The effect of dressing parameters on micro-grinding of titanium alloy

This paper is concerned with investigating the effects of dressing parameters and the effect of the cutting speed on the performance of micro-grinding of titanium Ti-6Al-4 V alloy. Extremely high dressing overlap ratios were used for the first time to dress the grinding pins, and the obtained micro-topography, measured on the surface of the pins, is found to be directly related to the grinding forces. More specifically, both the normal and tangential grinding force components increased with the dressing overlap ratio. Related effects of dressing on surface quality are also presented. Grinding with pins containing finer topography was accompanied by less loading with chips and hence a better surface finish. Moreover, down-dressing method generated rougher finished surface quality and induced lower grinding forces compared to the up-dressing. High values of the dressing overlap ratio (up to 1830) in the up-dressing method improved the surface finish significantly

High-speed high-efficient grinding of CMCs with structured grinding wheels

Ceramic Matrix Composites (CMCs) are counted as new materials which their implantation is limited due to their high machining costs as a result of high grinding forces and tool wear. To overcome mentioned problems, modified grinding wheels, one macro-structured by segmenting and another micro-structured (half lasered structured and half non-structured) were used in this study. The grinding tests were carried out at different material removal rates and cutting speeds. The grinding forces, generated surface roughness, and induced residual stress by means of grinding with the structured and non-structured wheels were compared. Reduction in the static cutting edges via wheel structuring resulted in a better performance of the grinding wheel through the reduction of rubbing and ploughing regimes. The grinding forces were respectively 30% and 20% lower in the case of segmented wheel and laser-structured wheel in comparison with the conventional grinding. In addition, the tensile residual stress can be reduced as a negative output of the grinding process via structuring. Moreover, a high-speed high-efficient grinding of CMCs without presence of surface damage was achieved by optimizing the process parameters. The material removal rate can be elevated without changing the grinding forces with application of the structured wheel