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Experimental investigation and numerical analysis of material removal efficiency using abrasive microaggregates in grinding processes of Ti6Al4V
Faculty of Mechanical and Energy Engineering, Koszalin University of Technology, Racławicka 15, 75-620, Koszalin, Poland, Racławicka 15.
Faculty of Mechanical and Energy Engineering, Koszalin University of Technology, Racławicka 15, 75-620, Koszalin, Poland, Racławicka 15.
Faculty of Mechanical and Energy Engineering, Koszalin University of Technology, Racławicka 15, 75-620, Koszalin, Poland, Racławicka 15.
KTH, School of Industrial Engineering and Management (ITM), Production engineering, Manufacturing and Metrology Systems.ORCID iD: 0000-0003-3056-781X
2024 (English)In: Precision engineering, ISSN 0141-6359, E-ISSN 1873-2372, Vol. 91, p. 476-488Article in journal (Refereed) Published
Abstract [en]

Reducing plastic interactions between abrasive grains and the material being processed improves grinding efficiency and lowers energy consumption. Widening the cutting zone with abrasive grains enhances chip formation and reduces lateral material displacement. This can be achieved by using abrasive microaggregates. The paper presents an experimental analysis of grinding with modified wheels containing abrasive microaggregates. It examines how these microaggregates impact the grinding wheel's surface microgeometry and material removal efficiency. The study measured changes in the number, surface area, volume, and spacing of active contact areas on the grinding wheel active surface. A comparative analysis using the Shos indicator showed that abrasive microaggregates promote the formation of active areas with wide cutting edges perpendicular to the cutting direction. Finite element method simulations confirmed that abrasive microaggregates enhance material removal by widening the micro-cutting zone and increasing lateral resistance, which reduces the formation of flashes along the cutting path. The study also assessed how these surface features impact the roughness of the ground surface. A comparative analysis of roughness parameters showed a statistically significant reduction in surface, volume, hybrid, and functional parameters when using grinding wheels with abrasive microaggregates. This analysis was conducted using bootstrap statistical hypothesis tests.

Place, publisher, year, edition, pages
Elsevier BV , 2024. Vol. 91, p. 476-488
Keywords [en]
Abrasive grain, Abrasive microaggregates, Chip separation, Cutting zone, Finite element methods, Grinding, Grinding wheel, Material removal, Roughness, Simulation, Texture
National Category
Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:kth:diva-355426DOI: 10.1016/j.precisioneng.2024.10.005ISI: 001340043400001Scopus ID: 2-s2.0-85206639873OAI: oai:DiVA.org:kth-355426DiVA, id: diva2:1909170
Note

QC 20241111

Available from: 2024-10-30 Created: 2024-10-30 Last updated: 2024-11-11Bibliographically approved

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Tomkowski, Robert

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