Coolant Delivery System for Creep-Feed Grinding - Mechanical ...

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Dalhousie University MECH 4010 – Design Project I – Fall Term Report Diamond. Diamond grinding wheels are produced naturally or synthetically. Diamond grinding wheels are used on hard, abrasive materials such as ceramics, cemented carbides, and glass. Table 1.1 – Hardness values of abrasive materials used in grinding wheels Abrasive Material Knoop Hardness Aluminum Oxide 2100 Silicon Carbide 2500 Cubic Boron Nitride 5000 Diamond (artificial) 7000 [Groover, 2004] 1.1.3 Grinding Fluids Proper application of cutting fluids reduces thermal effects in the work piece and high work surface temperatures. Cutting fluids are called grinding fluids when used in the grinding process. The main purposes of grinding fluids in grinding are reducing friction and removing heat from the process. Additionally, the grinding fluid is used to wash away pieces of metal chips and wheel particles. Types of grinding fluids include grinding oils and emulsified oils. Grinding oils are derived from petroleum and other sources. These products seem to be very attractive due to the large friction in the grinding process. However, grinding oils pose hazards in terms of fires and operator health, and their cost is quite high compared to emulsified oils. Additionally, grinding oils have a low capacity to carry away heat when compared with water based fluids. Therefore, mixtures of oils in water are most commonly used as grinding fluids. These types of oil-water mixtures are usually mixed with higher concentrations than emulsified oils used as conventional cutting fluids. This way, the friction reduction mechanism is emphasized. [Groover, 2004] 1.1.4 Analysis of the Grinding Process The cutting in the grinding process is characterized by very high speeds, and very small cut size. The peripheral speed of the grinding wheel is determined by the rotational speed of the grinding wheel. 3
Dalhousie University MECH 4010 – Design Project I – Fall Term Report v = πDN where v = the surface speed of the wheel (m/s, ft/min, etc.); N = spindle speed (rev/min); D = wheel diameter (m, ft, etc.). The depth of the cut, d, is called the infeed. The infeed is the distance the wheel is below the original work surface. As the grinding process proceeds, the grinding wheel is fed laterally across the surface of the work piece. The movement of the wheel refers to the crossfeed, and it determines the width of the grinding path, w. The width of the cut multiplied by the depth of the cut determines the cross-sectional area of the cut. Most grinding processes, the work piece moves past the wheel at a certain speed vm. The material removal rate (MRR) of the grinding process can be determined by [Groover, 2004] 1.1.5 Temperatures at the Work Surface MRR = vm wd Figure 1.2 – The geometry of surface grinding Due to the high rake angles and the plowing and rubbing of the abrasive particles against the work surface, high temperatures and friction are common in the grinding process. The heat generated in the grinding process is transferred to the work piece, unlike in conventional machining operations where most of the heat generated is removed by the chips. The transfer of heat to the work piece results in higher work surface temperatures. High surface temperatures 4
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