09-Abrasive and Non-Traditional Material Removal Processes

09-Abrasive and Non-Traditional Material Removal Processes...

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CHAPTER 9 Abrasive and Non-Traditional Material- Removal rocesses Processes Manufacturing Processes Prof. Tugrul Ozel
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9.2 Abrasives PCD Relative Knoop Hardness 1. Conventional abrasives: Aluminum oxide (Al O ) CBN SiliconCarbide 2 3 Silicon carbide (SiC) AluminumOxide Carbide 2. Superabrasives: Cubic Boron Nitride (cBN) PCD Relative Abrasive Wear Resistance Diamond CBN SiliconCarbide AluminumOxide Coated Carbides Carbide Manufacturing Processes Prof. Tugrul Ozel
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9.4 Abrasive Processes Abrasive Processes- Generally slower (more expensive) than other traditional machining processes. However, they can be used on very hard materials, and can achieve high levels of precision and finish. Abrasive Processes: •Grinding eburring •Deburring •Honing •Polishing •Lapping •Superfinishing Manufacturing Processes Prof. Tugrul Ozel
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9.4 Grinding •Grinding is a machining process which utilizes hard abrasive particles as a cutting medium. •Grinding wheels are composed of two materials: • Tiny abrasive particles called grains or grits, hich do the cutting. which do the cutting. • A softer bonding agent to hold the countless abrasives grains together in a solid mass urface grinding of roll Manufacturing Processes Prof. Tugrul Ozel Surface grinding of roll forming parts
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9.3 Physical Model f a Grinding Wheel of a Grinding Wheel Grinding Wheel Grinding Wheel orkpiece FIGURE 9.1 Schematic illustration of a physical model of a grinding wheel, showing its structure and wear and fracture patterns. workpiece Manufacturing Processes Prof. Tugrul Ozel
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. 3 Bond types 9. 3 Bond types •V i t r i f i e d ( ceramic bond) • Resinoid ( thermosetting resins) ubber (most flexible bond) Rubber (most flexible bond) • Metal (aluminum, bronze, steel cBN wheel (vitrified) used usually for CBN and diamond wheels) • Other bonds Manufacturing Processes Prof. Tugrul Ozel
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9.3 Common Types of Grinding Wheels FIGURE 9.2 Some ommon types of common types of grinding wheels made with conventional abrasives. Note that each wheel has a pecific grinding specific grinding face. Grinding on other surfaces is improper and unsafe. Manufacturing Processes Prof. Tugrul Ozel
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9.3 Superabrasive-Wheel Configurations FIGURE 9.3 Examples of superabrasive-wheel configurations. The annular regions (rim) are superabrasive grinding surfaces, and the wheel itself (core) is generally made of metal or composites. ote that the basic numbering of wheel type is the same as shown in Note that the basic numbering of wheel type is the same as shown in Fig. 9.2. The bonding materials for the superabrasives are: (a), (d) and (e) resinoid, metal,or vitrified; Manufacturing Processes Prof. Tugrul Ozel (b) metal; (c) vitrified; and (f) resinoid.
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9.4 Grinding and Chip Production FIGURE 9.6 The grinding surface of an abrasive wheel (A46-J8V), showing grains, porosity, wear flats on grains (see also Fig. 9.8), and metal chips from the workpiece dhering to the grains. Note the adhering to the grains. Note the random distribution and shape of the abrasive grains. Magnification: 50X FIGURE 9.7 Grinding chip being
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09-Abrasive and Non-Traditional Material Removal Processes...

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