High Performance Grinding and Advanced Cutting Tools
High Performance Grinding and Advanced Cutting Tools discusses the fundamentals and advances in high performance grinding processes, and provides a complete overview of newly-developing areas in the field. Topics covered are grinding tool formulation and
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A review of the literature has provided a mathematical foundation that quantifies grinding wheel performance in terms of grinding parameters and wheel wear up to the burn boundary of a particular workpiece tested. The transformation of these fundamental factors presented in the form of performance diagrams shows optimum bond compositions and wheel grades for a particular workpiece–wheel combination under predetermined operating conditions. A review of the literature has provided an insight into the causes and effects of wheel wear in terms of applied grinding loads, abrasive grain type, and abrasive strength. Relationships have also been formulated and tested that relate the wheel wear parameter, G-ratio, and the maximum tensile stress acting within the abrasive material. However, the effect of bond composition on wheel wear and performance has not been examined. A review of the strength of clay-based materials thus provides a basis for studying the effect of bond composition on bond strength and wheel performance. Studies of the influence of workpiece material composition on grinding wheel wear also ensure that any study on grinding wheel performance should include factors that affect workpiece hardness and vitreous-bond strength. The fired microstructure of all clay-based materials will depend on the structure of the raw materials used, the processing sequence, and the heat treatment schedule. The fired microstructure can contain: 1. 2. 3. 4. 5. 6.
Feldspar Quartz and possibly cristobalite A glass phase of variable composition Cracks around quartz and cristobalite particles Mullite-primary and secondary Pores-open and/or closed, depending on the heat treatment, and fissure-like pores resulting from differential shrinkage
The complexity of the grinding wheel bonding system can be appreciated given the shape, size, amount, distribution, and orientation of constituent particles and how M.J. Jackson and M.P. Hitchiner, High Performance Grinding and Advanced Cutting Tools, SpringerBriefs in Applied Sciences and Technology, DOI 10.1007/978-1-4614-3116-9, © Springer Science+Business Media New York 2013
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these variables affect the bond’s tribological properties such as wheel wear and grinding friction. The behavior of abrasive cutting tools is dependent on the type of abrasive grain used, its heat treatment schedule, and its bond content. The vitrification behavior is dependent on certain processing variables and the bonding systems used for precision grinding wheels. It is evident that rutile needles have a significant effect on the mechanical properties and the behavior of conventional abrasive cutting tools. If titanium-doped aluminum oxide is used as the cutting medium then heat treatment cycles should be designed that prevent the growth of the needles into the bonding system. The development of strength during heat treatment depends upon the nature of the compounds formed at the interfacial layer between abrasive grain and bonding material. Further studies are required to understand the natur
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