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High speed versus conventional grinding in high removal rate machining of alumina and alumina–titania
Authors:Ling Yin   H. Huang   K. Ramesh  T. Huang
Affiliation:aSchool of Mechanical Engineering, Tianjin University, Tianjin 300072, China;bSchool of Mechanical Engineering, University of Western Australia, Crawley, WA 6009, Australia;cSingapore Institute of Manufacturing Technology, Singapore, Singapore 638075
Abstract:High removal rate (up to 16.6 mm3/s per mm) grinding of alumina and alumina–titania was investigated with respect to material removal and basic grinding parameters using a resin-bond 160 μm grit diamond wheel at the speeds of 40 and 160 m/s, respectively. The results show that the material removal for the single-phase polycrystalline alumina and the two-phase alumina–titania composite revealed identical mechanisms of microfracture and grain dislodgement under the grinding conditioned selected. There were no distinct differences in surface roughness and morphology for both materials ground at either conventional or high speed. An increase in material removal rate did not necessarily worsen the surface roughness for the two materials at both speeds. Also the grinding forces for the two ceramics demonstrated similar characteristics at any grinding speeds and specific removal rates. Both normal and tangential grinding forces and their force ratios at the high speed were lower than those at the conventional speed, regardless of removal rates. An increase in specific removal rate caused more rapid increases in normal and tangential forces obtained at the conventional grinding speed than those at the high speed. Furthermore, it is found that the high speed grinding at all the removal rates exerted a great amount of coolant-induced normal forces in grinding zone, which were 4–6 times higher than the pure normal grinding forces.
Keywords:Alumina   Alumina–  titania   High speed grinding   High removal rate   Material removal   Surface roughness and morphology
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