Abb6 principle, 171 172
Above centre, 259, 262
Abrasion, mechanics of, 341 362
Challen and Oxley model, 351 356
chip formation, 354 356
wave rubbing, 352 354 wave wear, 354
indentation analysis, 350 351
friction angle, 350 351
slip line field, 350
indentation with sliding, 351
oblique cutting, 356 357
ploughing contact, 347 349
cone and sphere model, 349
primary, secondary and tertiary
shear, 341 343
blunt cutting action, 342 343
compressive to tensile stress,
342
minimum energy principle, 343
redundant energy, 342
shear strain rates, 342
rubbing contact, 343 347
interface friction, 344 345
junction growth, 345
three dimensional stresses,
345 347
wear, 357 362. See also Wear
Abrasive belt machining, 17
Abrasive contact, 335
Abrasive structure, 79 80
Abrasive surface, 79 82
abrasive structure, 79 80
grain distribution, 80 82
grain sharpness, 79
grain size, 79
grain spacing, 80 82
shape conformity, 79
wheel flexibility, 82
Abrasive type, 29
Abrasive wear, 361
Abrasives, 35 37, 105, 109 110,
387 388
aluminium oxide, 39 40
CBN, 38
conventional abrasive, 38 39
diamond, 37 38
silicon carbide, 38 39
sintered alumina, 40 41
super abrasives, 37 38
Abusive, 106
Accuracy, 3, 95 97, 163, 211,
215 216,218
ACO. See Adaptive control
optimisation
Acoustic emission, 72 73
Active grains per unit area, 81
Adaptive control, 226 227
Adaptive control optimisation (ACO)
monitoring, models, 229 230
Adaptive dwell, 222 223
Adaptive feed rate, 221 222
Adaptive strategy, 221
Additives, 117, 119 120
Adhesive wear, 358 359
Advisory system, 228 229
Air barrier, 124 125
Airjet, 117, 121
Air scraper, 125 126
Alloying, 106
Alternative lubrication, 116
Alumina, 110, 147, 149 153, 156,
159, 161
Aluminium oxide, 39 40
Angle approach grinding, 89
Apparent contact area, 315 316
Application, wheel, 49 51
Archard's law, 360
Asperity contact, 322
Atmospheric environment, 9
Attenuation, 240 241
Austenite, 106, 111
Auxiliary jet, nozzles, 127
Averaging, 383 384
Avoidance, damage, 105 106
Avoiding dynamic problems,
286 287
Background heating, 372
Background temperature,
365 370,384
Backlash, 165, 189 191
Bacteria, 115 116, 118
Balancing, 50 51
Barkhausen, noise sensor, I I 1 112
Barrelling, 21
Base, machine, 184 185
Basic adhesion, 343 344
Basic equations, 237 239
Basic grinding processes, 5 7
basic surface, 5
cylindrical grinding processes, 5
external variant, 5
internal variant, 5
processes range, 5 7
Basic temperature equation, 393
Bearings
air, 182 184
hybrid, 176 182
hydrodynamic, 174 175
hydrostatic, 176 182
journal, 184
plain, 174 175
rolling, 175 176
Below centre, 258
Bending deflection, 185 186
Block diagram, 236 237
Blunt/Blunting, 16, 26, 29, 62, 67 69,
77
Blunt cutting action, 342 343
Boiling temperature, 117 118
Bond fracture, 83
JUNUZA
Bond, wheel, 41 43
Bonded segments, 55
Bonding to a metal hub, 55
Brake roll dressers, 63
Brown alumina, 40
Bulk cooling, temperature, 114 115
Bum, 15, 30 31, 33, 86, 98 99
damage, 106 107
transition, 391
Bum out temperature, 374, 389
Calibration, 323 327
Carbon, 106, 108 109, 111
CBN. See Cubic boron nitride
Cementite, 106
Centreless, 168 173, 196, 200 202
Centreless grinding, 5, 7, 13, 30 31,
33,257 287
convenient waviness, 270 272
control wheel correction action,
272
work plate correction action,
271 272
deflection, effect of, 284 286
dynamic problems, avoidance,
286 287
in feed rate, 270
machine design, 269 270
processes, 258 261
external centreless grinding,
258 259
external shoe grinding,
260 261
internal centreless grinding, 260
internal shoe grinding, 261
productivity, 269 270
rounding action, simulation of,
272 277
rounding process, stability of,
278 284
roundness errors, 269 270
set up geometry, removal
parameter, 261 264
contact geometry, 261
plunge grinding, removal
parameter, 264
rounding investigation, 263
tangent angle, 262
work height, 262
work plate angle, 261 262
shape formation system, 277 278
wheel dressing, 266 268
control wheel dressing, 267
control wheel run out, 268
grinding wheel dressing, 266
work feed, 264 266
plunge feed, 264 265
through feed, 265
tilt angle, 266
work speed, 270
Ceramics, 2, 37, 39, 43, 56,
198 199,202,206
C factors for maximum
temperatures, 379 380
C frame structure, 167
Chatter, 42, 57, 98 99, 107
condition, 247 254
adding vibration damping, 254
graphic stability determination,
248 249
machine system, adding
flexibility to, 252 253
reducing grinding wheel contact
stiffness, 251 252
traverse grinding, reducing
overlap in, 250 251
using measured frequency
responses, 249 250
varying work speed, 253 254
wheel speed, 253 254
Chemical reaction, 105
Chemical thermal degradation,
37 38
Chemical wear, 362
Chip, 21 22
cross section area, 303 304
energy, 336 338, 367
flux, 374 375
formation, 354 356
formation energy, 336 337
length, 302
shape models, 301
thickness, 101 102, 292 294,
304 309,333
volume, 302 303, 331
Circular arc heat source, 366
Cleaning up, 59
Cleavage planes, 37
CNC. See Computer numerical
control
Coarse dressing, 62 63, 67 68
Coherence, coherent length,
128 130
Column deflection, 185 187
Complex operator, 238
Compliance, 240, 252
Compliance, machine, 164 171
Compressive, 109 111
to tensile stress, 342
Computer numerical control (CNC)
191,194,205,218
Computer simulation, 257
Concentrate, 117 119
Concentration, 49
Conditioning, 59
Conduction
into the grain, 395 396
into the workpiece, 395 396
Cone and sphere model, 349
Contact angle, 379
Contact area, 113
Contact length, 89 93, 98, 100
filtering, 240 241
ratio, 93, 326 327
Contact stiffness, 251 252
Contact surface temperatures,
380 381
Contact time, 316, 325 326
Contact width, 18, 23, 31
Continuous dressing, 74 75
Control capability, 211
Control systems, 227 228
Control wheel, 168 170, 267 268,
272
Convenient waviness, 270 272
Conventional abrasive, 38 39
Coolant, 95, 98, 102
Cooling, 16
Corrective action, 271 272
Corrosion, 116, 119,361
Corundum, 39
Cost(s), 4, 9, 37 38, 51, 95.
