Effect of different parameters on grinding efficiency and its monitoring by acoustic emission

Grinding efficiency is one of the most important considerations in the selection of grinding operation conditions because it has a significant impact on the productivity, quality, energy consumption and cost of production. Focusing on the core issues of grinding process, the paper presents some fundamental research findings in relation to grinding material removal mechanisms. The grinding efficiency is analysed by considering the rubbing, ploughing and cutting three stages of a single grit grinding process. By analysing the features of acoustic emission in single grit grinding tests, an evidence based scientific foundation has been established for monitoring grinding efficiency using acoustic emission. Accordingly, the energy consumption in the grinding is considered with the grit shape. Following the discussion of the models of temperature elevation and thermal stresses in grinding, the paper provides a logic depiction that explains why acoustic emission in grinding can be used for grinding thermal performance monitoring. As a result, the paper introduces a novel acoustic emission monitoring method that is capable to monitor grinding temperature and grinding wheel wear status

Chip formation mechanism using finite element simulation

Prediction of chip form produced during machining process is an important work when considering workpiece surface creation and possible damage caused by chips generated during machining. The paper presents a set of new results of cutting chip formation from the latest FEM model development. Generally three types of chips, namely, continuous, serrated and discontinuous chips, are generated during metal machining. The formation of these three types of chips is investigated in relation to various influential factors, such as rake angles and depth of cuts. Progressive damage model with damage evolution criterion is employed into the FEM model to reduce mesh dependency. It has been demonstrated that finite element simulation is a good tool for evaluation of chip formation in relation to operational parameters, tool settings as well as material properties

Analysis of grinding surface creation by single grit approach

This paper presents some new research findings in the investigation of single grit grinding in terms of surface creation. The investigation demonstrated that rubbing-ploughing-cutting hypothesis of grinding material removal mechanism is valid in both experiments and simulations. A finite element model (FEM) was developed to simulate the material deformation during the grit interacts with the workpiece. It was found that the cutting mechanism is the more effective in the first half of the scratch where the grit penetrates the workpiece. The ploughing is a prominent mechanism in the second half of the scratch where the grit is climbing up along the scratch path and uplifting the material at the front and the sides of it. This observation is very important to provide a greater insight into the difference between up-cut and down-cut grinding material removal mechanisms. Multi passes scratch simulations were performed to demonstrate the influence of ploughing on the ground surface formation. Moreover, by analysing the effects of grinding conditions, the shape of cutting edges and friction in grinding zone on the grinding surface formation, some useful relations between grinding performance and controllable parameters have been identified. It has demonstrated that ploughing has significant influences on ground surface formation and concluded that the influence of grit shape, friction and grinding kinetic condition should be considered together for the ploughing behaviour control, which could provide a good guidance for the improvement of grinding efficiency

Experimental study on single grit grinding of Inconel 718

This article presents an important investigation of material removal mechanism in grinding utilizing single grit scratch tests. The investigation helps people to understand the abrasive cutting behaviour when the abrasive cutting edge shape alters during single grit grinding. The results provide fundamental knowledge of the grinding material removal process, which helps to improve grinding performance and quality. Cubic boron nitride grits of 40/50 mesh size were used to perform scratch tests on the alloy Inconel 718. The concepts of material pile-up ratio and actual material removal area were introduced to measure the material removal efficiency during grinding. It is found that pile-up ratio decreases and actual material removal area increases when the depth of cut increases, albeit the material removal mechanism is highly dependent on the abrasive grit cutting edge shape. The material removal mechanism along the scratch length shows different behaviours at the entrance and exit sides of the scratching passes. When a grit was moving along its scratch path, it pushed material forward resulting in high material accumulation at the exit side of the scratches. Consequently, cutting is more prominent at the entrance side of the scratch, whereas ploughing or pile-up is extremely high at the exit side of the scratches. The research finding provides crucial information for grinding process optimization

Powder Mixed Electrical Discharge Machining and Biocompatibility: A State of the Art Review

Electrical Discharge Machining (EDM) is a well-known process for machining of difficult to cut materials. Along with adding the powder in dielectric liquid, change in properties of machining gap results in a variety of sparks forms and lead different mechanisms under specific operational conditions during machining. The discharge models significantly differ from conventional EDM and leave its characteristics surface features. Primary studies of Powder Mixed Electrical Discharge Machining (PMEDM) focused on the understanding of material removal rate, surface quality, and tool wear rate concerning the widespread of the operational conditions evolved in the process. Then, the interactions with the powder material during discharging and the resultant surface properties impel the researcher's interest to achieve functional surfaces. In this respect, PMEDM is a significant concern in recent years as an alternative and simple production technique to obtain functional surfaces for specific needs. Nowadays, among the specific needs, production of biocompatible surfaces with the use of the technique provides a challenging opportunity to the researchers to address osseointegration issues. The study presents an introduction and review of the research work in PMEDM. The studies concerning machining efficiency, surface integrity, and generation of functional surfaces are presented and discussed in the light of current research trends. Attempts made to improve biocompatible surfaces with the use of the process also included to clarify the future trends in PMEDM

TI6AL4V Surface Modification by Hydroxyapatite Powder Mixed Electric Discharge Machining for Medical Application

