Vitrified Wheels 145
659 Multiple Pore Size Distributions 145
6 5 10 Ultra-high-Porosity Vitrified Wheels 146
6 5 11 Combining Grade and Structure 147
6 5 12 Lubricated Vitrified Wheels 147
6 6 Vitrified Bonds for Diamond Wheels 147
661 Introduction 147
662 Hard Work Materials 147
663 Low Chemical Bonding 147
664 High Grinding Forces 148
665 Diamond Reactivity with Air at High Temperatures 148
666 Porous Vitrified Diamond Bonds 149
6 7 Vitrified Bonds for CBN 149
671 Introduction 149
672 Requirements for Vitrified CBN Bonds 150
673 CBN Wheel Structures 150
674 Grades of CBN Wheels 150
675 Firing Temperature 153
676 Thermal Stress 153
677 Bond Mix for Quality 153
6 8 Resin Bond Wheels 154
6 9 Plastic Bonds 155
6 10 Phenolic Resin Bonds 155
6 10 1 Introduction 155
6 10 2 Controlled-Force Systems 155
6 10 3 Abrasive Size 155
6 10 4 Benefits of Resilience 155
6 10 5 Phenolic Resin Bonds for Superabrasive Wheels 156
6 10 6 Wheel Marking Systems for Resin Bonds 156
6 11 Polyimide Resin Bonds 156
6 11 1 Introduction 156
6 11 2 Cost Developments and Implications 158
6 11 3 Induced Porosity Polyimide 158
6 12 Metal Bonds 158
6 12 1 Introduction 158
6 12 2 Bronze Alloy Bonds 158
6 12 3 Porous Metal Bonds 158
6 12 4 Crush Dressing 159
6 13 Other Bond Systems 160
6 13 1 Rubber 160
6 13 2 Shellac 161
6 13 3 Silicate 161
References 161
7 Dressing 165
7 1 Introduction 165
7 2 Traverse Dressing of Conventional Vitrified Wheels with Stationary Tools 166
721 Nomenclature 166
xi
722 Single-Point Diamonds 166
723 Diamond Size 166
724 Scaif Angle 168
725 Cooling 168
726 Dressed Topography 168
727 Dressing Feed and Overlap Ratio 169
728 Dressing Depth 170
729 Dressing Forces 170
7 2 10 Dressing Tool Wear 170
7 2 11 Rotationally Adjustable Tools 170
7 2 12 Profile Dressing Tools 171
7 2 13 Synthetic Needle Diamonds 171
7 2 14 Natural Long Diamond Blade Tools 173
7 2 15 Grit and Cluster Tools 174
7 2 16 Form Blocks 175
Traverse Dressing of Superabrasive Wheels with Stationary Tools 176
731 Introduction 176
732 Jig Grinding 176
733 Toolroom Grinding 176
Uniaxial Traverse Dressing of Conventional Wheels with Rotary
Diamond Tools 177
741 Introduction 177
742 Crush or Dressing Speed Ratio 178
743 Single-Ring Diamond and Matrix Diamond Disks 179
744 Dressing Conditions for Disk Dressers 181
745 Synthetic Diamond Disks 181
746 Sintered and Impregnated Rolls 181
747 Direct-Plated Diamond Rolls 182
748 Cup-Shaped Tools 182
Uniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary
Diamond Tools 182
751 Introduction 182
752 Dressing Depth 182
753 Crush Ratio 182
754 The Dressing Affected Layer 183
755 Touch Dressing 185
756 Truer Design for Touch Dressing 188
757 Impregnated Truers 188
758 CVD Needle Diamond Disks 190
Cross-Axis Traverse Dressing with Diamond Disks 192
761 Introduction 192
762 Traverse Rate 193
Diamond Form Roll Dressing 194
771 Manufacture and Design 194
772 Reverse Plating 196
773 Infiltrated Rolls 196
774 Reverse-Plated Rolls 197
775 Dress Parameters for Form Rolls 199
776 Dress Parameters for Form CBN Wheels 202
Contents
xii
777 Handling Diamond Rolls 203
7 8 Truing and Conditioning of Superabrasive Wheels 205
References 210
8 Grinding Dynamics 213
8 1 Introduction 213
811 Loss of Accuracy and Productivity 213
812A Need for Chatter Suppression 213
8 2 Forced and Regenerative Vibrations 213
821 Introduction 213
822 Forced Vibration 213
823 Regenerative Vibration 214
8 3 The Effect of Workpiece Speed 215
