6
Single-pass grinding an effective manufacturing method for finishing Krzysztof Nadolny, Jaroslaw Plichta, Daniela Herman, Bronisław Słowiński Koszalin University of Technology, 15/17 Racławicka Street, 75- 620 Koszalin, Poland [email protected] Abstract The paper presents the essence of the single-pass internal cylindrical grinding process. There is a descriptive presentation of the grinding wheels of zonally diversified structure and the attachment for precise forming the conical chamfer on the active surface of abrasive tools applied to this process. The experimental results enabled the effects of the structural diversification of grinding wheels on the process and results of the single-pass internal cylindrical grinding to be evaluated. The results of zonally diversified grinding were related to the effects of grinding using only the wheels made from grains of the same size. The mathematical models of changes in the grinding power and the roughness of the workpiece surface machined with the grinding wheels being tested were developed for the material removal rate fluctuating within Q w ≈924 mm 3 /s. 1. Introduction Nowadays, the single-pass internal cylindrical grinding constitutes the essential trend in the development of the abrasive-machining processes. These processes include the creep feed grinding (CFG) and the continuous path- controlled grinding (CPCG), e.g. the high-speed peelgrinding (HSP) [1-3], Quickpoint grinding [4, 5] and the lengthwise grinding with grinding wheels with cone- or radial-zone of rough grinding [6-8]. The intensive development of these processes is mostly connected with the popularisation of grinding wheels based on CBN grains, including the grinding wheels of zonally diversified structure. The recent developmental research [9-12] shows the potential for applications of the grinding wheels of zonally diversified structure with sintered corundum SG grains. It is especially concerning the operation of internal grinding. The tools of this type are less expensive than the CBN grinding wheels, but due to their high grinding effectiveness and very favourable process properties, they make it possible to remove the grinding allowance of the order of 0.2 mm in a single pass, ensuring the cut surface roughness within Ra≈0.30.4 m. It should be also emphasised that a conventional internal grinder is suitable for grinding with this new abrasive tools made from SG grains [13]. 2. Single-pass internal cylindrical grinding process The removal of a material layer to a thickness of 0.1-0.2 mm in a single pass is made easier due to the conical chamfer formed during the dressing of the grinding wheel in its cutting zone. It allows the total grinding allowance (a e tot ) to be evenly distributed along the abrasive-tool length, and because of that a larger number of active grains take part in rough grinding, i.e. the removal of the grinding allowance, which corresponds to the effective value of grinding depth (a e eff ) Fig. 1 [1-3, 6-8]. Figure 1. Single-pass internal cylindrical grinding with grinding wheels of zonally diversified structure: a) load of grinding wheel active surface, b) kinematics of grinding [1, 2] The value of the chamfer angle depends on a series of parameters such as the grinding-wheel coasting, the grinding allowance quantity, the grinding- wheel height and the requirements for the surface quality. The latter determine the width of the finishing and sparking out zone (Zone B) [1, 2, 6, 7]. Due to wear of the grinding wheel, the conical chamfer shifts a) b) 19th International Conference on Systems Engineering 978-0-7695-3331-5/08 $25.00 © 2008 IEEE DOI 10.1109/ICSEng.2008.94 236

[IEEE 2008 19th International Conference on Systems Engineering (ICSENG) - Las Vegas, NV, USA (2008.08.19-2008.08.21)] 2008 19th International Conference on Systems Engineering - Single-Pass

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Single-pass grinding – an effective manufacturing method for finishing

Krzysztof Nadolny, Jaroslaw Plichta, Daniela Herman, Bronisław Słowiński

Koszalin University of Technology, 15/17 Racławicka Street, 75- 620 Koszalin, Poland

[email protected]

Abstract

The paper presents the essence of the single-pass

internal cylindrical grinding process. There is

a descriptive presentation of the grinding wheels of

zonally diversified structure and the attachment for

precise forming the conical chamfer on the active

surface of abrasive tools applied to this process. The

experimental results enabled the effects of the

structural diversification of grinding wheels on the

process and results of the single-pass internal

cylindrical grinding to be evaluated. The results of

zonally diversified grinding were related to the effects

of grinding using only the wheels made from grains of

the same size. The mathematical models of changes in

the grinding power and the roughness of the workpiece

surface machined with the grinding wheels being

tested were developed for the material removal rate

fluctuating within Qw≈924 mm3/s.