See also individual entries below
Cost analysis, total life cycle
costs, 145
Cost per part, cost/part, 145,
147 152
Cost reduction, 145 161
AISI 52100, cost comparisons
for, 156 159
best condition, 157
conventional speed A12 03, 158
conventional speed CBN
wheels, 158
cost comparison, 158 159
grinding wheels, 157
high speed B91 CBN
wheel, 158
re dress life, 159
SG wheels, 158
cost per part, analysis, 147 152
cost elements, 147
dressing cycle time, 148 149
dressing frequency, 149
grinding cycle time, 147 148
labour cost/part, 150 151
parts per wheel, 149 150
total cycle time, 147
total variable cost/part, 152
wheel cost per part, 150
cost reduction, trials, 152 156
basic trials, 153 154
best condition, selection of,
155 156
confin nation trials, 156
direct effect, 154 155
cost variables, 145 146
Inconel 718, cost comparisons for,
159 161
conventional speed A12 03, 160
conventional speed vitrified
B151 CBN wheel, 160
grinding wheels, 159
high speed B 151 CBN wheel,
160
re dress life, 160 161
labour cost, 146 147
machine cost, 146 147
output, 145
overhead costs, 146
quality, 145
total life cycle costs, 145
wheel cost, 146 147
Cost variables, 145 146
Cracks/Cracking, 105, 109
propagation, 341, 360
Crankshaft grinding, 101
Creep feed grinding, 13, 99 100,
113,366,380,390,393
Cryogenic cooling, 121
Crystallite size, 40
Cubic boron nitride (CBN), 24 25,
28 29,38,110
Cup dresser, 63
Curve fits, 383 384
Cutting, 15 16, 22, 24, 29, 335 339
Cutting edge contacts, 294 298
cutting edge density, 296
cutting edge shape, 297 298
poisson distribution, 294 296
random cutting action, 294
times, 298 299
wear effect, 296 297
Cutting edge density, 296
Cutting edge shape, 297 298
Cycle, cycle time, 220 224, 227, 230,
145,147 149
Cylindrical, 164, 166 167, 175, 186
Cylindrical grinding, 5, 103, 171 18,
21 22,24 25
Damage, 99
avoidance, 105 106
temperatures, 369
Damping, 167
Damping parameters, 245 247
Database, intelligent, 228 229
Debris, 113, 115
Deep cut, 390
Deep form grinders, 195
Deep grinding, 97, 100, 366 367,
381,390,393
Defining contact length, 324 325
Deflected contact length, 91
Deflection, 18, 21
in phase, quadrature, 244, 253
length, 321, 323
static deflections, 284 286
Density, 117
Depth of cut, 234 239, 247, 332, 388
Depth of cut, real and programmed
or set, 18 19
Depth of grain penetration, 15, 17
Depth of material removed, 17 21
Determination of K, 360
Developments, 97 98, 100 101
of temperature analysis, 365
Diamond, 37 38
Diffusion, 108 109, Ill
Diffusivity, 378 379
Disk dresser, 63
Disposal, disposal cost, 115, 145 146
Down cut grinding, 15 16
Down feed, 17, 20
Drag power, 25
Dressable metal bond, 56
Dresser, 163, 165
Dresser cost, 145
Dresser sharpness, 165
Dresser size, 211
Dresser wear, 213 214
Dressing, 11, 100
conditions, 8
Dressing depth of cut, 61
Dressing effects, 335
Dressing feed per revolution, 61
Dressing frequency, 149
Dressing process, 60 61
Dressing roll speed ratio, 63 65
Dressing time, dressing cycle time,
148 149
Dressing tool, 165
sharpness, sharpness ratio, 61 62
Dressing tool wear, 68 69
Dressing traverse rate, 66 67
Dressing vibrations, 65 66
Drill flute grinding, 101
Dry electro discharge truing, 59
Dry grinding, 28 29, 117, 385 386
Dullness, 297 298
Dust, 113
Dwell, 170 171
Dwell period, 211, 215, 221,
223 227
Dwell time, 145 147
Dynamic deflections, 285 286
Dynamic magnifier, 245 247,
249 250,252
Dynamic relationships, 236 240
Dynamic stiffness, 236, 245
Effect of wear, 296 297
Effects, direct effects, 154 155
Elastic deformation, 236
Elastic modulus, 316
Elastic wheels, 13
Elasticity, 252 253
wheel, 56 58
Electrolytic In Process Dressing
(ELID),3,43,59,75 78
ELID grinding, 43, 56
Electro plated super abrasive, 44
Electro plated wheels, 59
ELID. See Electrolytic In Process
Dressing
Empirical relationships, 293
Emulsifier, 118 119
Emulsion, 98 99
Enclosed, 116
Energy, 102, 331 332
Energy components, 336 339
Energy monitoring, 369
Environmental aspects, 115
Epoxy bonds, 41