8 4 Geometrical Interference between Grinding Wheel and Workpiece 216
8 5 Vibration Behavior of Various Grinding Operations 218
8 6 Regenerative Self-Excited Vibrations 219
861 Modeling of Dynamic Grinding Processes 219
862 Grinding Stiffness and Grinding Damping 220
863 Contact Stiffness 221
864 Dynamic Compliance of the Mechanical System 223
865 Stability Analysis 223
8 7 Suppression of Grinding Vibrations 228
871 Suppression of Forced Vibrations 228
872 Suppression of Self-Excited Chatter Vibrations 228
8 8 Conclusions 232
References 233
9 Grinding Wheel Wear 235
9 1 Types of Wheel Wear 235
911 Introduction 235
9 2 Wheel Wear Mechanisms 235
921 Abrasive Wheel Wear 235
922 Adhesive Wheel Wear 236
923 Tribochemical Wheel Wear 236
924 Surface Disruptions 236
925 Diffusion 237
9 3 Wear of the Abrasive Grains 237
931 Types of Grain Wear 237
932A Combined Wear Process 238
933 Grain Hardness and Temperature 238
934 Magnitude of the Stress Impulses 238
935 Growth of Grain Flats 239
936 Grain Splintering 239
937 Grain Breakout 239
938 Bond Softening 240
939 Effect of Single-Grain Forces 240
9 3 10 Wear by Deposition 242
9 4 Bond Wear 242
941 Introduction 242
Contents xiii
942 Balancing Grain and Bond Wear 242
9 5 Assessment of Wheel Wear 243
951 Microtopography 243
952 Profile Wear 244
References 245
10 Coolants, the Coolant System, and Cooling 247
10 1 Introduction 247
10 2 Basic Properties of Grinding Fluids 247
10 2 1 Basic Properties 247
10 2 2 Primary Requirements 247
10 2 3 Secondary Requirements 248
10 3 Types of Grinding Fluids 248
10 4 Basic Properties 250
10 4 1 Composition of Oil-Based Fluids 250
10 4 2 Physical Properties of Water-Based and Oil-Based Fluids 250
10 4 3 Rinsing Capacity 252
10 4 4 Lubricating Capability 252
10 5 Additives 252
10 6 Application Results 254
10 7 Environmental Aspects 254
10 8 Supply System 255
10 8 1 Introduction 255
10 8 2 Fluid Supply System Requirements 255
10 8 3 Alternative Cooling Systems 257
10 9 Grinding Fluid Nozzles 257
10 9 1 Basic Types of Nozzle System 257
10 9 2 Jet Nozzle 258
10 9 3 Shoe Nozzle 258
10 9 4 Through-the-Wheel Supply 259
10 9 5 Minimum Quantity Lubrication Nozzles 259
10 9 6 Auxiliary Nozzles 260
10 10 Influence of the Grinding Fluid in Grinding 260
10 10 1 Conventional Grinding 260
10 10 2 Influence of the Fluid in Grinding Brittle-Hard Materials 262
10 10 3 High-Speed and High-Performance Grinding 263
10 11 Reduction of Temperature by Convective Cooling 267
10 11 1 Convective Cooling 267
10 11 2 Maximum Contact Temperature in Grinding 267
10 11 3 Fluid Convection Factor hf 268
References 270
11 Monitoring of Grinding Processes 275
11 1 Need for Process Monitoring 275
11 1 1 Introduction 275
11 1 2 Need for Sensors 275
11 1 3 Process Optimization 275
11 1 4 Grinding Wheel Wear 275
XIV
Contents
11 2 Sensors for Monitoring Process Variables 276
11 2 1 Introduction 276
11 2 2 Force Sensors 276
11 2 3 Power Measurement 281
11 2 4 Acceleration Sensors 282
11 2 5 Acoustic Emission Systems 282
11 2 6 Temperature Sensors 286
11 3 Sensors for Monitoring the Grinding Wheel 288
11 3 1 Introduction 288
11 3 2 Sensors for Macrogeometrical Quantities 288
11 3 3 Sensors for Microgeometrical Quantities 290
11 4 Sensors for Monitoring the Workpiece 292
11 4 1 Introduction 292
11 4 2 Contact-Based Workpiece Sensors for Macrogeometry 293
11 4 3 Contact-Based Workpiece Sensors for Microgeometry 296
11 4 4 Contact-Based Workpiece Sensors for Surface Integrity 296