1. Introduction

Nowadays, the single-pass internal cylindrical grinding

constitutes the essential trend in the development of the

abrasive-machining processes. These processes include

the creep feed grinding (CFG) and the continuous path-

controlled grinding (CPCG), e.g. the high-speed

peelgrinding (HSP) [1-3], Quickpoint grinding [4, 5]

and the lengthwise grinding with grinding wheels with

cone- or radial-zone of rough grinding [6-8]. The

intensive development of these processes is mostly

connected with the popularisation of grinding wheels

based on CBN grains, including the grinding wheels of

zonally diversified structure.

The recent developmental research [9-12] shows the

potential for applications of the grinding wheels of

zonally diversified structure with sintered corundum

SG grains. It is especially concerning the operation of

internal grinding. The tools of this type are less

expensive than the CBN grinding wheels, but due to

their high grinding effectiveness and very favourable

process properties, they make it possible to remove the

grinding allowance of the order of 0.2 mm in a single

pass, ensuring the cut surface roughness within

Ra≈0.30.4 m. It should be also emphasised that

a conventional internal grinder is suitable for grinding

with this new abrasive tools made from SG grains [13].

2. Single-pass internal cylindrical grinding

process

The removal of a material layer to a thickness of

0.1-0.2 mm in a single pass is made easier due to the

conical chamfer formed during the dressing of the

grinding wheel in its cutting zone. It allows the total

grinding allowance (ae tot) to be evenly distributed

along the abrasive-tool length, and because of that

a larger number of active grains take part in rough

grinding, i.e. the removal of the grinding allowance,

which corresponds to the effective value of grinding

depth (ae eff) – Fig. 1 [1-3, 6-8].

Figure 1. Single-pass internal cylindrical grinding with grinding wheels of zonally

diversified structure: a) load of grinding wheel active surface, b) kinematics of grinding [1, 2]

The value of the chamfer angle depends on

a series of parameters such as the grinding-wheel

coasting, the grinding allowance quantity, the grinding-

wheel height and the requirements for the surface

quality. The latter determine the width of the finishing

and sparking out zone (Zone B) [1, 2, 6, 7]. Due to

wear of the grinding wheel, the conical chamfer shifts

ae – working engagement ae eff – effective working engagement ae tot – total working engagement af – feed engagement dw – workpiece diameter D – grinding wheel diameter ns – grinding wheel rotational frequency

nw – workpiece rotational frequency vfa – axial table feed speed Q’w – material removal rate pre unit of active grinding wheel width T – total grinding wheel height T1 – height of rough grinding zone T2 – height of finish grinding zone

– angle of conic chamfer

a) b)

19th International Conference on Systems Engineering

978-0-7695-3331-5/08 $25.00 © 2008 IEEE

DOI 10.1109/ICSEng.2008.94

236

towards the finishing and sparking out region causing

its reduction [6, 7].

The above process of grinding was marked by

variable load of a grinding wheel in four basic zones

(Fig. 1). The load of a grinding wheel in Zone I was

increasing all the way to the constant value in region II.

It is possible to determine the load value in Zone II by

the specific material removal rate defined by the

following relation [1, 2]:

Q’w = · dw · nw · af · tg [mm3/s · mm], (1)

where: dw – workpiece diameter; nw – workpiece

peripheral speed; af – axial feed (feed engagement);

– angle of conic chamfer.

