Performance of Diamond and CBN Single-Layered Grinding Wheels in Grinding Titanium

For their unique properties, titanium alloys have found wide application in high-tech engineering. But these alloys are difficult to machine and to grind for their high chemical reactivity and poor thermal properties, which aggravate the grinding zone temperature and its detrimental effects. The objective of this article is a comparison of the grindability of Ti-6Al-4V regarding cubic boron nitride (CBN) and diamond brazed type monolayered grinding wheels under the influence of different environments. In grinding this alloy, cryogenic cooling did not help visibly for both CBN and diamond, but the application of oil and also of alkaline coolant significantly gave the best results.     

激光修整金刚石砂轮研究进展

金刚石砂轮在磨削领域起着举足轻重的作用.对于失效金刚石砂轮的止损,合理地选择金刚石砂轮修整方法成为一大难题.激光修整技术集光、电、热、机械等多种方法于一体,能有效实现金刚石砂轮的修整,受到国内外学者的广泛关注.综合阐述了激光修整金刚石砂轮的基本原理,分析了激光修整技术研究现状,并展望了未来激光修整金刚石砂轮的发展前景.     

Grinding Characteristics of Hard and Brittle Materials by ELID-Lap Grinding Using Fine Grain Wheels

In this investigation, ceramics such as zirconia and silicon carbide were ground by lap grinding using the ELID (electrolytic in-process dressing) method and using various-sized metal bonded wheels (mesh sizes of #1200-#8000). Differences in the ground finish, according to the wheel grain size, and surface roughness were investigated through the use of a Scanning Electron Microscope (SEM). It was found that the ground surface roughness improved proportionally to the grain size. The SEM observations also showed that the ground surfaces using wheels over #4000 were very smooth with several minute ground grooves crossing each other without brittle fracture. Brittle-ductile transition was studied using these wheels and the removal mechanisms of silicon and tungsten carbides were also investigated. It was found that for silicon, brittle-ductile transition was obtained using wheels over #8000 and for tungsten carbides, transition was achieved using wheels over #4000. Therefore, the work materials affect the changes in the removal mechanism.     

直流电化学两步处理精磨硬质合金表面对CVD金刚石涂层的影响

经开刃、精磨处理而具实际加工能力的钨钴硬质合金刀具在制备CVD金刚石涂层前需进行基体前处理,但常规的化学预处理技术对其规模化应用时,会受到腐蚀效率,工艺重复性的限制.以精磨YG6硬质合金铣刀片为研究对象,采用直流弧光放电等离子体CVD设备、SEM、激光Raman光谱仪、原子吸收光谱仪、表面轮廓仪、洛氏硬度计等,研究了直...     

高效砂轮的在线检测

硬质氮化硼磨料在很多加工场合可经济地代替常用的金刚砂，碳化硅等磨料，在加工过程中可显著提高生产率。但如何高效获得周转和平面理想的磨削结果，本文叙述的测量砂轮径跳的方法可达到其目的。     

New Vitrified Bond Diamond Grinding Wheel for Grinding the Cylinder of Polycrystalline Diamond Compacts

In this work, a kind of new vitrified bond based on Li2O-Al2O3-SiO2 glass ceramics was used to bond the diamond grains, which is made into grinding wheel and the cylindrical grinding process of polycrystalline diamond compacts （PDCs） by using the new vitrified bond diamond grinding wheel was discussed. Several factors which influence the properties of grinding wheel such as amount of vitrified bond and the kinds and amount of stuff in grinding wheel were also investigated. It was found that the new vitrified bond can firmly combine diamond grains, when there are only diamonds and vitrified bond in the structure of grinding wheel, the longevity of the grinding wheel is about 2.5-3 times as that of resin bond grinding wheel for processing PDCs. The grinding size precision of PDCs can be improved from 4-0.03 mm to 4-0.01 mm because of larger Young＇s modulus of vitrified bond than resin bond. The grinding time of a PDC product can be 1.75-2.0 min from 3.25-3.5 min, so this kind of grinding wheel can save much time for processing PDCs. Also, there is hardly noise when using this new vitrified bond diamond grinding wheel to process PDCs. The amount of vitrified bond in grinding wheel influences the longevity of grinding wheel. When the size of diamond grains is 90-107 μm, the optimal amount of vitrified bond in grinding wheel is 21% （wt pct）. When the amount of vitrified bond exceeds 21%, there are many pores in grinding block, which will decrease the longevity of grinding wheel. The existence of addition stuff such as Al2O3 or SiC can reduce the longevity of grinding wheel.     