11 4 5 Noncontact-Based Workpiece Sensors 299
11 5 Sensors for Peripheral Systems 303
11 5 1 Introduction 303
11 5 2 Sensors for Monitoring of the Conditioning Process 303
11 5 3 Sensors for Coolant Supply Monitoring 305
References 308
12 Economics of Grinding 311
12 1 Introduction 311
12 2 A Comparison Based on an Available Grinding Machine 311
12 2 1 Introduction 311
12 2 2 Aero-Engine Shroud Grinding Example 312
12 3 A Cost Comparison Including Capital Investment 313
12 3 1 Introduction 313
12 3 2 Automotive Camlobe Grinding Example 313
12 4 Cost Comparison Including Tooling 314
12 4 1 Introduction 314
12 4 2 Effect of Tooling Costs in Camlobe Grinding 315
12 5 Grinding as a Replacement for Other Processes 315
12 5 1 Introduction 315
12 5 2 Fine Grinding as a Replacement for Lapping 315
12 5 3 High-Speed Grinding with Electroplated CBN Wheels to
Replace Turn Broaching 316
12 6 Multitasking Machines for Hard Turning with Grinding 316
12 7 Summary 318
References 318
Section II Application of Grinding Processes
13 Grinding of Ductile Materials 321
13 1 Introduction 321
13 1 1 Grindability 321
Contents xv
13 1 2 Effect of Chip Form 321
13 1 3 Chemical Reactivity 322
13 2 Cast Irons 322
13 2 1 Gray Cast Iron 322
13 2 2 White Cast Iron 323
13 2 3 Malleable Cast Iron 323
13 2 4 Nodular Ductile Cast Iron 323
13 3 Steels 323
13 3 1 Plain Carbon Steels 323
13 3 2 Alloy Steels 325
13 3 3 Tool Steels 325
13 3 4 Stainless Steels 327
13 4 Heat-Resistant Superalloys 328
13 4 1 Precipitation-Hardened Iron-Based Alloys 328
13 4 2 Nickel-Based Alloys 329
13 4 3 Cobalt-Based Alloys 329
13 4 4 Titanium 329
References 330
14 Grinding of Ceramics 331
14 1 Introduction 331
14 1 1 Use of Ceramic Materials 331
14 1 2 Machining Hard Ceramics 331
14 1 3 Wheel-Dressing Requirements 331
14 1 4 ELID Grinding 332
14 1 5 Advantages of ELID 332
14 2 Background on Ceramic Materials 332
14 2 1 History 332
14 2 2 Structure 333
14 2 3 Ceramic Groups 333
14 2 4 Ceramic Product Groups 333
14 2 5 Application of ZTA Ceramics 334
14 2 6 Grinding of Ceramics 335
14 3 Diamond Wheels for Grinding Ceramics 335
14 3 1 Type of Diamond Abrasive 335
14 3 2 Types of Diamond Wheel 336
14 3 3 Wheel Truing and Dressing 338
14 4 Physics of Grinding Ceramics 339
14 5 ELID Grinding of Ceramics 344
14 5 1 Mechanism of ELID Grinding Technique 344
14 5 2 Research Studies on ELID 345
14 5 3 Summary on ELID Grinding 347
References 348
15 Grinding Machine Technology 349
15 1 The Machine Base 349
15 1 1 Introduction 349
15 1 2 Cast-Iron Bases 349
15 1 3 Reuse of Cast Bases 349
xvi Contents
15 1 4 Welded Bases 350
15 1 5 Damping in Machine Tools 350
15 1 6 Large Mass Bases 351
15 1 7 Tuned Mass Dampers 351
15 1 8 Composite Material Bases 351
15 1 9 Granite Bases 353
15 2 Foundations 353
15 3 Guideways 354
15 3 1 Introduction 354
15 3 2 Definition of Axes 354
15 4 Slideway Configurations 355
15 4 1 Introduction 355
15 4 2 Flat and Vee Way 355
15 4 3 Double Vee Slideway 355
15 4 4 Dovetail Slideway 357
15 4 5 Plain Slideway Materials 358
15 5 Hydrostatic Slideways 358
15 5 1 Hydrostatic Bearing Principle 359
15 5 2 Plane-Pad Hydrostatic Slideway Configurations 360
15 5 3 Plane-Pad Hydrostatic Flowrate 361
15 5 4 Hydrostatic Slideway Materials and Manufacture 362
15 5 5 Round Hydrostatic Slideways 362
15 5 6 Diaphragm-Controlled Hydrostatic Slideways 363
15 5 7 Self-Compensating Hydrostatic Slideways 363
15 6 Recirculating Rolling Element Slideways 363