Equivalent chip thickness, 21 22, 101
limitations, 292 294
Equivalent diameter, 87 89,
317 319
Errors, 163, 169, 171 174, 182, 189,
201 202
Error compensation, 214, 216
Esters, 120
Excitation test, 242 244
Experimental plan, 154
Extreme pressure, 120
Face grinding, 5, 87 90, 92
Fatigue, fatigue life, 105, 360 361
Feed, 108, 112
Feedback, 194
Feed change points, 211
Feed drive, 187 195
Feed position, 211, 216, 218
Feed rate, 211, 215 216, 218 219,
221 222
Feed time, 147
Ferrite, 106, 111
Filtration, 117, 122
Fine dressing, 62 63, 67 68
Finished surface temperatures,
380 381
Fires, 116, 120
Flash contact, 299
Flash heating, 371
Flexibility, 252 253
Flood delivery, 114
Flow rate, 123, 134 135, 138, 179
Fluid boiling, 366, 377
Fluid convection, 366 367, 376 377
coefficient, 377 378
Fluid cooling, 100, 366, 390
Fluid delivery, 12, 123 131
air barrier, 124 125
air scraper, 125 126
auxiliary nozzle, 127
coherence, 128
coherent length, 129
finishing requirements, 124
fluid speed, 126
highly porous wheels, 125
hydrodynamic effect, 123 124
jet positioning, 127 128
nip, 130 131
nozzle arrangement, 126 127
nozzle comparisons, 129 130
nozzle position, 126
pore feeding, 125
roughing, 124
sealing the wheel, 125
shoe nozzle, 130
size control, 123 124
webster nozzle, 128 129
Fluid drag, 24 25
Fluid supply system, 122
Fluid(s)
delivery, 105
properties, 116 117
Fluids, application of, 113 143
alternative lubrication, 116
bulk cooling, 114 115
contact area cooling, 113
dry grinding, 117
fluid accelerate, power
required to, 141 143
spindle power, 141
total power, 141 143
fluid disposal, 115
fluid properties, 116 117
gas jet cooling, 120 121
grinding fluids
functions of, 113
types of, 113
MQL, 115, 120 121.
See also individual entry
neat oils, 118 120
mineral oil, 120
synthetic oils, 120
nozzle design. See Nozzle design
nozzle flow rate, requirement,
134 141
oil, 116
pumping system, 121 123.
See also Pumping system
safe use, 115
swarf flushing, 115
total life cycle costs, 116
water based fluids, 116, 117 118
|
fluid composition, 118
fluid treatment, 117 118
re circulation system, 117
wheel wear, reduction of, 113 114
Flushing, 115
Force loop, 168 170
Forced vibration, 234
Form dressing tools, 60
Fracture, 36, 40
Free vibration, 239
Friability, 36, 40
fiiction, 113, 129
Friction angle, 350 351
Friction factor, 344, 346 347, 353,
355,357
Friction power, 180 181
Fume extraction, 115
Fungal growth, 116
G ratio, 84 85, 96
Gap elimination, 230
Gas jet cooling, 120 121.
See under Minimum quantity
lubrication
Gauging, 164, 214 216
Geometric contact length, 89 90,
316 317,324 327
Geometric instability, geometric
stability, 279 282
Geometric stability parameter,
280 282
Geometrical interference, 236
Grade, wheel grade, 47 48
Grains, 11, 13
Grain contact analysis, 368
Grain density, 332
variations, 308 309
Grain depth, 334
Grain distribution, 80 82
Grain heating, 371 372
Grain impact, 15
Grain macro fracture, 83
Grain micro fracture, 16, 83
Grain penetration, 15 17, 300
Grain shape, 333 335
Grain sharpness, 29, 79, 100, 388
Grain size, 79
grit size, 45 47
Grain spacing, 80 82, 300, 304,
306 311,313
Grain temperatures, 384
Grain thermal properties, 369
Grain wear, 15, 82 87
bond fracture, 83
G ratio, 84 85
grain macro fracture, 83
grain micro fracture, 83
preferred wheel wear, 84
re sharpening, 86 87
rubbing wear, 82 83
wear flats, 85 86
wear measurement, 84
wheel loading, 83 84
Grains as cutting tools, 291
Grind hardening, I I I
Grinding chips, 291 292
Grinding conditions, 105, 112
Grinding efficiency, 117
Grinding energy, 23 25, 85 86,
368 369
Grinding fluid, 8 9, 362, 389
Grinding force(s), 26 29, 96,
99, 103
ratio, 26
stiffness, 238, 249
Grinding in manufacture
accuracy, 3
cost, 4
machining hard materials, 2
origin of, I
quality, 2
reducing the operations, 4 5
role of, 1 5
speed of production, 2 4
strategic process, 1 2
surface quality, 3
surface texture, 3
value added chain, 4
Grinding machine, developments, 7.