Performance Improvement of Grinding of SiC Using Graphite as a Solid Lubricant

Grinding is a widely employed finishing process for different materials. It is inherently characterized by its high specific energy requirement unlike other machining processes. This leads to a high grinding zone temperature, which impairs the workpiece quality by inducing thermal damage in the form of surface and subsurface cracks, phase transformations, tensile residual stresses, etc. The microcracks and residual stresses induced in the surface of the ceramics during grinding can severely limit the application of ceramic components. This article deals with an investigation on using graphite as a solid lubricant to reduce friction and thereby improve the surface integrity of ground silicon carbide (SiC). An experimental setup has been developed, and experiments have been conducted to study the effect of using a graphite lubricant on the surface roughness, grinding forces, and specific energy while grinding SiC material. Results indicate that there is a considerable improvement in the performance of grinding SiC using graphite as a solid lubricant when compared with dry grinding in terms of specific energy requirements, surface roughness, and damage. The employment of graphite as a solid lubricant in ceramic grinding makes the process more economical and reliable.     

Growth of SiC as Binder to Adhere Diamond Particle and Tribological Properties of Diamond Particles Coated SiC

The purpose of this work was to grow SiC as binder to adhere diamond particles to graphite substrate by low pressure chemical vapor deposition(LPCVD) at 1100 °C and 100 Pa using methyltrichlorosilane(MTS: CH3 SiCl3) as precursor. The composite coatings on graphite substrates were analyzed by various techniques. Results show that a dense SiC coating with a cloud-cluster shape was formed both on the diamond particles and the substrate after deposition. The thermal stress(290.6 MPa) strengthened the interfacial bonding between the diamond particle and the SiC coating, which is advantageous for the purpose of adhering diamond particles to graphite substrate. The applied load of sliding wear test was found to affect not only the friction coefficient, but also the wear surface morphology. With increasing loads, the asperity penetration was high and the friction coefficient decreased.     

圆柱齿轮磨齿机的选型

对圆柱齿轮磨齿机中的蜗杆砂轮磨齿机和成型磨磨齿机的磨削原理及应用场合作了介绍,从用户的角度对机床选型、对机床供应商的要求作了分析,指出国内磨齿机机床厂家,应联合夹具专业厂商、磨料生产厂商组成强大的综合服务队伍,对于争夺日趋激烈的磨齿机市场具有现实意义.     

Experimental Studies on the Grind-Hardening Effect in Cylindrical Grinding

In recent years high-strength and high-temperature alloys are used for structural and other applications. These newer high-performance materials are inherently “more difficult to machine” and also necessitate the need for higher dimensional and geometrical accuracy. Grinding is one of the most familiar and common abrasive machining processes used for the finishing operation. Compared to other machining processes such as turning, milling, etc., the specific energy developed during grinding is very high. At a critical level of specific grinding energy, the temperature rise[1]experienced by the workpiece may be such that thermal damage is induced. Heat damage induced by the grinding process is well documented and may be categorized by temper colors that are at least unsightly and probably indicative of more serious damage, including thermal cracks, tempered zone, etc.,[2]which can lead to catastrophic failure of critical machine parts that shortens the life of products subject to cyclic loading. In this work, a new heat treatment process called “grind hardening” and a mathematical model are introduced, and this work deals with how the in-process energy in grinding can be effectively utilized to improve the surface hardness and surface texture, and also to prevent damages. An experimental study has also been carried out in grinding AISI 6150 and AISI 52100 steels with an alumina wheel, and the results are discussed.     

Diamond Turning and Grinding of Aluminum-Based Metal Matrix Composites

This paper reports research results obtained from diamond turning and grinding of aluminum-based MMCs reinforced with either SiC or Al₂O₃ particles. Both polycrystal diamond (PCD) and single crystal diamond (SCD) tools were used for turning the MMCs at depths of cut ranging from 0 to 1.6 um. Diamond grinding wheels were used to grind the MMCs at depths of cut from 0.1 to 1 µm. Besides die depth of cut, ductile-mode turning of the reinforcing particles might also be affected by the orientation of the particles. Grinding using a 3,000-grit diamond wheel at depths of cut of 1 and 0.5 µm produced ductile streaks on the Al₂O₃ particles and the SiC particles, respectively. There was almost no subsurface damage except rare cracked particles. At the same depth of cut, the surfaces ground with the diamond grinding wheel revealed more ductile streaks on the reinforcement ceramic particles than those obtained from SCD turning.     