Titanium surface modification by the Hydroxyapatite (HA) mixed Electric Discharge Machining (EDM) is an alternative and promising technique to enhance the biocompatibility and to promote the biological performance in bone, which is dependent on surface properties, such as surface roughness, chemistry, and wettability. HA powder is used for the first time with electrical discharge machining to improve osteoblastic cell activity on the developed surfaces for TI6AL4V. Different HA concentrations in deionized water were tested as an experimental variable during EDM. Abrasive polishing and electrical discharge machined control surfaces without powder addition also analyzed to compare the results. The surface characteristics of analyzed samples were evaluated by Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), X-Ray Diffractometry (XRD), white light interferometry, and contact angle measurements. The wettability tests suggest that the hydroxyapatite powder mixed EDM’ed surfaces shows highly hydrophilic characteristics compared the other surfaces, abrasive polished and EDM’ed without powder addition in the dielectric. The results from the MTT assay revealed that those surfaces modified using HA powder addition in distilled water dielectric liquid promoted the most significant cell attachment/growth. The results indicate that HA powder mixed EDM offers a promising method for the surface modification of biomaterials such as titanium alloys

TI6AL4V Surface Modification by Hydroxyapatite Powder Mixed Electric Discharge Machining for Medical Application

Titanium surface modification by the Hydroxyapatite (HA) mixed Electric Discharge Machining (EDM) is an alternative and promising technique to enhance the biocompatibility and to promote the biological performance in bone, which is dependent on surface properties, such as surface roughness, chemistry, and wettability. HA powder is used for the first time with electrical discharge machining to improve osteoblastic cell activity on the developed surfaces for TI6AL4V. Different HA concentrations in deionized water were tested as an experimental variable during EDM. Abrasive polishing and electrical discharge machined control surfaces without powder addition also analyzed to compare the results. The surface characteristics of analyzed samples were evaluated by Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), X-Ray Diffractometry (XRD), white light interferometry, and contact angle measurements. The wettability tests suggest that the hydroxyapatite powder mixed EDM’ed surfaces shows highly hydrophilic characteristics compared the other surfaces, abrasive polished and EDM’ed without powder addition in the dielectric. The results from the MTT assay revealed that those surfaces modified using HA powder addition in distilled water dielectric liquid promoted the most significant cell attachment/growth. The results indicate that HA powder mixed EDM offers a promising method for the surface modification of biomaterials such as titanium alloys

Ti6Al4V Surface Modification by Hydroxyapatite Powder Mixed Electrical Discharge Machining for Medical Application

Titanium surface modification by the Hydroxyapatite (HA) mixed Electrical Discharge Machining (EDM) is an alternative and promising technique to enhance the biocompatibility and to promote the biological performance in bone, which is dependent on surface properties, such as surface roughness, chemistry, and wettability. HA powder is used for the first time with electrical discharge machining to improve osteoblastic cell activity on the developed surfacesforTI6AL4V. Different HA concentrations in deionized water were tested as an experimental variable during EDM. Abrasive polishing and electrical discharge machined control surfaces without powder addition also analyzed to compare the results. The surface characteristics of analyzed samples were evaluated by Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), X-Ray Diffractometry (XRD), white light interferometry, and contact angle measurements. The wettability tests suggest that the hydroxyapatite powder mixed EDM’ed surfaces shows highly hydrophilic characteristics compared the other surfaces, abrasive polished and EDM’ed without powder addition in the dielectric. The results from the MTT assay revealed that those surfaces modified using HA powder addition in distilled water dielectric liquid promoted the most significant cell attachment/growth. The results indicate that HA powder mixed EDM offers a promising method for the surface modification of biomaterials such as titanium alloys

Morphology Analysis and Characteristics Evaluation of Typical Super Abrasive Grits in Micron Scale

Distribution characterization of geometry shape and size of abrasive grits with high quality in tight size band and exact pattern is crucial for modern tool manufacturer to make fine powder abrasive tool and other powder tools, but complex to be classified and evaluated accurately due to the lack of scientific method. In contrast to industrial methods with sieving mesh size or simplified projection criteria with circumscribed (inscribed or escribed) circle or rectangle, a set of new systemic criteria is developed and validated by measuring three representative grits samples in micron scale under 2D/3D microscopy platform. The features of micron abrasive grits under morphology classification include total four groups, six subgroups and eighteen sub-types in consideration of spatial geometry and statistical size distribution. For grinding performance analysis and simulation, it would be better to use a set of dominant volumetric geometries rather than use single simple geometry. Furthermore, the significance of abrasive grits geometries in grinding performance is discussed

Sensor Based Cost Modelling for a Knowledge Support System Development

Nowadays, many small or medium size manufacturing companies face significant challenges of quality, cost and cycle time in their production life cycle. In order to deal with these challenges, the utilization of knowledge management system in their facilities becomes an appealing solution. However, most their current knowledge management system is not flexible enough and adequate for handling high amount of production data or calculating manufacturing cost of a product adaptively. Therefore, a novel knowledge support system framework for calculating unit product manufacturing cost through a generic cost model becomes necessary for small or medium size companies (SMC) to effectively optimise a manufacturing system in order to produce, repair or remanufacture products with the highest efficiency, best quality performance and lowest cost. This paper presents a generic cost model that considers production time based on sensors in a manufacturing system. This means the basic elements of model would adapt cycle time variation, which is one of the most important data of the generic cost models that will be obtained from the sensors on the machines