8 9912,163 208
bearings. See Bearings
column deflection, 185 187
feed drives, 187 195
grinding machine elements, 164
joints, 187 195
machine base, 184 185
machine layout, design principles,
171 173
machine requirements, 163 164
accuracy, 163
stiffness, 163
thermal deflections, 163 164
wear, 164
machine stiffness, compliance,
164 171
bearing deflections, 167 168
C frame structure, 167
compliances, 168 170
damping, 167
force loop, 168 170
grinding performance,
improvement, 170
slide ways, 167 168
spark out time, improvement,
170 171
static stiffness, 164 167
U frame structure, 167
slide ways, 187 195
spindle bearings, wheel heads, 174
spindle elements, 174
spindle roundness, 174
spindle types, 174
thermal deflection, 185 187
trend in, 195 208
Grinding performance, 66 69
coarse dressing, 67 68
dressing tool wear, 68 69
dressing traverse rate, 66 67
fine dressing, 67 68
medium dressing, 67 68
Grinding power, 25 26, 67 71
Grinding system elements,
specification, 7 9
atmosphere, 9
basic elements, 7
elements characteristics, 8 9
grinding fluid, 9
grinding machine, 9
system elements, 8
Grinding temperatures, 13,
392 394
Grinding wheel developments, 8, 11,
35 58
abrasives, 35 37.
See also individual entry
grinding wheels, 43 44
high speed wheels, 51 56.
See also individual entry
wheel bonds, 41 43.
See also individual entry
wheel design, application, 49 51
balancing, 50 51
safety, 49
wheel mounting, 49 50
wheel elasticity, 56 58
wheel specification, 44 49.
See also individual entry
wheel vibrations, 56 58
Grinding wheel dressing, 59 78
CBN wheels
touch dressing for. See also
Touch dressing
continuous dressing, 74 75
ELID, 75 78
grinding performance, 66 69.
See also individual entry
rotary dressing tools, 63 66.
See also individual entry
speed, 66
stationary tools, dressing, 59 63.
See also individual entry
Grinding wheel stiffness, 18
Guide plates, 265
Halogenate, 120
Hardness, 36 37, 47, 344, 347,
357 358,361
hardened, 106 108, 110
Health, 115
and safety, 9
Heat, 98 100
Heat capacity, 116 117
Heat dissipation, 371
Heat exchanger, 122 123
Heat flows, 365 366
Heat flux, heat flux definition, 374
Heat input, 370
lieal partitioning, 363, 373 374
Heat to the wheel, 367
Heat treatment, I 10
HEDG. See High Efficiency Deep
Grinding
HEG. See High efficiency grinding
High efficiency deep grinding
(HEDG), 10, 97, 100 102
High efficiency grinding (HEG),
97 99
High removal rate grinding, 390 391
High wheel speed grinders, 195
High work speed grinding, 103
High aspect ratio grains, 40
High porosity, 296 298
wheels, 41
High speed domains, 97
High speed grinding, 95 103
creep feed grinding, 99 100
HEDG, 100 102
chip thickness, 101 102
crankshaft grinding, 101
development, 100 101
drill flute grinding, 101
specific energy, 102
temperature analysis, 102
viper grinding, 102
HEG, 97 99
developments, 97 98
emulsion, 98 99
machine requirements, 98
neat oil, 98 99
speed ratio, 99
high work speed grinding, 103
cylindrical grinding, 103
speed stroke grinding, 103
high speed domains, 97
trends in, 95 97
accuracy, 95 97
cost, 95
productivity, 95
quality, 95
removal rate, 95 97
High speed wheels, 51 56
balanced stresses, 5 t 54
practical consideration,
design of, 54 56
bonded segments, 55
bonding to a metal hub, 55
central reinforcement, 54 55
dressable metal bond, 56
metal bonds, 55
solid wheels, 54
tapered wheel, 55
unbalanced stresses, 51
Hoop stresses, 44, 50
Horizontal surface grinding, 17 18,
20,23
Hydrodynamic effect, 123 124
Ice air jet blasting, 121
Impregnated diamond dressing tools,
59
Impulsive vibration, 233 234
Inconel, 159 161
Indentation analysis, 350 351
Indentation model, 334
4UZS
Indentation with sliding, 351
In feed rate, 18, 30 31, 32, 270
Integer speed ratio, 234
Intelligent control, 218 219
Interface friction, 344 345
Interference, 274 276
Internal grinding, 5, 7
Interrupted cuts, 42
IR imaging, 386
Iron, iron carbon diagram, 106
Irritant effects, 115
Jet, jet nozzle, 127, 130 132, 142
Joints, 187 195
Journal, 177 181, 183 184
Junction growth, 345
Kinematics, 8
Kinematic contact length, 91
Kinematic models, 300
LabouT cost, 146 147, l% 151
Legislation, 115
Light running tests, 244 245
Limit chart(s), 31 33, 218 219, 258
Limiting stability, 239
Linear motor, 194, 196, 207 208
Loss of contact, 274 276
Low temperature grinding, 350
Lubrication, 341, 354 356, 358, 362
mechanical, chemo physical, 113
Machine control, 216 219
Machine cost, 146 147, 151 152
Machine design, 269 270
Machine mountings, 234
Machine requirements, 98, 163 164
Machine stiffness, 269
Machine tool stiffness, 18
Macro fracture, 62
Magnetic fluid grinding, 204
Martensite, 106, 108 109, 111
Material removal, basic, 15 31
abrasive type, effect of, 29
chip thickness, 21 22
forces, 25 29
grinding energy, 23 25
grinding force ratio, 26
grinding power, 25 26
material removal rate, 22 23
material removed, depth of, 17 21
barrelling, 21
size error, 20 21
stiffness factor, 19 20
power, 25 29
removal process, 15 17
removal rate maximising, 30 33
limits charts, 31 33
process limits, 30 31
typical forces, 26 29
wet grinding, 29
Material removal, grains, 291 313
chip cross section area, 303 304
chip length, 302
chip thickness, 292 294, 304 309
chip,volume, 302 303
cutting edge contacts, 294 299.