面向大规模定制的外圆磨床定制设计

随着市场全球化的发展和竞争程度的不断加剧，原有的大批量生产模式逐渐被大规模定制模式所代替，面向大规模定制的产品族设计成为研究的重点，本文对基于Internet面向大规模定制模式下的外圆磨床设计方法进行了探讨，其实现过程主要包括两步：产品族模型的建立和产品实例的生成，并对该网络系统的实现进行了理论研究。     

Computation of the External Magnetic Field, Near-Field or Far-Field, From a Circular Cylindrical Magnetic Source Using Toroidal Functions

A method is developed for computing the magnetic field from a circular or noncircular cylindrical magnetic source. A Fourier series expansion is introduced which yields an alternative to the more familiar spherical harmonic solution, Elliptic integral solution, or Bessel function solution. This alternate formulation coupled with a method called charge simulation allows one to compute the external magnetic field from an arbitrary magnetic source in terms of a toroidal expansion which is valid on any finite hypothetical external observation cylinder. In other words, the magnetic scalar potential or the magnetic field intensity is computed on a exterior cylinder which encloses the magnetic source. Also, one can compute an equivalent multipole distribution of the real magnetic source valid for points close to the circular cylindrical boundary where the more familiar spherical multipole distribution is not valid. This method can also be used to accurately compute the far field where a finite-element formulation is known to be inaccurate     

Effect of SiC Additions on the Spontaneous Crystallization and Properties of Diamond

The effect of silicon carbide additions on the spontaneous crystallization and properties of diamond is studied. The results demonstrate that increasing the SiC content of the growth charge increases the crystal yield (reduces the concentration of paramagnetic centers) and the fraction of small crystals and influences the melt composition.     

SiC材料的低速率浅刻蚀工艺研究

对比研究了SiC材料在CF4+O2混合气体中的ICP刻蚀和RIE刻蚀,获得了刻蚀速率、刻蚀表面粗糙度随刻蚀功率、偏置功率、工作真空、氧含量等工艺条件的变化规律,研究结果表明,通过牺牲一定的刻蚀速率可以获得原子量级的刻蚀表面粗糙度,能够满足SiC微波功率器件研制的要求.     

基于粒子群优化算法的金刚石砂轮磨粒边缘提取

为了实现对金刚石砂轮磨粒边缘的有效提取,将基于粒子群优化算法的Canny算子应用在金刚石砂轮磨粒的边缘检测上。用最大类间方差作为目标函数,优化Canny算子的阈值,实现边缘的有效提取。分别对实测的单颗磨粒和多颗磨粒进行了边缘提取,实验结果显示该算法可以较好地提取金刚石砂轮磨粒边缘。该方法不需要人为设定阈值,可以实现阈值的自动获取和优化。最后,利用四连通成分和八连通成分与像素总数的比值,将阈值可优化设定的Canny算子与传统的Canny算子以及最大类间方差的方法做对比,结果表明所应用的方法有效地提高了检测的准确性。     

精细陶瓷材料的金刚石砂轮磨削性能

本文探讨了精细陶瓷材料的金刚石砂轮磨削性能的共同特点以及不同种类陶瓷和不同磨削方式的影响。研究结果表明：陶瓷材料磨削时，砂轮磨损大，磨削比小，磨削力大、磨削效率低，磨后陶瓷零件使用寿命大大降低；必须根据陶瓷种类的不同选择不同的磨削方式。     

Parametric Study of Temperature Distribution in Electrodischarge Diamond Grinding

Electrodischarge diamond grinding (EDDG) is a potential process for machining of advance engineering components, but there is no theory to support it. The work reported in this article makes an attempt in this direction. This article reports on determination of temperature distribution in the workpiece due to EDDG using the finite element method. The temperature distribution in the workpiece domain due to EDDG is obtained by superposition of the two temperature distributions for grinding and electrical discharge mechining (EDM) (i.e., 2D for grinding and axisymmetric for EDM). The effects of duty cycle, on-time, current, energy partition, time of machining, and feed velocity while machining are computationally investigated.     

Low-Pressure Fabrication of Diamond–SiC–Si Composites

A technique is proposed for fabricating diamond–SiC–Si composites via chemical reactions between silicon and carbon directly in the green compact at pressures no higher than 10⁵Pa. An important advantage of the process is the ability to fabricate complex-shaped bodies from diamond-containing composites exhibiting unique mechanical properties.     

金刚石刀具研磨声发射信号的非高斯性特征分析

为确保金刚石刀具的制备效率和质量,采用声发射信号作为监测手段对金刚石刀具的精密研磨辅助进行过程调控.然而,该声发射信号的有效特征不能通过传统的信号处理方法辨识,实际研磨中仅能通过人工监听和操作经验定性判断.因此,本文从砂轮磨粒与刀具研磨面的微观接触特点出发,采用泊松过程模型对金刚石刀具研磨中声发射信号的激励机制进行了分析,阐明该信号具有非高斯性特征,采用线性系统理论阐明这一特征可被不失真地传输和接收,同时也给出了该信号高斯化近似的约束条件.最后通过工艺实验验证了该声发射信号的非高斯性特征在金刚石刀具研磨过程中的存在性,也证实了这一特征不受研磨速度和研磨压力等工艺参数的影响,而是与刀具研磨面的耐磨方向存在固有关联关系,从而为声发射信号监测在金刚石刀具研磨自动化系统中的合理应用奠定了方法基础.