Handbook of Machining with Grinding Wheels

Grinding offers capabilities that range from high-rate material removal to high-precision superfinishing, and has become one of the most widely used industrial machining and surface finishing operations. Reflecting modern developments in the science and practice of modern grinding processes, the Handbook of Machining with Grinding Wheels presents a broad range of abrasive machining technologies with a focus on the fundamental concepts and practical applications. Written by an international team of experts unrivalled in their experience and standing in the field, this comprehensive reference takes a unified approach to abrasive machining that emphasizes the underlying physical principles and how this knowledge can best be applied to solving new grinding problems. Coverage is split neatly into two main sections, with the first dedicated to basic concepts such as grinding parameters, removal mechanisms, abrasive characteristics, and economic efficiency. The remainder of the book addresses applications, including grinding of ductile and brittle materials, grinding machines, and surface, cylindrical, internal, centerless, and ultrasonic-assisted grinding. Reflecting the diverse research and industrial experience of the authors, the Handbook of Machining with Grinding Wheels combines theoretical and practical information into an authoritative and convenient reference source. It will help deepen knowledge and sharpen problem-solving skills applied to practically any industrial grinding challenge.

Table of Contents:
THE BASIC PROCESS OF GRINDING Introduction From Craft to Science Basic Uses of Grinding Elements of the Grinding System The Importance of the Abrasive Grinding Wheels for a Purpose Problem Solving References Grinding Parameters Introduction Process Parameters Grinding Temperatures Appendix: Drawing Form and Profile Tolerancing References Material Removal Mechanisms Significance Grinding Wheel Topography Determination of Grinding Wheel Topography Kinematics of the Cutting Edge Engagement Fundamental Removal Mechanisms Material Removal in Grinding of Ductile Materials Surface Formation in Grinding of Brittle-Hard Materials Energy Transformation References Grinding Wheels Introduction Wheel Shape Specification Wheel Balance Design of High-Speed Wheels Bond Life Wheel Mount Design Wheel Design and Chatter Suppression References The Nature of the Abrasive Introduction Silicon Carbide Alumina (Alox)-Based Abrasives Electrofused Alumina Abrasives Chemical Precipitation and/or Sintering of Alumina Diamond Abrasives CBN Grain Size Distributions Future Grain Developments Postscript References Specification of the Bond Introduction Single-Layer Wheels Electroplated (EP) Single-Layer Wheels Brazed Single-Layer Wheels Vitrified Bond Wheels for Conventional Wheels Vitrified Bonds for Diamond Wheels Vitrified Bonds for CBN Resin Bond Wheels Plastic Bonds Phenolic Resin Bonds Polyimide Resin Bonds Metal Bonds Other Bond Systems References Dressing Introduction Traverse Dressing of Conventional Vitrified Wheels with Stationary Tools Traverse Dressing of Superabrasive Wheels with Stationary Tools Uniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond Tools Uniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary Diamond Tools Cross-Axis Traverse Dressing with Diamond Discs Diamond Form-Roll Dressing Truing and Conditioning of Superabrasive Wheels References Grinding Dynamics Introduction Forced and Regenerative Vibrations The Effect of Workpiece Velocity Geometrical Interference between Grinding Wheel and Workpiece Vibration Behavior of Various Grinding Operations Regenerative Self-Excited Vibrations Suppression of Grinding Vibrations Conclusions References Grinding Wheel Wear Three Types of Wheel Wear Wheel Wear Mechanisms Wear of the Abrasive Grains Bond Wear Assessment of Wheel Wear References Coolants Introduction Basic Properties of Grinding Fluids Types of Grinding Fluids Base Materials Additives Application Results Environmental Aspects The Supply System Grinding Fluid Nozzles Influence of the Grinding Fluid in Grinding References Monitoring of Grinding Processes The Need for Process Monitoring Sensors for Monitoring Process Variables Sensor for Monitoring the Grinding Wheel Sensors for Monitoring the Workpiece Sensors for Peripheral Systems References Economics of Grinding Introduction A Grinding Cost Comparison Based on an Available Grinding Machine A Cost Comparison Including Capital Investment Cost Comparison Including Tooling Grinding as a Replacement for Other Processes Multitasking Machines for Hard-Turning with Grinding Summary References APPLICATION OF GRINDING PROCESSES Grinding of Ductile Materials Introduction Cast Irons Steels Heat-Resistant Superalloys References Grinding of Ceramics Introduction Background on Ceramic Materials Diamond Wheels for Grinding Ceramics Physics of Grinding Ceramics ELID Grinding of Ceramics References Grinding Machine Technology The Machine Base Foundations Guideways Slideway Configurations Hydrostatic Slideways Recirculating Rolling Element Slideways Linear Axis Drives and Motion Control Elements of AC Servodrive Ballscrew Systems Linear Motor Drive Systems Spindle Motors and Grinding Wheel Drives Drive Arrangements for Large Conventional Wheels Drive Arrangements for Small Wheel Spindle Units Spindles for High-Speed Grinding Miscellaneous Wheel Spindles and Drives Rotary Dressing Systems Power and Stiffness Requirements for Rotary Dressers Rotary Dressing Spindle Examples Dressing Infeed System References Surface Grinding Types of Surface Grinding Process Basics of Reciprocating Grinding Basics of Creep Grinding Basics of Speed-Stroke Grinding Successful Application of Creep Feed Grinding Face Grinding Fine Grinding Appendix: Lapping Kinematics References External Cylindrical Grinding The Basic Process High-Speed Grinding Automotive Camlobe Grinding Punch Grinding Crankshaft Grinding Roll Grinding References Internal Grinding Introduction The Internal Grinding Process Abrasive Type Process Parameters Machine Tool Selection Troubleshooting References Centerless Grinding The Importance of Centerless Grinding Basic Process Basic Relationships Feed Processes Centerless Wheel and Dressing Geometry The Workrest Speed Control Machine Structure High Removal Rate Grinding Economic Evaluation of Conventional and CBN Wheels The Mechanics of Rounding Vibration Stability Dynamic Stability Avoiding Critical Frequencies Summary and Recommendations for Rounding Process Control References Ultrasonic Assisted Grinding Introduction Ultrasonic Technology and Process Variants Ultrasonic-Assisted Grinding with Workpiece Excitation Peripheral Grinding with Radial Ultrasonic Assistance Peripheral Grinding with Axial Ultrasonic Assistance Ultrasonic-Assisted Grinding with Excitation of the Wheel Summary References Glossary Notation and Use of SI Units Index