23
Contemporary Machining Processes
based on the surface topography of grinding wheels and simulated the grinding process of cemented carbide. The simulation results were analyzed to obtain a surface
roughness model and a specific grinding energy model based on an undeformed chip
thickness distribution. Some rules for the influence of the grinding wheel surface
conditions on maximum material removal rate were derived from the analysis, so
that adjustments were introduced to improve the maximum material removal rate of
the grinding wheel. The optimization results were verified through grinding tests of
a cemented carbide. In turn, Cai, Yao et. al. (2020) proposed a model to predict the
peripheral grinding force in the grinding process. The actual cutting depth, including the influence of the different grain paths of each element, was calculated to simulate the actual cross-section cutting area and the wear flat area. Through simulation
of grinding force using the grinding wheel topography and the grinding kinematic
directly, the influence of the workpiece residual was included. The authors claimed
that the simulated grinding force was more accurate than the force predicted on the
basis of the total material removal rate (Cai, Yao et. al. 2020). Even though these and
similar results are helpful, it is impossible to abstract them into a general theory or
model describing the effectiveness of the variety of grinding wheels combined with
numerous hard alloys and cemented carbides to be machined. It seems, however,
that among the most crucial issues related to the efficiency of diamond grinding are
stable interaction conditions between the diamond grit and machined material, wear
resistance of the grinding wheel, surface quality and integrity after machining, costs,
and environmental impact.
Electrical discharge diamond grinding (EDDG), in popular use recently for processing electrically conductive materials, is an improvement (Rao et al., 2017). In
EDDG, electrical discharge erosion similar to electrical discharge machining (presented in detail in Section 1.5) is combined with mechanical abrasion of diamond
grinding, which improves the material removal rate and average surface roughness
Ra significantly (Unune et al., 2018). In addition, erosion discharges during EDDG
remove contaminations from the grinding wheel and sharpen the abrasive grains,
prolonging the high-performance level of the tool. Balaji and Yadava (2013) indicated that the process prevents the generation of excessive temperature and thermal
stress during the grinding. The principle of electrical discharge diamond grinding is
explained in Figure 1.5.
EDDG is a complex machining process involving several disciplines of science
and engineering to understand the random occurrence of spark and impact of the
nonlinear behavior of a workpiece material due to temperature-dependent thermal
properties (Balaji and Yadava, 2013). As a result, the diamond grinding process is
improved in three respects: intensification of the machining, machinability improvement of difficult-to-cut materials, and automation of the entire process. In response
to the environmental challenge, taking into account economic considerations as
well, innovative anhydrous processes of diamond-spark grinding (DSG) of difficultto-process materials are proposed, where the application of solid lubricants promotes
savings of water resources (Gutsalenko and Rudnev, 2020).
The EDDG and DSG processes provide new perspectives on understanding relations and peculiarities of hard-alloy and cemented carbide grinding, microscale
Contemporary Machining Processes
based on the surface topography of grinding wheels and simulated the grinding process of cemented carbide. The simulation results were analyzed to obtain a surface
roughness model and a specific grinding energy model based on an undeformed chip
thickness distribution. Some rules for the influence of the grinding wheel surface
conditions on maximum material removal rate were derived from the analysis, so
that adjustments were introduced to improve the maximum material removal rate of
the grinding wheel. The optimization results were verified through grinding tests of
a cemented carbide. In turn, Cai, Yao et. al. (2020) proposed a model to predict the
peripheral grinding force in the grinding process. The actual cutting depth, including the influence of the different grain paths of each element, was calculated to simulate the actual cross-section cutting area and the wear flat area. Through simulation
of grinding force using the grinding wheel topography and the grinding kinematic
directly, the influence of the workpiece residual was included. The authors claimed
that the simulated grinding force was more accurate than the force predicted on the
basis of the total material removal rate (Cai, Yao et. al. 2020). Even though these and
similar results are helpful, it is impossible to abstract them into a general theory or
model describing the effectiveness of the variety of grinding wheels combined with
numerous hard alloys and cemented carbides to be machined. It seems, however,
that among the most crucial issues related to the efficiency of diamond grinding are
stable interaction conditions between the diamond grit and machined material, wear
resistance of the grinding wheel, surface quality and integrity after machining, costs,
and environmental impact.
Electrical discharge diamond grinding (EDDG), in popular use recently for processing electrically conductive materials, is an improvement (Rao et al., 2017). In
EDDG, electrical discharge erosion similar to electrical discharge machining (presented in detail in Section 1.5) is combined with mechanical abrasion of diamond
grinding, which improves the material removal rate and average surface roughness
Ra significantly (Unune et al., 2018). In addition, erosion discharges during EDDG
remove contaminations from the grinding wheel and sharpen the abrasive grains,
prolonging the high-performance level of the tool. Balaji and Yadava (2013) indicated that the process prevents the generation of excessive temperature and thermal
stress during the grinding. The principle of electrical discharge diamond grinding is
explained in Figure 1.5.
EDDG is a complex machining process involving several disciplines of science
and engineering to understand the random occurrence of spark and impact of the
nonlinear behavior of a workpiece material due to temperature-dependent thermal
properties (Balaji and Yadava, 2013). As a result, the diamond grinding process is
improved in three respects: intensification of the machining, machinability improvement of difficult-to-cut materials, and automation of the entire process. In response
to the environmental challenge, taking into account economic considerations as
well, innovative anhydrous processes of diamond-spark grinding (DSG) of difficultto-process materials are proposed, where the application of solid lubricants promotes
savings of water resources (Gutsalenko and Rudnev, 2020).
The EDDG and DSG processes provide new perspectives on understanding relations and peculiarities of hard-alloy and cemented carbide grinding, microscale