Region III is marked by a decrease in load

analogous to its increase in Zone I, with the difference

that except for the removal of grinding allowance there

occurs also finish grinding. Region IV includes both

the finish grinding, following from elastic strains

between the workpiece and the grinding-wheel spindle,

and the sparking out.

3. Grinding wheels of zonally diversified

structure

Grinding wheels designed for testing were built on

the basis of grains of microcrystalline sintered

corundum SG bonded with special glass-crystalline

binder. It is composed of dispersed particles of

a crystalline phase (15 m) in glass matrix. Thanks to

generating a scattered crystalline phase, which is

harder than the matrix, from glass it is possible to

improve the mechanical properties of such the binders

(including hardness). Moreover, respecting the

occurrence of intergranular boundaries in binder, the

mechanism of destructive processes in binder is very

similar to the mechanism being effective in abrasive

grains, especially the microcrystalline ones [14].

Abrasive grains of the different type and size in

both their functional zones mark the developed

grinding wheels – Fig. 2.

The first one where the rough grinding process is

realised (Zone A) includes the grains of sintered

corundum (SG) size 46. This zone was covered 70% or

80% of the grinding-wheel height and additionally it

had a conical chamfer adapted to the amount of

grinding allowance. However, the region of a grinding

wheel designed for the finishing and sparking out

processes (Zone B) is composed of finer grains (80 or

60 size) of the same material. The tests also gave

consideration to the grinding wheel totally made from

grains SG size 46, which provided the reference for the

results obtained with grinding wheels of zonally

diversified structure (Fig. 3).

Figure 2. Grinding wheel of zonally diversified

structure a) microscope view of rough grinding zone – Zone A; b) microscope view of

finish grinding zone – Zone B; c) structure

Figure 3. Grinding wheels used in

experimental investigations

The diversified structures being discussed and the

application of the conical chamfer were aimed at

optimal adapting the abrasive tool to the variable loads

in respective process zones in the course of single-pass

grinding. These modifications were also aimed to

provide the intensive removal of material and the high

quality of the cut surface as well.

4. Precision dressing device

A special attachment for precise shaping the conical

chamfer at a small angle (<1.5) on the active surface

of grinding wheels has been developed. A slide plate

which is equipped with a disk-shaped holder for

a diamond dressing cutter and a micrometer screw

Name 46/80-30% 46/80-20% 46-100%

Structure

Designation 1 - 35x20x10 -

SG/F46 K 7 V DG 70% /

SG/F80 I 7 V DG 30%

1 - 35x20x10 - SG/F46 K 7 V DG 80% /

SG/F80 I 7 V DG 20%

1 - 35x20x10 - SG/F46 K 7 V DG 100%

Name 46/60-30% 46/60-20%

Structure

Designation 1 - 35x20x10 - SG/F46 K 7 V DG 70% /

SG/F60 I 7 V DG 30% 1 - 35x20x10 - SG/F46 K 7 V DG 80% /

SG/F60 I 7 V DG 20%

237

which enables to set precisely the required value of

a chamfer angle (±0,03) is the most important

component of this attachment. This screw secured to

the lower part of the base directly displaces its upper

part, which supports the slide plate (Fig. 4).

Figure 4. Functional elements of device to

precision dressing: 1 – dresser, 2 – slide plate, 3 – upper basis turning about specified angle, 4 – immovable bottom base, 5 – micrometer

screw, 6 – axis of rotation of upper base, 7 – driving motor, 8 – toothed rack, 9 – limit

switch, 10 – blockade of table, 11 – bracket of casing, 12 – backing plate, 13 – dresser base

The attachment featuring a power transmission

system for a slide plate consists of a power pack,

a driving motor, a worm gear and a toothed rack. The

to-and-fro motion is controlled by switches located at

extreme positions of a slide plate. The whole system

was fixed to the upper part of the base in order to

maintain the stable kinematics of dressing at various

values of the angle. The components of the attachment

were mounted on a standard dresser base of a RUP 28P

grinding machine.

