Grinding Technology:
Theory and Applications of Machining with Abrasives |  |
A significant update to the most authorative source available anywhere on applications for grinding wheels. A blend of theorgy and application expertise useful for education, troubleshooting, design or improvement of grinding practices. Written explicitly for researcher or engineers associated with grinding and abrasive processes.
The Second Edition includes:
New abrasives grains
Greatly expanded sections on superabrasives, particularly CBN
Expanded section on thermal aspects with separate chapters for convention, creep grinding, high efficiency deep grinding (HEDG)
New chapter of fluid flow in grinding
New chapter on computer simulation
Integration of simulation with machine tool controls
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| FROM THE PREFACE
The first edition of this book was intended to provide an integrated scientific foundation for understanding of the grinding process, which can be practically utilized for enhancing and optimizing grinding operations. After 18 years in print, the first edition is still selling and is widely referenced, but many of the newer developments in grinding led us to think that the time had come for a new edition. This second edition builds upon the first edition with greatly expanded coverage of the thermal aspects of grinding, creep feed grinding, grinding with superabrasives, fluid flow, process simulation, optimization, and intelligent control of grinding machines.
This book is written both for the researcher and the practicing engineer. As with the first edition, it is expected that the second edition will be used as a textbook or supplement for advanced courses on machining and grinding, for industrial short courses, and as a source of fundamental and practical information about the grinding process and its utilization.
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THE AUTHORS
The Authors
Stephen Malkin was Distinguished Professor and former head of the Department of Mechanical & Industrial Engineering at the University of Massachusetts. An author of more than 200 papers, he was intemationally recognized for research on grinding and abrasive processes. As an industrial consultant and lecturer, he has been a leader in the practical utilization of grinding technology. Dr. Malkin was a fellow of the International Institution for Production Engineering Research (CIRP), the American Society of Mechanical Engineers (ASME), and Society of Manufacturing Engineers (SME). His awards included the ASME Blackall Award of 1993, the SME Gold Medal of 1996, the University of Mass Outstanding Engineering Faculty Award of 1997, and the ASME William T. Ennor Manufacturing Technology Award of 2004 in recognition of his leading role in the transformation of abrasive machining from an empirical craft to an applied science.
Changsheng Guo is Principal Scientist and Project Leader at the United Technologies Research Center (UTRC) leading projects in modeling, simulation, and optimization of manufacturing processes. Before joining UTRC, he was Co-Director of the grinding research program at the University of Mass and Technical Director of Chand Kare Technical Ceramics. Dr. Guo's research focuses fundamentals and applications for grinding, milling, superabrasive machining, and ceramic machining. With more than 80 published papers, Dr. Guo is an associate editor for Machining Science and Technology and an associate member of the International Academy for Production Engineering (CIRP). His numerous awards include UTRC's Outstanding Achievement Award, the Pratt & Whitney leadership award, the F. W. Taylor Medal of CIRP in 1996, the US DOE energy pioneer award in 1995, and the ASME Blackall Award in 1993.
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TABLE OF CONTENT
- Grinding Wheels: Composition and Properties 11
- Grinding Geometry and Kinematics 43
- Wheel Truing, Dressing, and Topography 81
Dressing of Conventional Wheels 82
Truing and Dressing of Superabrasive Wheels 84
Generation of Wheel Topographyi
- Grinding Mechanisms 115
Grinding Debris (Swarj) 116
Grinding Forces, Power, and Specific Energy 118
Grinding Mechanisms: Conventional Abrasives 120
Grinding Mechanisms: CBN Wheels 134
Creep Feed Grinding 141
Controlled Force Grinding 142
Heavy Duty Grinding 147
Empirical Relationships 152
- Thermal Aspects: Conventional Grinding 157
Heat Transfer Analysis: Plunge Grinding 159
Thermal Damage 169
Workpiece bum 170
Tempering and Rehardening 173
Residual stresses 176
Abrasive Cut Off 181
- Thermal Aspects: Creep Feed Grinding 189
Workpiece Temperature and Burnout 192
Energy Partition: Simple Modelfor Creep Feed Grinding 194
Energy Partition: Variation along the Grinding Zone 196
Energy Partition: Single Grain Model 201
Transient Temperature 203
Thermal Comparison: Regular and Creep Feed Grinding 209
- Thermal Aspects: Grinding with CBN Abrasives 215
Vitrified CBN Wheels 216
Electroplated CBN Wheels 219
High Efficiency Deep Grinding (HEDG) 224
- Fluid Flow in Grinding 231
Fluid Flow through Grinding Zone:Flood Application 232
Fluid Flow through the Grinding Zone: Creep Feed Grinding 236
Analysis of Useful Flow Rate through the Grinding Zone 238
Analysis of Hydrodynamic Forces 248
- Surface Roughness 257
Ground Surface Morphology 258
Ideal Surface Roughness 265
Empirical Roughness Behavior 272
- Wheel Wear and Lubrication 285
Quantifying Wheel Wear 286
Wheel Wear Mechanisms 289
Analysis of Wheel Wear 294
Attritious Wear and Grinding Chemistry 301
Grinding Fluids and Lubrication 304
Evaluating Wheel Performance 308
- Grinding Deflections: Grinding Cycles, Inaccuracies, and Vibrations 315
Continuous Infeed Analysis 315
Grinding Cycle Behavior 319
Discrete Infeed Analysis 321
Inaccuracies and Elastic Deflections
Accelerated Spark In and Spark Out 327
Grinding Vibrations 331
Vibration Suppression 335
- Simulation, Optimization, and Intelligent Control 339
Original Simulation Software for Cylindrical Grinding 340
GrindSim@: Simulation, Calibration, and Optimization
of Cylindrical Grinding 345
Simulation of Creep Feed Form Grinding 353
Machine Tool Control 361
- Index 369
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