15 7 Linear Axis Drives and Motion Control 366
15 7 1 Introduction 366
15 7 2 Hydraulic Drives 367
15 7 3 Electrohydraulic Drives 367
15 7 4 AC Servo and Ball Screw Drives 367
15 8 Elements of AC Servo-Drive Ball Screw Systems 368
15 8 1 Ball Screw 368
15 8 2 Ball Nut 369
15 8 3 AC Servo Motors 370
15 8 4 Encoders 370
15 8 5 Resolvers 373
15 9 Linear Motor Drive Systems 373
15 9 1 Introduction 373
15 92A Linear Motor System 374
15 9 3 Laser Interferometer Encoders for Linear Motor Drives 374
15 10 Spindle Motors and Grinding Wheel Drives 375
15 10 1 Introduction 375
15 11 Drive Arrangements for Large Conventional Wheels 376
15 11 1 Rolling Element Spindle Bearings for Large Wheels 376
15 11 2 Hydrodynamic Spindle Bearings for Large Wheels 378
15 11 3 Hydrostatic Spindle Bearings for Large Wheels 379
15 12 Drive Arrangements for Small Wheel Spindles 381
15 12 1 Introduction 381
15 12 2 Rolling Bearing Spindles with Belt Drive for Small Wheels 381
Contents xvii
15 13 High-Speed Spindles for Small Wheels 381
15 13 1 Direct Drive Motors 381
15 13 2 Dynamic Balancing of High-Speed Spindles 382
15 13 3 Oil-Mist Lubrication for High-Speed Spindles 382
15 13 4 Adjustment of Bearing Preload for High-Speed Spindles 383
15 13 5 Use of Ceramic Balls for High-Speed Spindles 383
15 13 6 Liquid Cooled High-Speed Spindles 383
15 13 7 Floating Rear Bearing for High-Speed Spindles 383
15 14 Spindles for High-Speed Grinding 384
15 14 1 Introduction 384
15 14 2 Spindles Bearings for High-Speed Grinding of Hardened Steel 384
15 14 3 Spindle Bearings for HEDG 384
15 14 4 Spindle Cooling for High-Speed Grinding 384
15 14 5 Spindle Bearings for Very Small High-Precision
High-Speed Wheels 385
15 14 6 Active Magnetic Bearings for High-Speed Wheels 385
15 15 Miscellaneous Wheel Spindles and Drives 385
15 15 1 Hydraulic Spindle Drives 385
15 15 2 Air Motors and Bearings 386
15 16 Rotary Dressing Systems 386
15 16 1 Pneumatic Drives 386
15 16 2 Hydraulic Drives 387
15 16 3 Electric Drives 387
15 17 Power and Stiffness Requirements for Rotary Dressers 388
15 18 Rotary Dressing Spindle Examples 390
15 18 1 Introduction 390
15 18 2 DFW-ACI Air-Driven Spindle 390
15 18 3 ECI Hydraulic Spindle 390
15 18 4 DFW-HI Heavy-Duty Hydraulic Spindle for
Internal Grinders 390
15 18 5 DFW-HO 5/8 Heavy-Duty Hydraulic Spindle Typically
Used for Centerless Wheels 391
15 18 6 DFW-HO Variable-Speed Hydraulic Dresser 392
15 18 7 DFW-HHD Hydraulic Heavy-Duty Plunge Dresser 392
15 18 8 DFW-HTG Heavy-Duty Hydraulic Spindle 393
15 18 9 DFW-NTG Belt-Drive Spindle 393
15 18 10 DFW-VF44 AC Servo High-Frequency Spindle 394
15 18 11 DFS-VS8 DC Servo Variable-Speed Dresser 394
15 19 Dressing Infeed Systems 395
15 19 1 Introduction 395
15 19 2 DFW-SB-HO Single, Hydraulically Driven Carrier 396
15 19 3 Mini Double-Cylinder Infeed 396
15 19 4 Double-Barrel Infeed Carrier 397
15 19 5 Double-Barrel Plunge-Form Dresser DFW-GA-H 397
15 19 6 Triple Barrel Infeed Carrier with Hydraulic-Mechanical
Compensator 398
15 19 7 DFW-CG-SM-HC Stepping Motor Carrier 398
15 19 8 Stepping Motor Carrier for a Cylindrical Grinder 399
15 19 9 Combination Stepper Motor and DC Traverse Motor 399
xviii
Contents
15 19 10 FW-BS-E Plunge-Roll Infeed System for a Creep-Feed Grinder 400
15 19 11 Servo-motor Infeed and Double-Barrel Carrier Dresser 401
15 19 12 Two-Axis CNC Profile Dresser 401
References 405
Additional References 408
16 Surface Grinding 409
16 1 Types of Surface Grinding Process 409