5. Experimental conditions

Experimental investigations were carried out on

a RUP 28P universal grinding machine equipped with

an electro-spindle Fischer type EV-70/70-2WB

(maximum rpm 60 000 min-1

, power of machine

cutting 5.2 kW). Semi-fabricated rolling bearings made

of 100Cr6 steel of hardness 63±2 HRC was ground.

Grinding liquid was prepared as 5% solution of oil

Castrol Syntilo R HS. A grinding wheel was dressed

before every test with a single-diamond grain dresser.

The measurements of grinding power were taken using

the high-speed spindle control system and the

roughness of machined surfaces was recorded on

a profile measurement gauge ME10.

Investigations were realised on the basis of a three-

level plan of experiment making it possible to

determine a second class nonlinear model. From

among five classes of mathematical model for test

objects, which was made available by the application

software Experiment Planner 1.0, the function

describing the recorded results matched with maximum

accuracy was selected. An analysis of the matching

ratio for individual model classes was carried out

parallel to measured roughness parameters and

grinding power [13]. Consequently, it was settled that

the exponential model optimally describes the

roughness of machined surfaces (as a criterion the

coefficient of dimensional correlation R was assumed).

However, it results from the comparison of models

describing the consumption of grinding power that the

highest matching ratio was achieved by a multinominal

function. The experiments were carried out making

three repeated measurements for each of the scheduled

measuring points.

6. Experimental results1

The experimental investigations were aimed to

evaluate the effects of the abrasive-grain size

diversification in the finish grinding zone and the

percentage share of the respective grinding-wheel

zones on the course and results of single-pas internal

grinding.

The grinding power growth ΔP (defined as the

difference between the grinding power P and the initial

power Pinitial) recorded in the course of grinding and the

roughness of machined surfaces denoted by the

parameter Ra (arithmetic mean roughness values). The

experimental results were the basis for working out the

mathematical models describing the changes in the

discussed quantities at variable values of grinding

allowance and the rate of axial table feed speed for five

types of grinding wheels.

The diagram of variations in arithmetic mean

machined surface roughness Ra (Fig. 5) show that the

lowest values were measured for grinding wheels with

higher, amounting to 30% share of the finish grinding

zone. The advantage of these tools is clearly visible for

small values of the working engagement and the axial

table feed.

The lowest value Ra were obtained as a result of

abrasive machining with a 46/80-30% grinding wheel,

may be explained by a large number of grinding micro-

tips in the finish grinding zone made from grains size

80. The surface machined with a conical chamfer of

a grinding wheel is finally subjected to the finishing

1 Described investigations were realized within the Investigative

Project of the Committee for Research Projects No. 4 T07D 036 29

5

2

3

1

7

9

9

4

6

8

13

12 11

11

10

238

and sparking out process with a large number of edges

distributed on the surface of a cylindrical zone. The

proceeding of this process is confirmed by comparing

the size of chips observed on the active surfaces of

both the zones of this abrasive tool (Fig. 6).

Figure 5. Mathematical models describing

effect of the grinding wheel structure on the workpiece roughness Ra

Figure 6. Chips on the active surface of

grinding wheel 46/80-30%: a) rough grinding zone (x400); b) finish grinding zone (x1000)

Consequently, the surface marked by even twice

lower values of the parameter Ra compared with the

abrasive tool totally made from grains size 46 was

abrasive machined at lower material removal rates.

A slightly higher roughness, within low values of

vfa, was obtained when a 46/60-30% grinding wheel

was used. In case of this tool, almost a three-time

increase in Qw from 8.96 (for ae=0.15 mm,

vfa=1.0 mm/s) to 23.93 mm3/s (for ae=0.20 mm,

vfa=2.0 mm/s) caused only a 30% increase in the

roughness of machined surfaces. It shows that the

operation of the cylindrical finish-grinding zone, which

in a wide range of the material removal rate provides

the sparkling out of the machined surface, is correctly

done.