See also Cutting edge contacts
cutting tools, 291
grinding chips, 291 292
removal rate, 302 303
surface roughness, 309 312
uncut chip, 300 301
Maximum chip thickness, 307
Maximum removal rate, 33
Maxwell's principle, 247
Mean chip thickness, 307
Measured specific energy, 329
Measurements, 325
Mesh number, 46 47
Metal bonds, 43, 55
Metal bond wheels, 75
Micro fracture, 39 40, 68
Micro grinding, 163
Micro hardness, 108
Mineral oil, 120
Minimum energy, 337 338
Minimum energy principle, 343
Minimum quantity lubrication
(MQL), 115,120 123
cryogenic cooling, 121
ice air jet blasting, 121
mist cooling, 121
with oil, 120 121
Mist
cooling, 121
oils, 120 121
Mode, rocking mode, tuning fork
mode, 242 243
Monitoring, power, 112
Morphology, 39
Movement directions, 188 190
Moving heat source, 365
Moving line source, 392 393
MQL. See Minimum quantity
lubrication
Multi part grinders, 196 197
Multi plunge grinding, 226 227
Multi point diamond tools, 60
Multi tool grinders, 197
Nano grinding, 3 4, 10, 12, 163, 200,
202 203
Natural frequency, 183, 236, 245,
249 250,252
Neat oil(s), 98 99, 118 120
New abrasives, 11, 35
New processes, 10
Nip, 130 131
Nital etch, 107
Nitrogen, 117, 120 121
No load power, 24 25
Normal force, 26, 29
Nozzle design
calculations, 131 134
rectangular nozzle, 133 134
round orifice nozzle, 131 133
round pipe nozzle, 133
turbulence, 131
Oblique cutting, 356 357
Oblique heat source, 366
Oil, 116, 377 378, 389 390, 392
One dimensional method, 382 383
Operator inputs, 231
Optimisation, 12, 30
Organic bonds, 41 42
Orifice(s), 129, 131 134, 183 184
Origins, I
Output, 145
Overhead costs, 146
Overlap, 250 251
Overlap ratio, 61
Oxidative wear, 361
Oxidising, 106
Part feeding, 172
Part program, 220, 229
Parts per dress, parts/dress, 149 152,
158 160
Parts per wheel, 149 150
Passes, 15 16, 19 21
Payback time, 151
Pearlite, I I I
Peclet number, 378 379
Peripheral grinding, 5
pH, 118
Phase transformation, 105
Phase, phase angle, phase shift,
235 236,238,249
Phenolic bonds, 42
Physical reasons, 330 331
Pink alumina, 40
Planar grinding, 2
Plastic bonds, 41
Ploughing, 15 16, 335 339
Ploughing contact, 347 349
Ploughing energy, 335 339
Plunge grinding, plunge feed,
264 265
Polar plot, 243 244
Polyamide bonds, 42
Polyurethane bonds, 41
Pore feeding, 125
Porosity, 48
Position offset, 213
Power, 98
power level, 112, 223, 226, 231
Power monitoring, 231
Power ratio, 181
Precipitation, 105
Preferred wheel wear, 84
Pre production trials, 220
Pressure, 123
Pressure distribution, 320 322
Preston's law, 358
Primary shear, 341 343
Process compensation, 12
Process control, 112, 211 231
grinding, intelligent control of,
220 227
adaptive control of multi plunge
grinding, 226 227
adaptive dwell control, 222 223
adaptive feed rate control,
221 222
adaptive strategy, 221
time constant.
