Fundamental Studies on Wheel Wear in ELID Grinding

Ph.DDOCTOR OF PHILOSOPH

Modeling and analyses of electrolytic in-process dressing (ELID) and grinding

Ph.DDOCTOR OF PHILOSOPH

Elid superfinishing of spherical bearings

Driven by a requirement to extend the lifespan of self-aligning lined spherical bearings, this research investigates the use of Elid (electrolytic in-process dressing) as a method of improving ball surface finish. Elid is a continuous and self-regulating electrochemical dressing process that modifies the surface of a grinding, lapping, or superfinishing wheel. It provides improved grit protrusion, impedes wheel loading / glazing and promotes effective cutting. The characteristics of the newly-developed Elid superfinishing process are in many ways fundamentally different to conventional superfinishing. The main difference is that the use of super-abrasives prevents the wheel from self-sharpening; the normal mechanism by which dulled conventional abrasives are removed and a wheel’s surface refreshed. Because the wheel’s performance and condition is continually maintained inprocess by the Elid system, metal resin bonded (MRB) wheels containing very small super-abrasives can be used. It is the utilization of these fine abrasives (30 to 0.12 μm) that enables surface roughness values below 5 nm Ra to be consistently produced on the spherical surface of corrosion-resistant steel balls. This research provides an in-depth understanding of the Elid spherical superfinishing process; investigating the most effective use of the Elid system, wheel dressing requirements and process performance. Optimisation is provided in terms of evaluating the critical operating parameters, the most effective superfinishing cycle and the implications to the complete ball production chain. A range of techniques are used to evaluate processing performance and ball output quality. These include in-process monitoring of Elid and wheel spindle power levels, analysis of wheel condition, rates of ball surface generation and material removal, ball finish and form. Although predominantly concentrated on corrosion-resistant steel, testing is also conducted on titanium and various ball coatings. In investigating various ways of using the Elid system, this work considers electrodischarge truing, pre-process dressing, Elid 1, Elid 2, Elid 3, and Elid combined with electrolytically assisted superfinishing. The initial process solution of Elid 3 (electrodeless) superfinishing provides the capability of working on all standard size balls, however the dressing system lacks stability. The development of a fixturing system that has a small separate electrode enables Elid 1 (conventional) to be used on the majority of ball sizes. Elid 1 allows more aggressive and consistent dressing, a faster rate of ball material removal and thus a substantially reduced processing time. Results with a #12,000 wheel show that surface quality is vastly improved through the use of Elid whilst maintaining current production standards of form accuracy. Surface finishes of 2nm Ra are achieved, which is an order of magnitude better than balls currently produced using barrelling / polishing. Processing times are equivalent or faster when using Elid 1. Alternatively, consistently sub 10 nm Ra finishes can be reached with a #2,000 wheel using Elid 2 (interval dressing). Generally MRB-CBN wheels provide a more effective carbide cutting action than conventional superfinishing wheels. Controlling wheel condition and achieving full and even ball to wheel conformity are the two most significant contributory factors to the success of Elid spherical superfinishing. Insufficient control of these factors results in poor output quality. Monitoring of wheel spindle and Elid power usage provides useful information in assessing the condition of the wheel and identifying potential problems. High spindle power correlates with fast material removal and is a result of high loads and a free cutting action. Elid processing can be employed for improving surface finish after the conventional honing stage, or after cylindrical grinding for improving both ball form and finish.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Design and development of an on-machine profile measurement system for an ELID grinding machine

Master'sMASTER OF ENGINEERIN

Verification of Implant Surface Modification by a Novel Processing Method

Metals have been used clinically as biomaterials, especially in the orthopaedic and dental fields. Metals used as implants wear at contact surfaces, producing metal particles and metal ions that may be harmful. Newly developed metal implants and methods of implant surface modification are currently under scrutiny. We evaluated the use of electrolytic in-process dressing (ELID) as a surface finishing method for metal implants. Metal implants processed using the ELID method (ELID group) or not processed (Non-ELID group) were inserted surgically into rabbit femurs. The rabbits were sacrificed postoperatively over a 24-week period. We assessed the concentrations of the cytokines, interleukin (IL)-1β, IL-6, and tumor necrosis factor-α, the resistance to implant pull-out, and histopathology at the implant site. There was no significant difference between the groups regarding the cytokine concentrations or implant pull-out resistance. Many particles indicating wear around the implant were noted in the Non-ELID group (n=10) but not the ELID group (n=13), while a fibrous membrane adhering to the every implant was noted in the ELID group. The formation of a fibrous membrane rather than metal particles in the ELID group may indicate improved biocompatibility, and it suggests that ELID may prevent corrosion in the areas of contact

Ultra-high precision grinding of BK7 glass

With the increase in the application of ultra-precision manufactured parts and the absence of much participation of researchers in ultra-high precision grinding of optical glasses which has a high rate of demand in the industries, it becomes imperative to garner a full understanding of the production of these precision optics using the above-listed technology. Single point inclined axes grinding configuration and Box-Behnken experimental design was developed and applied to the ultra-high precision grinding of BK7 glass. A high sampling acoustic emission monitoring system was implemented to monitor the process. The research tends to monitor the ultra-high precision grinding of BK7 glass using acoustic emission which has proven to be an effective sensing technique to monitor grinding processes. Response surface methodology was adopted to analyze the effect of the interaction between the machining parameters: feed, speed, depth of cut and the generated surface roughness. Furthermore, back propagation Artificial Neural Network was also implemented through careful feature extraction and selection process. The proposed models are aimed at creating a database guide to the ultra-high precision grinding of precision optics

Improving the Properties of Carbon Steel Using Silication by Chemical Vapor Deposition (CVD)

The silication is one of the surface treatment technologies that can produce silic containing surface layers with high hardness, good corrosion, and wear resistance on the steel matrix.This study aims to add silica to the carbon steel used locally in the manufacture of some elements of the machines in a manner of CVD (deposition steam chemical) and to increase the hardness and stamina and resistance to shock and friction, also earning silica steel high resistance to corrosion and scratching, and soluble in acids, with the application of Asalkna for (2) hours at temperatures 565,1000,1100,1200 oC, using ammonium chloride and ammonium fluoride in a mixture silication.Found that the proportion of silica formed on the surface of steel and its compounds are the best we can when the heat treatment of the degree of 1100oC and use of fluoride of ammonium in a mixture Asalkna, and also increases hardness outer surface of the steel carbon and high summit of silica compared with the top of the iron in the case of sample treatment and the presence of the amount of very little silica compared with the high percentage of iron ore in the case of the sample; and the increasing rate of protection to the surface of the steel from corrosion at the same previous conditions. Keywords: CVD - FeSi (chemical vapor deposited Silicon Iron