Still smaller variation of roughness was recorded

for the second grinding wheel with grains size 60 in the

finishing zone T2=0.2T in height. It also shows

a coarser surface, which was machined with this tool.

Thus, one can conclude that the application of larger

grains in a cylindrical zone of a grinding wheel has

a negative effect on the achieved roughness of the

machined surface. It results from the smaller

concentration of larger grains on the active surface of

a grinding wheel, which leads to a smaller number of

grain tips and an increase in a cross-section of a layer

machined with a single grain, and because of this

forming the larger chips and increasing the roughens of

machined surfaces.

The higher values of the parameter Ra, from among

tools being tested, were observed on the surface

machined with a 46/80-20% grinding wheel. The

measuring results were even worse than in case of

a 46-100% grinding wheel, which was assumed to be

the reference test piece for grinding wheels, where the

zonally diversified structure was applied in order to

reduce the roughness of the machined surface. If the

initial and final values are going for a level very close

to the grinding results using other tool with a 20%

finishing zone (46/60-20%) and a 46-100% grinding

wheel, then the surfaces machined at vfa=1.5 mm/s are

very different from them. The obtained form of

a function approximating the changes in the surface

machined with a 46/60-20% grinding wheel is clearly

different from the other models. It is believed that the

results obtained using this grinding wheel, for the axial

table feed 1.5 mm/s, were interfered by the action of

random events affecting the process being tested.

Along with an increase of the material removal rate

the differences in the obtained roughens of machined

surfaces were decreasing. It is evident, among others

when comparing the changes in arithmetic mean

roughness values Ra as a function of the feed vfa for

ae=0.20 mm. Figure 7 presents the results for

a grinding wheel, which the average value of the

parameter Ra was the lowest from among all the results

(46/80-30%) and a grinding wheel of homogenous

structure (46-100%).

Due to the application of the finish grinding zone of

30% in height composed of grains size 80, the fraction

of the very porous tool surface generated with grains

46 was reduced. The remaining area of the active

surface of grinding wheels is not sufficiently able to

realise the rough grinding process, because it was

adapted for finishing and sparkling out the surface.

However, at higher values of material removal rate,

due to the increased elastic strains in the working

system, the conical chamfer removes the smaller part

of the total working engagement, leaving more

material for grinding by a cylindrical part.

Grinding wheel 46/80-30% Grinding wheel 46/80-20%

Grinding wheel 46/60-30% Grinding wheel 46/60-20%

Grinding wheel 46-100% Equations of the mathematical models and multidimensional correlation coefficients R

Ra 46/80-30% = exp (– 5.8308 + 20.6671ae + 2.0297vfa +

– 0.5659aevfa – 42.9730ae2 – 0.3417vfa

2)

R = 0.9676

Ra 46/80-20% = exp (– 5.0062 + 12.5468ae + 3.4801vfa +

– 2.4964aevfa – 21.2447ae2 – 0.9167vfa

2)

R = 0.9833

Ra 46/60-30% = exp (– 3.5361 + 11.0142ae + 1.0202vfa +

– 1.1660aevfa – 22.7025ae2 – 0.1244vfa

2)

R = 0.9997

Ra 46/60-20% = exp (– 2.4145 + 9.9775ae – 0.0349vfa +

– 2.1584aevfa – 14.5539ae2 + 0.1927vfa

2)

R = 0.9993

Ra 46-100% = exp (– 2.9030 + 8.9847ae + 0.8500vfa +

– 1.1845aevfa – 16.6350ae2 – 0.1134vfa

2)

R = 0.9755

Grinding conditions: vs = 60 [m/s] vw = 0.75 [m/s] ae = 0.15÷0.20 [mm] q = 80 = 0.60÷0.91 [] ns = 35300÷39200 [rpm] nw = 341 [rpm] vfa = 1.0÷2.0 [mm/s] QCCS = 5.0 [l/min] b = 12.6÷14.4 [mm]

a) b)

