Handbook of Machining with Grinding Wheels

Grinding is a crucial technology that employs specific abrasive processes for the fabrication of advanced products and surfaces. Handbook of Machining with Grinding Wheels, Second Edition highlights important industry developments that can lead to improved part quality, higher productivity, and lower costs. Divided into two parts, the book begins with an explanation of grinding behavior and ends with a focus on new and emerging industrial applications. While the first edition focused on the basics of abrasive machining technology and presented a unified approach to machining with grinding wheels, the second edition ties in the continued need for traditional processes in conjunction with the latest applications. This book highlights new research topics that include: nanotechnology, alternative energy, and additive manufacturing, compares related approaches, and provides numerous references throughout the book. New in the Second Edition: Contains the latest information on abrasives, bonds, and dressing Updates classic stability lobes for grinding Introduces a new method for tracking dynamic instability in centerless grinding Provides a section in the chapter on ultrasonic-assisted grinding, which contains recent work on modelling of the process Adds material on fluid cooling Presents experimental results for in-process feedback to the grinding process Includes new examples on grinding machine technology (particularly for dressing) A single source reference covering every aspect of the grinding process, Handbook of Machining with Grinding Wheels functions as a definitive guide to grinding technology for both practicing engineers and students studying graduate-level courses (such as abrasive machining; grinding R&D; metal removal processes; machining of brittle materials; and principles of cutting).

THE BASIC PROCESS OF GRINDINGIntroductionFrom Craft to ScienceBasic Uses of GrindingElements of the Grinding SystemThe Importance of the AbrasiveGrinding Wheels for a PurposeProblem SolvingReferencesGrinding ParametersIntroductionProcess ParametersGrinding TemperaturesAppendix: Drawing Form and Profile TolerancingReferencesMaterial Removal MechanismsSignificanceGrinding Wheel TopographyDetermination of Grinding Wheel TopographyKinematics of the Cutting-Edge EngagementFundamental Removal MechanismsMaterial Removal in Grinding of Ductile MaterialsSurface Formation in Grinding of Brittle–Hard MaterialsEnergy TransformationReferencesGrinding WheelsIntroductionWheel Shape SpecificationWheel BalanceDesign of High-Speed WheelsBond LifeWheel Mount DesignWheel Design and Chatter SuppressionReferencesThe Nature of the AbrasiveIntroductionSilicon CarbideAlumina (Alox)-Based AbrasivesElectrofused Alumina AbrasivesChemical Precipitation and/or Sintering of AluminaDiamond AbrasivesCubic Boron NitrideFuture Grain DevelopmentsReferencesSpecification of the BondIntroductionSingle-Layer WheelsElectroplated and Electroless-Plated Single-Layer WheelsBrazed Single-Layer WheelsVitrified Bond Wheels for Conventional WheelsVitrified Bonds for Diamond WheelsVitrified Bonds for CBNResin Bond WheelsPlastic BondsPhenolic Resin BondsPolyimide Resin BondsMetal BondsOther Bond SystemsReferencesDressingIntroductionTraverse Dressing of Conventional Vitrified Wheels with Stationary ToolsTraverse Dressing of Superabrasive Wheels with Stationary ToolsUniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond ToolsUniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary Diamond ToolsCross-Axis Traverse Dressing with Diamond DisksDiamond Form Roll DressingTruing and Conditioning of Superabrasive WheelsReferencesGrinding DynamicsIntroductionForced and Regenerative VibrationsThe Effect of Workpiece SpeedGeometrical Interference between Grinding Wheel and WorkpieceVibration Behavior of Various Grinding OperationsRegenerative Self-Excited VibrationsSuppression of Grinding VibrationsConclusionsReferencesGrinding Wheel WearTypes of Wheel WearWheel Wear MechanismsWear of the Abrasive GrainsBond WearAssessment of Wheel WearReferencesCoolants, the Coolant System, and CoolingIntroductionBasic Properties of Grinding FluidsTypes of Grinding FluidsBasic PropertiesAdditivesApplication ResultsEnvironmental AspectsSupply SystemGrinding Fluid NozzlesInfluence of the Grinding Fluid in GrindingReduction of Temperature by Convective CoolingReferencesMonitoring of Grinding ProcessesNeed for Process MonitoringSensors for Monitoring Process VariablesSensors for Monitoring the Grinding WheelSensors for Monitoring the WorkpieceSensors for Peripheral SystemsReferencesEconomics of GrindingIntroductionA Comparison Based on an Available Grinding MachineA Cost Comparison Including Capital InvestmentCost Comparison Including ToolingGrinding as a Replacement for Other ProcessesMultitasking Machines for Hard Turning with GrindingSummaryReferencesAPPLICATION OF GRINDING PROCESSESGrinding of Ductile MaterialsIntroductionCast IronsSteelsHeat-Resistant SuperalloysReferencesGrinding of CeramicsIntroductionBackground on Ceramic MaterialsDiamond Wheels for Grinding CeramicsPhysics of Grinding CeramicsELID Grinding of CeramicsReferencesGrinding Machine TechnologyThe Machine BaseFoundationsGuidewaysSlideway ConfigurationsHydrostatic SlidewaysRecirculating Rolling Element SlidewaysLinear Axis Drives and Motion ControlElements of AC Servo-Drive Ball Screw SystemsLinear Motor Drive SystemsSpindle Motors and Grinding Wheel DrivesDrive Arrangements for Large Conventional WheelsDrive Arrangements for Small Wheel SpindlesHigh-Speed Spindles for Small WheelsSpindles for High-Speed GrindingMiscellaneous Wheel Spindles and DrivesRotary Dressing SystemsPower and Stiffness Requirements for Rotary DressersRotary Dressing Spindle ExamplesDressing Infeed SystemsReferencesAdditional ReferencesSurface GrindingTypes of Surface Grinding ProcessBasics of Reciprocating GrindingBasics of Creep GrindingBasics of Speed-Stroke GrindingSuccessful Application of CF GrindingFace GrindingFine GrindingReferencesExternal Cylindrical GrindingThe Basic ProcessHigh-Speed GrindingAutomotive Camlobe GrindingPunch GrindingCrankshaft GrindingRoll GrindingReferencesInternal GrindingIntroductionThe Internal Grinding ProcessAbrasive TypeProcess ParametersMachine Tool SelectionTrouble ShootingReferencesCenterless GrindingThe Importance of Centerless GrindingBasic ProcessesBasic RelationshipsFeed ProcessesCenterless Wheels and Dressing GeometryThe WorkrestSpeed ControlMachine StructureHigh Removal Rate GrindingEconomic Evaluation of Conventional and CBN WheelsThe Mechanics of RoundingVibration Stability TheoryDynamic Stability LimitsAvoiding Critical FrequenciesSummary and Recommendations for RoundingProcess ControlReferencesUltrasonic-Assisted GrindingIntroductionUltrasonic Technology and Process VariantsUltrasonic-Assisted Grinding with Workpiece ExcitationPeripheral Grinding with Radial Ultrasonic AssistancePeripheral Grinding with Axial Ultrasonic AssistanceUltrasonic-Assisted Grinding with Excitation of the WheelSummaryReferencesGlossaryAppendix: Notation and Use of SI Units

