Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy

Belt grinding of flat surfaces of typical parts made of steel and alloys, such as grooves, shoulders, ends, and long workpieces, is a good alternative to milling. Several factors can influence the belt grinding process of flat surfaces of metals, such as cutting speed and pressure. In this work, the importance of pressure in the belt grinding was investigated in terms of technological and experimental aspects. The grinding experiments were performed on structural alloy steel 30KhGSN2/30KhGSNA, structural carbon steel AISI 1045, corrosion-resistant and heat-resistant stainless steel AISI 321, and heat-resistant nickel alloy KHN77TYuR. The performance of the grinding belt was investigated in terms of surface roughness, material removal rate (MRR), grinding belt wear, performance index. Estimated indicators of the belt grinding process were developed: cutting ability; reduced cutting ability for belt grinding of steels and heat-resistant alloy. It was found that with an increase in pressure p, the surface roughness of the processed surface Ra decreased while the tool wear VB and MRR increased. With a decrease in plasticity and difficulty of machinability, the roughness, material removal rate, reduced cutting capacity (Performance index) qper, material removal Q decreased, and the tool wear VB increased. The obtained research results can be used by technologists when creating belt grinding operations for steels and alloys to ensure the required performance is met

Product Quality Planning in Laser Metal Processing Based on Open Innovation Using Quality Function Deployment

The results of the development of a modified quality function deployment (QFD) method, obtained for the first time to improve the product quality planning process in the metal cutting of laser technologies confirming the dynamics of open innovation, are presented. When using new marketing technologies, the requirements of consumers are established; a factorial model of customer satisfaction was determined with after an assessment by expert methods, their wishes were transformed into indicators of product quality, and its concept was developed. Product quality is enhanced by optimizing project specifications. The method of functional cost analysis (FCA) was applied for the manufacturing processes, which made it possible to reduce the costs of their implementation. New methods of product quality control were applied. The developed planning process is described by a sequence diagram, an algorithm, and a responsibility matrix. The research used search methods including Internet resources required for open innovation, namely functional modeling methods (IDEF) and the method of advanced product quality planning (APQP). The results of the achieved advantages of open innovation (reduction in research and development costs, implementation of the principles of total quality management (TQM), customer orientation, process approach, improvement) are recommended for further application both at the enterprise and in the metalworking of mechanical engineering. The practical significance of the results of this work is the reduction in internal and external failures by 12%; reduction in time for new product development by 9%; reduction in costs for online resources by 11% and quality control during production by 7%; reduction in labor costs for process management by 25%; and the stability of the process, which improved by 25%

A Study on the Machinability of Steels and Alloys to Develop Recommendations for Setting Tool Performance Characteristics and Belt Grinding Modes

This article presents a methodology for designing belt grinding operations with grinding and lapping machines. It provides the results of a study on the machinability of various steels and alloys with belt grinding, which are then classified according to an indicator that we have developed. Namely, cast aluminum alloys, structural alloy steels, structural carbon steels, corrosion-resistant and heat-resistant stainless steels, and heat-resistant nickel alloys have been investigated. The machinability index is the ratio of the performance indicators of the grinding belt and the depth of cut to the indicators of grade 45 structural carbon steels (similar to steel AISI 1045) and similar steels and alloys. The performance indicators of the grinding belt are chosen from a set of calculated and estimated indicators. Experimentally determining the dependences of the performance indicators on the belt grinding modes and conditions, taking into account the established levels of machinability, allowed us to develop recommendations for designing belt grinding operations with grinding and lapping machines. The proposed methodology for designing belt grinding operations guarantees optimal performance and ensures that the necessary quality of the machinable surfaces is achieved. At the same time, it takes into account variable machining conditions, which change within specified limits