239

Figure 7. Effect of the grinding wheel structure on the variations of the workpiece roughness

Ra (ae=0.20 mm)

Figure 8. Mathematical models describing

effect of the grinding wheel structure on the

grinding power P

An additional factor affecting an increase in the

roughness of machined rings is a decreasing number of

grinding passes U of the cut surface by the active

surface of a grinding wheel along with an increasing

feed. According to the obtained results, the grinding

wheels with the highest zone of finish grinding are

much more sensitive to the changes in overlap

cylindrical grinding with axial table feed speed. It

gives the reasons to judge that along with the increased

tool peripheral speed vs, which leads to a higher

number of grinding passes, the significance of the

grinding wheel of zonally diversified structure is

growing.

Mathematical models describing changes in the

grinding power growth ΔP as a function of the working

engagement and the axial table feed speed are

compiled in Figure 8.

One can conclude from the present results that in

case of all grinding wheels being tested the comparable

power consumption in the course of the grinding

process was recorded. The results obtained for

a 46-100% grinding wheel slightly diverged from the

results recorded for the grinding tools of zonally

diversified structure. They show higher power demand,

which is undoubtedly evident in case of grinding with

the largest working engagement ae=0.20 mm. It

follows from increased cross-sections of layers

machined with single grains of this tool. The active

surface of this grinding wheel is marked by a relatively

smaller number of grinding tips, which undergo higher

load in the course of the grinding process, and

consequently induces an increase in grinding power.

The recorded changes mostly depend on feed speed

and grinding thickness. It is clearly evident from Fig 9

showing the comparison of the power gain averages

P, obtained as a result of abrasive machining with all

the grinding wheels for the axial table feed speed

vfa=1.0; 1.5; 2.0 mm/s and ae=0.15 and 0.20 mm.

Figure 9. Comparison of mean values

of the grinding power increase P for all grinding wheels

It results from this comparison that an 33% increase

in the material removal rate Qw resulting from changes

in the working engagement from 0.15 to 0.20 mm

induces an average 45% increase in power

consumption in the process being investigated.

However, the doubling of Qw resulting from an

increase in axial table feed speed from 1.0 to 2.0 mm/s

induces an 59% increase in grinding power for

ae=0.20 mm and 71% at ae=0.15 mm. It means, that

the grinding thickness more significantly determines

the obtained grinding power gains than the axial table

feed speed.

0,00

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1

Axial feed speed v fa [mm/s]

Ari

thm

eti

ca

l m

ea

n d

ev

iati

on

of

the

pro

file

Ra

[

m] 46/80-30% 46-100%

0.16

0.28

0.33

0.27

0.39

0.37

Qw =

11

.96

[m

m3/s

]

Qw =

17

.95

[m

m3/s

]

Qw =

23

.93

[m

m3/s

]

a e = 0.20 [mm]

-43%

-18%

+5%

0.40

0.35

0.30

0.25

0.20

0.15

0.10

0.05

0.00

0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1

Grinding wheel 46/80-30% Grinding wheel 46/80-20%

Grinding wheel 46/60-30% Grinding wheel 46/60-20%

Grinding wheel 46-100% Equations of the mathematical models and multidimensional correlation coefficients R