Brian Rowe is considered the father of centerless grinding in addition to other notable research on grinding that includes thermal aspects, dynamic aspects, and fluid-film bearings. He established a laboratory and school dedicated to manufacturing processes at Liverpool John Moores University and is an Emeritus Professor. Ichiro Inasaki is the dean of the Graduate School of Science and Technology at Keio University, Japan. He has developed a laboratory with outstanding research activities and his "intelligent grinding wheel" is featured in the Noritake Museum and represents one of his best accomplishments and contributions. He led CIRP in 2004/2005 as the president and was granted several awards. Eckart Uhlmann is professor and director of the Institute for Machine-Tools and Management at Technical University of Berlin, Germany. Dr. Uhlmann received this chaired professorship after a very successful industrial career with Hermes Abrasive in Germany. As the head of his institute he holds the leading position in research on all aspects of abrasive machining with grinding wheels. Dr. Mike Hitchiner is manager of precision technology at Saint Gobain Abrasives (Norton), the largest grinding wheel company in the world. Mike has devoted all his life to research, development and practical application of grinding processes. He started this activity during his D Phil at the University of Oxford in England, and was later considered "Mr. CBN Grinding" by the precision grinding industry. Today he focuses on working with machine tool builders and developing new grinding processes. He has brought an important industrial perspective to this book, as well as hundreds of applications.

Grinding is a crucial technology that employs specific abrasive processes for the fabrication of advanced products and surfaces. "Handbook of Machining with Grinding Wheels", Second Edition highlights important industry developments that can lead to improved part quality, higher productivity, and lower costs. Divided into two parts, the book begins with an explanation of grinding behavior and ends with a focus on new and emerging industrial applications. While the first edition focused on the basics of abrasive machining technology and presented a unified approach to machining with grinding wheels, the second edition ties in the continued need for traditional processes in conjunction with the latest applications. This book highlights new research topics that include: nanotechnology, alternative energy, and additive manufacturing, compares related approaches, and provides numerous references throughout the book.