16 2 Basics of Reciprocating Grinding 409
16 2 1 Process Characterization 410
16 211 Real Depth of Cut 411
16 212 Speed Ratio 411
16 213 Specific Removal Rate 411
16 214 Upcut and Downcut Grinding 411
16 215 Nonproductive Time 412
16 2 2 Influences of Grinding Parameters on Grinding Performance 412
16 221 The Influence of Cutting Speed (Wheel Speed) 412
16 222 The Influence of Feed Rate (Work Speed) 412
16 223 The Influence of Infeed 413
16 224 The Influence of the Interrupted Cut 413
16 225 Reciprocating Grinding Without CF 413
16 226 Multiple Small Parts 413
16 2 3 Economics 414
16 3 Basics of Creep Grinding 414
16 3 1 Introduction 414
16 3 2 Process Characterization 415
16 3 3 Fligh-Efficiency Deep Grinding 416
16 3 4 The Influence of the Set Parameters in CF Grinding 416
16 341 The Influence of Cutting Speed vc 416
16 342 The Influence of Infeed ae and Feed Rate vft 417
16 343 The Influence of Dressing Conditions 417
16 344 The Influence of Grinding Wheel Specification 417
16 345 The Influence of Up- and Downcut Grinding 418
16 346 Process 418
16 347 Work Results 419
16 348 Grinding Wheels 420
16 349 Grinding Wheel Wear 420
16 3 5 Requirements for CF Grinding Machines 421
16 3 6 Typical Applications 421
16 3 7 Economics of CF Grinding 422
16 4 Basics of Speed-Stroke Grinding 422
16 4 1 Introduction 422
16 5 Successful Application of CF Grinding 424
16 5 1 CF Grinding with Vitrified Wheels Containing Alox and
Silicon Carbide 424
16 5 2 Coolant Application in CF Grinding 425
16 521 Film Boiling 426
16 522 Coolant Delivery System 427
16 523 Coolant System Capacity 427
Contents xix
16 524 Coolant Pressure 427
16 525 Piping 429
16 526 Nozzle Design 429
16 5 3 Continuous Dress CF 434
16 531 The Viper Process 435
16 5 4 CF Grinding with CBN 438
16 541 Electroplated CBN 438
16 542 Vitrified CBN 441
16 543 Process Selection 441
16 6 Face Grinding 451
16 6 1 Introduction 451
16 6 2 Rough Grinding with Segmented Wheels 455
16 6 3 Rough Machining/Finish Grinding 458
16 6 4 Single-Sided Face Grinding on Small Surface Grinders 459
16 6 5 High-Precision Single-Sided Disk Grinding 460
16 6 6 Double-Disk Grinding 464
16 7 Fine Grinding 476
16 7 1 Principles and Limitations of Lapping 476
16 7 2 Double-Sided Fine Grinding 477
16 7 3 Comparison of Fine Grinding with Double-Disk Grinding 480
16A 1 Appendix: Lapping Kinematics 481
16A 1 1 Introduction 481
16A 2 Kinematic Fundamentals 483
16A 3 Analysis of Path Types and Velocities 484
16A 4 Kinematic Possibilities of Machines 486
References 488
17 External Cylindrical Grinding 493
17 1 The Basic Process 493
17 1 1 Introduction 493
17 1 2 Work Drives 493
17 1 3 The Tailstock 494
17 1 4 Wheel Speeds 494
17 1 5 Stock Removal 495
17 1 6 Angle-Approach Grinding 496
17 1 7 Combined Infeed with Traverse 497
17 2 High-Speed Grinding 497
17 2 1 Introduction 497
17 2 2 Energy and Temperature in High-Speed Grinding 498
17 2 3 Coolant Drag and Nozzle Design in High-Speed Grinding 506
17 2 4 Maximum Removal Rates 506
17 2 5 Peel Grinding 507
17 3 Automotive Camlobe Grinding 509
17 3 1 Incentives for Change 509
17 3 2 Camlobe Profile Features 510
17 3 3 Camshaft Grinders Using CBN 511
17 3 4 Raising Dynamic Thresholds and Work Removal Rates 513
17 3 5 Improving Productivity within Burn Thresholds 515
17 3 6 Camshaft Work-Rests and Force Equalizing 516
XX
Contents
17 4 Punch Grinding 520
17 5 Crankshaft Grinding 522
17 6 Roll Grinding 526
References 529
18 Internal Grinding 531
