This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
A Model for Grinding Burn
Annotation ability available
Sector:
Language:
English
Abstract
Extensive experimental data was collected for CBN surface grinding of M2 tool steel to determine the relative grinding performance of three different vitrified CBN abrasive grit sizes. The results define the relationships between the grinding forces, the material removal rate and the resulting specific energy, while providing an evaluation of the ground surface characteristics including surface finish, microstructure, hardness and residual stress. The interaction of grinding process inputs including wheel grit size, workpiece velocity and depth of cut are considered, and a series of single factor tests and a 23 factorial test are conducted. The grinding forces increase linearly with increasing material removal rate for the range of parameters tested. As expected, decreasing abrasive grit size increases the grinding forces and required power while the surface finish is improved; however, unlike conventional abrasive grinding, the tangential grinding force and resulting power and specific energy differ only slightly. The results of the factorial test indicate that abrasive selection, workpiece velocity and actual depth of cut, along with second order interactions between abrasive selection/workpiece velocity and depth of cut/workpiece velocity significantly influence the normal force response, while the tangential force response is influenced by the main effects of workpiece velocity and depth of cut and slightly by the abrasive selection. CBN grinding leads to compressive residual stresses at the workpiece surface, while grinding at similar conditions with conventional abrasives leads to tensile residual stresses. For high material removal rate grinding where visible oxide layers appear on the workpiece surface, the evaluation of near ground surface metallurgy indicates formation of untempered martensite at the surface and a transition region of overtempered martensite between the workpiece surface and the bulk material. It is shown that this burn occurs at the same effective grinding temperature for each abrasive. The talk concludes with comments about applying this burn limit model to interpret observations of workpiece burn in OD grinding.
Recommended Content
Authors
Citation
Mann, J., Farris, T., and Chandrasekar, S., "A Model for Grinding Burn," SAE Technical Paper 972247, 1997, https://doi.org/10.4271/972247.Also In
References
- REX M2 Technical Data Sheet Colt Industries, Crucible Specialty Metals Division
- Mehl R. Metals Handbook, 7 8 ASM International 120 121
- Metzger J. Superabrasive Grinding Butterworth and Co. Ltd 1986
- Peterson R. Design and Analysis of Experiments Marcel Dekker Inc.
- Farmer D. Brecker J. Shaw M.C. Grinding Fundamentals Carnigie Institute of Technology 1994
- Hucker S.A. Farris T.N. Chandrasekar S. “Estimation of Contact Stiffness for Grinding of Hardened Steel,” ASME PED Vol 67/TRIB Vol4, Contact Problems and Surface Interaction in Manufacturing and Tribological Systems, 191 198 1993
- Hahn R.S. Lindsay R. “The Influence of Process Variables on Material Removal, Surface Integrity, Surface Finish and Vibration in Grinding,” Proc 10 th Annual MTDR Conf., ASME Pergamon 1969 95 117
- Malkin S. Joseph N. “Minimum Energy in Abrasive Processes,” Wear 32 15 23 1975
- Shaw M.C. Principles of Abrasive Processing, Oxford 1996
- Brach K. Pai D.M. Ratterman E. Shaw M.C. “Grinding Forces and Energy,” ASME Journal of Engineering for Industry 110 1988 25 31
- Backer W.R. Marshall E.R. Shaw M.C. “The Size Effect in Metal Cutting,” Trans ASME 74 1952 61 72
- Optiz H. Guhring K. “High Speed Grindings,” Annals CIRP 16 61 73 1968
- Kumar K. Matarrese R. Ratterman E. “Control of Residual Stress in Production Grinding with CBN,” SAE 890979 1989
- Tarasov L. “A Metallurgical Approach to Grinding Hardened Steel,” The Tool Engineer, 14 329 336 1950
- Malkin S. Cook N. “The Wear of Grinding Wheels Part 1-Attritious Wear,” ASME Journal of Engineering for Industriy 93 1120 1128 1971
- Littman W. Wulff J. “The Influence of the Grinding Process on the Structure of Hardened Steel,” ASM Transactions 47 692 714 1955
- Malkin S. “Burning Limit for Surface and Cylindrical Grinding of Steels,” Annals CIRP 27 1 233 236 1978
- El-Helieby S. Rowe G. “A Quantitative Comparison between Residual Stresses and Fatigue Properties of Surface-Ground Bearing Steel,” Wear 58 155 172 1981
- Ramanath S. Shaw M.C. “Abrasive Grain Temperature at the Beginning of a Cut in Fine Grinding,” ASME Journal of Engineering for Industry, 110 15 18 1988
- Mann J.B. “CBN Grinding of M2 Tool Steel and the Strength of Ground Surfaces,” Purdue University May 1994
- Johnson G. “Beneficial Compressive Residual Stresses Resulting from CBN Grinding,” Tech Report MR86-625 SME 1986
- Jen T.C. Lavine A.S. “A Variable Heat Flux Model of Heat Transfer in Grinding: Model Development,” ASME Journal of Heat Transfer 117 473 478 1995
- Kohli S. Guo C. Malkin S. “Energy Partition to the Workpiece for Grinding with Aluminum Oxide and CBN Abrasive Wheels,” ASME Journal of Engineering for Industry, 117 160 168 1995
- Neailey K. “Surface Integrity of Machined Components-Microstructural Aspects,” Metals and Materials 4 2 1988 93 96
- Tomlinson W. Blund L. Spraggett S. “The Effect of Workpiece Speed and Grinding-Wheel Condition on the Thickness of White Layers Formed on EN 24 Ground Surfaces,” Journal of Engineering for Industry, 109 3 203 205 1991
- Ju Y. Farris T.N. Chandrasekar S. “Heat Partition and Temperatures in Grinding,” 4 Manufacturing Sceince and Engineering ASME 259-268 1996
- Chandrasekar S. Farris T.N. Bulsara V.H. Hucker S.A. Hebbar R.R. Mann J.B. “Thermal Aspects of Surface Finishing Processes,” Advances in Mechanical Engineering Narosa Publishing House New Dehli 677 701 1996
- Hucker S.A. “Grinding of Hardened Steel for Tribological Performance,” Purdue University 1994