P46/80-30% = – 1102.2941 + 2614.7509ae + 1301.0939vfa +

+ 1033.3333aevfa + 202.2988ae2 – 370.8276vfa

2 R=0.9999

P46/80-20% = 909.1829 – 556.9732ae – 1181.0939vfa +

+ 3366.6666aevfa – 202.2989ae2 + 300.1609vfa

2 R=0.9916

P46/60-30% = 12.6341 + 1487.2797ae – 103.0345vfa +

+ 2146.6666aevfa – 128.7356ae2 – 3.6552vfa

2 R=0.9977

P46/80-20% = – 371.6475 + 4361.9923ae – 58.41762vfa +

+ 853.3333aevfa – 2685.0575ae2 + 87.2874vfa

2

R=0.9999

P46-100% = – 1061.8401 + 5357.9693ae + 766.9406vfa +

– 686.6666aevfa + 4193.1034ae2 – 102.8506vfa

2

R=0.9969

Grinding conditions: vs = 60 [m/s] vw = 0.75 [m/s] ae = 0.15÷0.20 [mm] q = 80 = 0.60÷0.91 [] ns = 35300÷39200 [rpm] nw = 341 [rpm] vfa = 1.0÷2.0 [mm/s] QCCS = 5.0 [l/min] b = 12.6÷14.4 [mm]

410

561

702

614

799

974

P av = 359.7v fa + 256.29

P av = 292.57v fa + 118.82

0

100

200

300

400

500

600

700

800

900

1000

1100

0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1

Axial feed speed v fa [mm/s]

Av

era

ge

in

cre

as

e o

f g

rin

din

g p

ow

er Pav [

W]

a e = 0.15 [mm]

a e = 0.20 [mm]

+50%

+39%

+59%

+71%

Qw =

8.9

6 [m

m3/s

]

Qw =

11

.96

[m

m3/s

]

Qw =

17

.95

[m

m3/s

]

Qw =

13

.44

[m

m3/s

]

Qw =

23

.93

[m

m3/s

]

Qw =

17

.92

[m

m3/s

]

240

7. Conclusions

Recapitulating the obtained results of changes in

values of the parameter Ra it should be stressed that

the most significant influence on the roughness of

a workpiece was affected by the finish-grinding zone.

By increasing the value T2 from 20 to 30% of the total

grinding-wheel height T it was possible to considerably

decrease the arithmetic mean of the departures of the

roughens profile from the mean line for the machined

surface. Despite the difference in size of the grain used

for the cylindrical zone, the grinding wheels with the

same ratio T1/T2 achieve better results of machining

than the other grinding wheels, which proves the key

effect of this parameter on the final roughness of

a workpiece. Comparing the values of the parameter

Ra measured after grinding at the axial table feed speed

of 1.0 mm/s, the division into two groups of grinding

wheels was evident. The lower values were obtained in

grinding using tools with a 30% zone T2, however in

case of the other grinding wheels the machined

surfaces were coarser. For two grinding wheels with

a higher cylindrical zone (46/80-30% and 46/60-30%),

the roughness was affected by grain size in this part of

a grinding zone.

It follows from the obtained mathematical models

describing the changes in grinding power as a function

of ae and vfa (Fig. 8) that, the value of the working

engagement was a major limitation for achieving the

higher material removal rates in the process being

investigated. The assumed variation range for ae from

0.15 to 0.20 mm corresponds to the grinding allowance

used in manufacturing processes of grinding the

bearing rings. An increase in value of this parameter is

not required for such the applications of the single-pass

internal cylindrical grinding processes. However, the

material removal rate could be speeded up by

increasing the axial table speed rate, which in a smaller

extent influence the power consumption. It also results

from the present investigations that the grinding power

is variable within a very limited range due to the

diversified structure of the applied abrasive tools.

The maximum material removal rate obtained in the

present experiments (Qw≈24 mm3/s) is comparable

with the material removal rate obtained in similar

processes with the application of the CBN grinding

wheels [6, 7]. It follows from the above that one can

replace the expensive tools made of super-hard

materials with relatively cheaper grinding wheels made

with SG grains in the single-pass internal cylindrical

grinding process, simultaneously achieving the

roughens of the machined surface below the value

Ra=0.4 m. However, one should remember about

significantly weaker wear resistance of the SG grinding

wheels compared to the tools made from e.g. cubic

boron nitride.

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