18 1 Introduction 531
18 2 The Internal Grinding Process 531
18 3 Abrasive Type 533
18 3 1 Grain Selection 533
18 3 2 Impact on Grain Configuration 534
18 3 3 Quill Designs for CBN 535
18 4 Process Parameters 537
18 4 1 Wheelspeed 537
18 4 2 Workspeed 538
18 4 3 Oscillation 538
18 4 4 Incoming Part Quality 538
18 4 5 Dressing 538
18 4 6 Grinding Cycles 539
18 4 7 Automatic Compensation of Process Variations 540
18 5 Machine Tool Selection 545
18 5 1 Introduction 545
18 5 2 Fuel Injection 545
18 5 3 Automotive Components (Lifters, Tappets, UJ Cups, and
Plain Bearings) 547
18 5 4 Machine Layout 547
18 5 5 Wheel Speeds 549
18 5 6 Work-Spindle Run-Out 549
18 5 7 Work-Loading Mechanisms 549
18 5 8 Coolant 550
18 5 9 Gauging 551
18 5 10 Flexible Multipurpose Grinders 551
18 6 Trouble Shooting 555
References 556
19 Centerless Grinding 559
19 1 The Importance of Centerless Grinding 559
19 2 Basic Processes 560
19 2 1 External Centerless Grinding 560
19 2 2 Approximate Guide to Work Height 561
19 2 3 Internal Centerless Grinding 562
19 2 4 Shoe Centerless Grinding 562
19 2 5 Roundness and Rounding Geometry 563
19 2 6 System Interactions 565
19 3 Basic Relationships 566
19 3 1 Depth of Cut 566
19 3 2 Removal Rate 566
19 3 3 Power 567
Contents xxi
19 3 4 Specific Energy 567
19 3 5 Contact Length 567
19 3 6 Equivalent GW Diameter 568
19 3 7 Equivalent Chip Thickness 568
19 3 8 Grinding Ratio 569
19 4 Feed Processes 569
19 4 1 Plunge Feed 569
19 4 2 Through-Feed and Through-Feed Rate 571
19 5 Centerless Wheels and Dressing Geometry 571
19 5 1 The Grinding Wheel 571
19 5 2 Grinding Wheel Dressing 572
19 5 3 The Control Wheel 573
19 5 4 Control Wheel Dressing 574
19 5 5 Control Wheel Runout 575
19 6 The Workrest 575
19 7 Speed Control 576
19 7 1 Spinning Out of Control 576
19 7 2 Failure to Turn 578
19 8 Machine Structure 578
19 8 1 The Basic Machine Elements 578
19 8 2 The Grinding Force Loop 579
19 8 3 Structural Layout 581
19 8 4 Spindle Bearings 583
19 9 High Removal Rate Grinding 585
19 9 1 Introduction 585
19 9 2 Routes to High Removal Rate 586
19 9 3 Improved Grinding Machines and Auxiliary Equipment 587
19 9 4 Process Limits 588
19 9 5 Specific Energy as a Measure of Efficiency 590
19 10 Economic Evaluation of Conventional and CBN Wheels 591
19 10 1 Introduction 591
19 10 2 Cost Relationships 591
19 10 3 Wheel Cost/Part 591
19 10 4 Labor Cost/Part 592
19 10 5 Machine Cost/Part 594
19 10 6 Total Variable Cost/Part 594
19 10 7 Experiment Design 594
19 10 8 Machine Conditions and Cost Factors 595
19 10 9 Materials, Grinding Wheels, and Grinding Variables 597
19 10 9 1 AISI52100 Steel Trials 597
19 10 9 2 Inconel 718 Trials 598
19 10 10 Direct-Effect Charts 599
19 10 11 Redress Life and Cost Comparisons 599
19 10 11 1 AISI 52100 Comparisons 599
19 10 11 2 Inconel 718 Comparisons 600
19 10 12 Effects of Redress Life 600
19 10 13 Economic Conclusions 600
19 11 The Mechanics of Rounding 601
xxii Contents
19 11 1 Avoiding Convenient Waviness 601
19 11 1 1 Rules for Convenient Waviness 602
19 11 2 Theory of Formation of the Workpiece Profile 603
19 11 3 Workpiece Movements 605
19 11 4 The Machining-Elasticity Parameter 606
19 11 5 The Basic Equation for Rounding 608
19 11 6 Simulation 609
19 11 7 Roundness Experiments and Comparison with Simulation 611
19 12 Vibration Stability Theory 613
19 12 1 Definitions of Stability 614
19 12 2 A Model of the Dynamic System 615
19 12 3 Transfer Functions 616