See Time constant
knowledge based intelligent
control system, 227 231
ACO. See Adaptive control
optimisation
advisory system, 228 229
CNC. See Computer numerical
control
frame work for, 228
gap elimination, 230
intelligent databases, 228 229
operator inputs, 231
power sensing, 231
temperature sensing, 230
thermal damage, 231
touch dressing, 230 231
machine control, classes of,
216 219
CNC, 218
intelligent control, 218 219
manual control, 217
switching control, 217
process variability, 211 216
dresser wear, size variation
dueto,213 214
in process gauging, 214 216
limits, 212 213
process stabilisation, 214
tolerances, 212 213
wheel wear, variation due to,
211 212
Process limits, 30 31
Process monitoring, I 11 112
Process operation and control, 12
Process stabilisation, 214
Process variability, 211 216
Production rate, 197
Productivity, 95, 269 270
Pumping power, 180
Pumping system, 121 123
elements, 122
heat exchanger, 122 123
pressure, 123
separation, 122
supply flow rate, 123
wheel absorption of fluid, 123
PVD coatings, 387
Quality, 2, 95, 145
Quantifying sharpness, 333
Quenched, quenching, 109, 111
Random, 234
Real contact, 315 327
apparent contact area, 315 316
real contact length, 316 320
rough wheel analysis, 321 323
roughness factor, calibration of,
323 327
comparison with Verkerk,
323 324
contact length ratio, 326 327
defining contact length,
324 325
Qi measurement, 325
smooth wheel analysis, 320 321
Real contact area, 3 t 5 3 16
Real contact length, 316 320,
359,368
Real contact pressures, 322
Re circulation system, 117
Rectangular nozzle, 127,
133 134
Re dress life, 37, 43, 159, 160 161,
214,218 219,359
Redressing, 105, 112
Redundant energy, 342
Regenerative, 235 236
Regulating wheel, 258, 267
Re hardening, damage, 108 109
Reinforced wheels, 54 55
Relationship to h,q, 329 330
|
Relative vibration, 243 245
Removal parameters, 261 264
Removal process, 15 17
Removal rate, 2 4, 10 13, 95 97,
105,110,112,134,200,302 303,
391,399,390 392
maximising, 30 33
Repeatability, 165, 200, 211
Re sharpening, 86 87
Residual stresses, 109 111
Resin, 101
resinoid, 40, 42, 45, 48
Resin bonded CBN, 63
Resolution, 165, 172, 187, 199 200,
203 205
Resonance, resonant frequency, 173,
183,245 247
Restrictors, 183 184
Role of grinding, 1 5
Roll dressers, 63
Roots, 239
Rotary dressing tools, 63 66
dressing roll speed ratio,
63 65
dressing vibrations, 65 66
grinding wheel dressing speed, 66
Rotational stresses, 50 52, 54
Rough wheel analysis, 321 323
Roughness, 15, 30, 32, 95 96, 103,
145 148,153 155,170 172,200,
203 204,206,208,211 213,
218 220,231,309 312
Roughness factor, calibration of,
323 327
Round orifice nozzle, 131 133
Round pipe nozzle, 133
Rounding, rounding process, 263,
272 277
Roundness, 13, 147, 153 155, 165,
170 174,202,212 213,215 216,
222,231
errors, 269 270
Rubber wheels, 42
Rubbing, 15 16
ploughing and cutting, 335 339
Rubbing contact, 343 347
Rubbing wear, 82 83
Ruby alumina, 40
Run out, 163, 165, 202, 268
Safe use, 115
Safety and health, 9
Safety, 49
Sealing the wheel, 125
Seeded gel (SG), 35, 40
Segmented designs, 43, 52
Self excited vibration, 234 236
Self lubricating, 116
Self sharpening, 40, 105
Sensors, 111 112
Servo, 165, 187, 193, 195, 202
Set up, 261 264
SG. See Seeded gel
Shallow cut, 113, 390
Shape conformity, 79
Sharpness effects, 333 335
Shear strain rates, 342
Shear zones, 341 343
Shelf life, 41, 49
Shellac wheels, 42
Shock,233
Shoe grinding, 260 261
Shoe nozzle, 127, 130
Side plates, 139
Silicon carbide, 38 39
Silicones, 120
Single layer wheels, 43, 55
Single point diamonds, 60
Sintered alumina, 40 41
Size control, 123 124
Size effect, 329 331
Size error(s), 20 21, 96
Sliced bread analogy, 330 332
Slide ways, 167 168, 187 195
Sliding heat source, 366, 378
Sliding or rubbing energy, 336 337
Slip line field, 350
Smooth wheel analysis, 320 321
Soft wheels, 41, 56
Softening, 105, 107 108, 110 111
Sol gel process, 41
Solid lubricants, 116
Solid wheels, 54
&alubility wear, 3S7
Soluble, 118
Spark out, 20, 25, 106, 108, 145,
147 148,151,154,156,158 161,
170 171,215,221 222,225
Sparse contacts, 324
Specific energy, 102, 329 339,
387 389
grain shape, sharpness effect,
333 335
dressing effects, 335
indentation model, 334
quantifying sharpness, 333
wear, 335
rubbing, ploughing and cutting,
335 339
size effect, 329 331
measured specific energy, 329
physical reasons, 330 331
relationship to heq, 329 330
surface area effect, 331 333
chip thickness, 333
chip volume, 331
depth of cut, 332
grain density, 332
Specific grinding energy, 33
Specific heat capacity, 117, 140
Specific removal rate, 25
Speed, 2, 106, 108, 111 112
Speed ratio, 99
Speed stroke grinders, 196
Speed stroke grinding, 10 11, 103
Spherical/round chip, 306 307
Spindle bearing, 174
Splash guards, 186
Stand off distance, 147 148
Static stiffness, 245, 249
Stationary tools, dressing, 59 63
coarse dressing, 62 63
dressing process, 60 61
dressing tool sharpness, sharpness
ratio, 61 62
fine dressing, 62 63
form dressing tools, 60
multi point diamond tools, 60
overlap ratio, 61
single point diamonds, 60
Steel, 157
Stick slip, 191
Stiffness, 242 247
machine, 163 171
Stiffness factor, 19 20, 170
Stock removal, 147
Strategic process, 1 2
Structure number, 48
Sub surface temperatures, 381 384
Super abrasives, 10, 37 38, 105
Super abrasive wheels, 145
Surface area effect, 331 333
Surface grinding, 5 6
Surface quality, 3
Surface roughness, 292, 294, 303,
309 312
Surface texture, 3, 15
Shoe nozzle, 127, 130
Side plates, 139
Silicon carbide, 38 39
Silicones, 120
Single layer wheels, 43, 55
Single point diamonds, 60
Sintered alumina, 40 41
Size control, 123 124
Size effect, 329 331
Size error(s), 20 21, 96
Sliced bread analogy, 330 332
Slide ways, 167 168, 187 195
Sliding heat source, 366, 378
Sliding or rubbing energy, 336 337
Slip line field, 350
Smooth wheel analysis, 320 321
Soft wheels, 41, 56
Softening, 105, 107 108, 110 111
Sol gel process, 41
Solid lubricants, 116
Solid wheels, 54
Solubility wear, 357
Soluble, 118
Spark out, 20, 25, 106, 108, 145,
147 148,151,154,156,158 161,
170 171,215,221 222,225
Sparse contacts, 324
Specific energy, 102, 329 339,
387 389
grain shape, sharpness effect,
333 335
dressing effects, 335
indentation model, 334
quantifying sharpness, 333
wear, 335
rubbing, ploughing and cutting,
335 339
size effect, 329 331
measured specific energy, 329
physical reasons, 330 331
relationship to heq, 329 330
surface area effect, 331 333
chip thickness, 333
chip volume, 331
depth of cut, 332
grain density, 332
specific energy, 331 332
work speed, 332 333
threshold force effect, 331
Specific grinding energy, 33
Specific heat capacity, 117, 140
Specific removal rate, 25
Speed, 2, 106, 108, 111 112
Speed ratio, 99
Speed stroke grinders, 196
Speed stroke grinding, 10 11, 103
Spherical/round chip, 306 307
Spindle bearing, 174
Splash guards, 186
Stand off distance, 147 148
Static stiffness, 245, 249
Stationary tools, dressing, 59 63
coarse dressing, 62 63
dressing process, 60 61
dressing tool sharpness, sharpness
ratio, 61 62
fine dressing, 62 63
form dressing tools, 60
multi point diamond tools, 60
overlap ratio, 61
single point diamonds, 60
Steel, 157
Stick slip, 191
Stiffness, 242 247
machine, 163 171
Stiffness factor, 19 20, 170
Stock removal, 147
Strategic process, 1 2
Structure number, 48
Sub surface temperatures, 381 384
Super abrasives, 10, 37 38, 105
Super abrasive wheels, 145
Surface area effect, 331 333
Surface grinding, 5 6
Surface quality, 3
Surface roughness, 292, 294, 303,
309 312
Surface texture, 3, 15
Swarf, 7 9
swarf flushing, swarf separation,
114 115,122
Synthetic oils, 120
System elements, 8
Tailstock, 164
Tangent angle, 262 263
Tangential force, 15, 25 26, 29
Tapered wheel, 55
Temper, damage, 107 108
Temperatures, 9, 13, 102
Temperature measurement, 384 387
Temperature modelling, 112
Temperature rise, 182
Temperature sensing, 230
Temperatures in grinding, 365 396
background heating, 372
chip energy, 367
damage temperatures, 369
energy monitoring, 369
t1ash heating, 371
fluid convection, 366 367
grain contact analysis, 368
grain heating, 371 372
grain thermal properties, 369
grinding energy, 368 369
heat dissipation, 371
heat flows, 365 366
heat input, 370
heat partitioning, 367
heat to the wheel, 367
moving heat source, 365
real contact length, 368
sub surface temperatures, 381 384
temperature analysis, development
of, 365
temperature measurement,
384 387
wheel contact analysis, 368
work partition ratio, 367
workpiece conduction, 366
workpiece surface temperatures,
372 381
workpiece thermal properties,
369 370
work wheel fraction, 367
Tensile, 105, 110 111
Thermal conductivity, 110, 116 117
Thermal damage, 11, 115, 231
avoidance, damage, 105 106
avoiding, 105 112
burn, damage, 106 107
grind hardening, I I I
iron carbon diagram, 106
process monitoring, I I 1 112
Barkhausen, noise sensor,
111 112
monitoring power, 112
process control, 112
re hardening, damage, 108 109
surface cracks, 109
residual stresses, 109 111
temper, damage, 107 108
types of, 105
Thermal deflections, 163 t 64
Thermal expansion, 109 111
Thermal gradient, I I I
Thermal properties, 36 37, 117
Thermal shock, 38
Thermal wear, 362
Thermocouples, 384 385
Three dimensional stresses,
345 347
Threshold, 248 252
Threshold force effect, 331
Through feed, thru feed, 265
Tilt, 171 173, 188, 203 204, 208
Tilt angle, 266
Time constant, 223 224
during dwell, 225 226
during in feed, 224 225
role of, 223 224
Tolerance(s), 3, 11, 212 213
Tool wear, 341, 358, 362
Topography, 297, 308
Total contact length, 92 93
Total life cycle costs, 116
Touch dressing
for CBN wheels, 69 74
acoustic emission, 72 73
contact sensing, 72 73
grinding performance, 69 71
purpose of touch dressing, 69
touch dressing equipment,
71 72
wheel loading, 73 74
equipment, 71 72
Transfer functions, 239 240
Transformation, 105, 109, 111
Transition, 110 111
Transitional flow, 133
Traverse grinding, 21, 250 251
Trends, 95 97
Triangular chip, 301, 305
Tribo chemical conditions, 357 358
Truing, 35, 42, 59
Turbulence, 131
Twisting loads, 42
Two dimensional method, Moi M)2
U frame structure, 167
Ultra precision, 198 208
Ultrasonic assisted grinding,
206 207
Ultrasonic grinding, 10
Unbalance, 234, 241
Uncut Chip, 300 301
Up grinding, 91
Useful flow, useful flow rate,
achievable useful flow rate,
135 137
Value added, 4
Vapours, water vapour, 117
Vibrations, 8 9, 11 12, 211
wheel, 56 58
Vibration absorbing mounts, 185
Vibration mode, 242, 245
Vibration, problem solving, 233 254
chatter condition, 247 254.