19 12 4 Nyquist Test for Stability 618
19 12 5 The Depth of Cut Function 618
19 12 6 The Geometric Function and Geometric Stability 619
19 12 7 Static and Dynamic Compliance Functions 623
19 12 7 1 Static Compliance 623
19 12 7 2 Dynamic Compliances 623
19 12 8 Added Static Compliance 626
19 13 Dynamic Stability Limits 627
19 13 1 Threshold Conditions 627
19 13 2 Classic Dynamic Stability Charts 630
19 13 3 Workspeed in Relation to Resonant Frequency 633
19 13 4 A New Dynamic Stability Parameter Adyn 635
19 14 Avoiding Critical Frequencies 637
19 14 1 Selection of Work Rotational Speed 637
19 14 2 Selection of Wheel Rotational Speed 638
19 14 3 Selection of Dresser Speed 638
19 14 4 Speed Rules 638
19 15 Summary and Recommendations for Rounding 639
19 16 Process Control 639
References 643
20 Ultrasonic-Assisted Grinding 647
20 1 Introduction 647
20 2 Ultrasonic Technology and Process Variants 648
20 3 Ultrasonic-Assisted Grinding with Workpiece Excitation 650
20 4 Peripheral Grinding with Radial Ultrasonic Assistance 650
20 5 Peripheral Grinding with Axial Ultrasonic Assistance 653
20 6 Ultrasonic-Assisted Grinding with Excitation of the Wheel 656
20 6 1 Ultrasonic-Assisted Cross-Peripheral Grinding 656
20 6 2 Ultrasonic-Assisted Face Grinding 659
20 7 Summary 662
References 664
Glossary 667
Appendix: Notation and Use of SI Units 693
|
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| discipline | Fertigungstechnik |
| edition | Second edition |
| format | Electronic eBook |
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| id | DE-604.BV043549241 |
| illustrated | Not Illustrated |
| indexdate | 2024-07-10T07:28:35Z |
| institution | BVB |
| isbn | 9781482206685 9781482206708 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-028964552 |
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| publishDate | 2016 |
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| spelling | Marinescu, Ioan D. aut Handbook of machining with grinding wheels Ioan D. Marinescu [and four others] Second edition Boca Raton, FL CRC Press 2016 1 Online-Ressource Illustrationen, Diagramme txt rdacontent c rdamedia cr rdacarrier Schleifen (DE-588)4128669-8 gnd rswk-swf Schleifen (DE-588)4128669-8 s DE-604 http://www.crcnetbase.com/isbn/9781482206708 Verlag URL des Erstveröffentlichers Volltext HEBIS Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028964552&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Marinescu, Ioan D. Handbook of machining with grinding wheels Schleifen (DE-588)4128669-8 gnd |
| subject_GND | (DE-588)4128669-8 |
| title | Handbook of machining with grinding wheels |
| title_auth | Handbook of machining with grinding wheels |
| title_exact_search | Handbook of machining with grinding wheels |
| title_full | Handbook of machining with grinding wheels Ioan D. Marinescu [and four others] |
| title_fullStr | Handbook of machining with grinding wheels Ioan D. Marinescu [and four others] |
| title_full_unstemmed | Handbook of machining with grinding wheels Ioan D. Marinescu [and four others] |
| title_short | Handbook of machining with grinding wheels |
| title_sort | handbook of machining with grinding wheels |
| topic | Schleifen (DE-588)4128669-8 gnd |
| topic_facet | Schleifen |
| url | http://www.crcnetbase.com/isbn/9781482206708 http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028964552&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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