See also Chatter condition
contact length filtering, grinding
wheel, 240 241
damping, 245 247
forced vibration, 234
grinding, dynamic relationship for,
236 240
basic equations, 237 239
basic solutions, 239
block diagram, 236 237
free vibration, 239
transfer functions, 239 240
impulsive vibration, 233 234
machine stiffness characteristics,
242 245
excitation test, 242 244
light running tests, 244 245
resonance parameters, 245 247
self excited vibration, 234 236
stiffness, 245 247
Viper grinding, 102
Vitrified, 101
Vitrified bonds, 42 43
Vitrified CBN, 63, 69
Volume, I I I
Waste disposal, 9
Water evaporation, 116
Water based fluids, 116
Wave models, 353
Wave rubbing, 352 354
Wave wear, 354
Wavelength, 234, 240 241
Waviness break frequency, 57
Waviness, 270 272
Wear, 164, 335, 357 362
abrasive wear, 361
adhesive wear, 358 359
Archard's law, 360
chemical wear, 362
corTosion, 361
determination of K, 360
fatigue, 360 361
grinding fluid, 362
oxidative wear, 361
real contact length, 359
thermal wear, 362
tribo chemical conditions,
357 358
wear life cycle, 359
wear particles, 108
wheel wear, 211 212
yield mode, 360
Wear flats, 85 86
Wear length, 316
Wear life cycle, 359
Wear measurement, 84
Wear resistance, 36 37
Webster nozzle, 128 129
Wet grinding, 29, 386 387
Wheel behaviour, I I
Wheel bonds, 41 43
metal bonds, 43
organic bonds, 41 42
vitrified bonds, 42 43
Wheel cleaning, 114, 121, 124, 1
Wheel contact analysis, 368
Wheel contact effects, 79 93
abrasive surface, 79 82.
See also Abrasive surface
contact length, 89 93
contact length ratio, 93
deflected contact length, 91
geometric contact length,
89 90
kinematic contact length, 91
total contact length, 92 93
grain wear, 82 87.
See also Grain wear
wheel workpiece conformity,
87 89
equivalent diameter, 87 89
Wheel cost, 146 147
Wheel deflection, 18
Wheel design, 49 51
Wheel dulling, 113 114
Wheel flanges, 49 50
Wheel flexibility, 82
Wheel interference, 241
Wheel life, 40 41, 43, 52, 296
Wheel loading, 73 74, 83 84
Wheel mounting, 49 50
Wheel porosity, 135, 137 138
Wheel roughness, 211
Wheel shape, 211
Wheel sharpness, 16, 18, 24, 28, 36,
40,66,223,225,230
Wheel size, 211, 213
Wheel specification, 44 49
concentration, 49
conventional abrasive wheels
standard marking system for, 45
grade, 47 48
grain size, 45 47
porosity, 48
selection, I 10
structure number, 48
super abrasive wheels
marking system for, 45
27 Wheel speed, 32, 95 98, 100 101,
103,212,214,224,253 254,
359 361
Wheel structure, 13
Wheel wear, 9, 13, 15 16, 18 19, 30,
32,62 63,67,72,74,96,102,
233,236,238,240,316,392
reduction, 113 114
Wheel head, 174
Wheel regenerative, 234 236, 238,
240 241,253
Wheel workpiece conformity,
87 89
White layer, 108
Width of grinding contact, 22 23
Work feed, 264 266
Work height, 262
Work material, 392
Work partition ratio, 367
Work speed, 32, 106, 108, 111,
234 235,240 241,244,249 250,
252 254,270,332 333,359,361,
373,375,379 382,387 390,394
Work head, 164, 175, 188, 205 206
I+IU
Workpiece bending, 21
Workpiece conduction, 366
Workpiece material(s), 8, 37, 39, 42
Workpiece roughness, 66 67
Workpiece surface temperatures,
372 381
Workpiece temperature rise, 372 373
Workpiece thermal properties,
369 370
Work plate angle, 261 262
Work regenerative vibration,
235 236
Work table, 166, 196
Work wheel fraction, 367, 375 376,
395 396
Yield mode, 360
Yield stress, I 10
Zirconia alumina, 38, 40
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