Analysis of the Cutting Abilities of the Multilayer Grinding Wheels—Case of Ti-6Al-4V Alloy Grinding
Abstract
:1. Introduction
2. Materials and Methods
2.1. Measurement Methodology
2.2. Methodology of the Surface Roughness Assessment
2.3. Methodology of the Surface Feature Variability Assessment after the Grinding Process
3. Results and Discussion
3.1. Analysis of the Grinding Wheel Topography
3.2. Ground Surface Roughness Analysis
4. Conclusions
- The addition of abrasive aggregates increases the size of the active areas of the grinding wheels. These areas are characterized by favorable geometrical features related, inter alia, to the increased width of the cutting edges compared to the active areas present on the surface of the conventional grinding wheel.
- The assessment of the grinding wheel’s cutting ability was carried out using the Shos parameter. It allows for assessing the elevation of the active surfaces, their sharpness, and the orientation of the cutting edges in relation to the cutting direction. The Shos value for the layer with abrasive aggregates is 40% higher than for the layer with conventional abrasive grains;
- The use of bootstrap for the statistical hypothesis tests makes it possible to evaluate the differentiation of the ground surface features as a result of mean roughness parameters values. Those analyses take into account the actual form of the probability distribution of those parameters. They also express the irregularity of the surface roughness parameter values as a result of the grinding process variability;
- The modification of the grinding wheels as an application of new middle layer containing the addition of abrasive aggregates increases the tool’s ability to smooth the machined surface. In the case of surfaces ground with multilayer grinding wheels, more favorable values of roughness parameters were observed for the group of amplitude parameters (Sa, Sq, and Ssk), functional parameters (Spk, Vmp, and Sxp), and feature parameters (Sha and Shv);
- The effects of the application of an intermediate layer with the participation of abrasive aggregates affects the load-bearing capacity of the machined surfaces. The use of abrasive aggregates, with an impact surface larger than the base grains, results in the formation of a topography characterized by a smaller area (Sha value lower by 12%) and a smaller volume of peaks (Shv value lower by 34%) compared to the surfaces obtained as a result of grinding with a conventional grinding wheel.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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Process Parameters | |
grinding method | reciprocating grinding |
workpiece material | Ti-6Al-4V |
grinding wheel speed | vs = 18 m/s |
lateral feed | ap = 1 mm/stroke |
feed rate | vw = 4 m/min |
depth of cut | ae = 0.1 mm |
dresser | single-point diamond dresser |
dressing depth (ad) | ad = 0.05 mm |
dressing speed (vd) | vd = 5 mm/s |
grinding condition | wet grinding |
coolant | EMU 12 in 5% water solution |
coolant preassure | 7 bar |
coolant flow rate | 20 L/min |
Ti-6Al-4V Workpiece Properties | |
Average tensile strength MPa | 895 |
Yield point MPa | 825 |
Young’s Modulus GPa | 110 |
Thermal conductivity W/(m·K) | 6.7 (20 °C) |
Density g/cm3 | 4.43 |
Grinding Wheel Topography Measurement | |
Equipment | Confocal microscope LEXT OLS4000 with Anti Vibrant AV1 table |
Lenses | Olympus 20×, WD = 0.4 |
Magnification | ×428 |
Elementary measurement area | 646 μm × 646 μm for Olympus × 20 lense, with numerical magnification x1 |
Applied stitching | 5 × 5 cells with 10% overlap |
Number of areas measured | 3 × (2972 μm × 2972 μm) for each tool |
Specimen Topography Measurement | |
Equipment | Interference profilometer Taylor Hobson CCI 6000 |
Lenses | Nikon × 20/0.40DI WD 4.7 |
Magnification | ×428 |
Elementary measurement area | 899 μm × 899 μm for Olympus ×20 lense, with numerical magnification ×1 |
Number of areas measured | 60 × (899 μm × 899 μm) |
Parameter | Conventional Tool | Multilayer Tool | Unit | p-Value | Statistically Significant Difference |
---|---|---|---|---|---|
Amplitude parameters | |||||
Sq | 0.37 ± 0.009 | 0.33 ± 0.006 | µm | 2.62 × 10−4 | yes |
Ssk | 0.78 ± 0.09 | 0.03 ± 0.08 | 9.99 × 10−6 | yes | |
Sku | 7.5 ± 0.4 | 6.2 ± 0.5 | 6.31 × 10−2 | no | |
Sp | 2.6 ± 0.1 | 2.5 ± 0.1 | µm | 3.84 × 10−1 | no |
Sv | 2.0 ± 0.1 | 1.8 ± 0.1 | µm | 2.86 × 10−1 | no |
Sz | 4.6 ± 0.2 | 4.3 ± 0.1 | µm | 1.94 × 10−1 | no |
Sa | 0.27 ± 0.006 | 0.25 ± 0.005 | µm | 3.01 × 10−2 | yes |
Functional parameters | |||||
Smr | 0.9 ± 0.1 | 0.9 ± 0.6 | % | 8.91 × 10−1 | no |
Smc | 0.42 ± 0.01 | 0.39 ± 0.01 | µm | 2.00 × 10−2 | yes |
Sxp | 0.62 ± 0.02 | 0.68 ± 0.02 | µm | 2.20 × 10−2 | yes |
Spatial parameters | |||||
Sal | 21.8 ± 0.7 | 14.4 ± 0.3 | µm | 9.89 × 10−6 | yes |
Str | 0.0973 ± 0.0060 | 0.0334 ± 0.0009 | 9.99 × 10−6 | yes | |
Hybrid parameters | |||||
Sdq | 0.065 ± 0.001 | 0.066 ± 0.001 | 2.74 × 10−1 | no | |
Sdr | 0.21 ± 0.01 | 0.22 ± 0.01 | % | 2.59 × 10−1 | no |
Volume parameters | |||||
Vv | 0.46 ± 0.01 | 0.41 ± 0.01 | µm³/µm² | 2.30 × 10−3 | yes |
Vmp | 0.033 ± 0.001 | 0.019 ± 0.001 | µm³/µm² | 9.99 × 10−6 | yes |
Vmc | 0.27 ± 0.01 | 0.27 ± 0.01 | µm³/µm² | 6.69 × 10−1 | no |
Vvc | 0.42 ± 0.01 | 0.36 ± 0.01 | µm³/µm² | 8.29 × 10−6 | yes |
Vvv | 0.0384 ± 0.0013 | 0.0421 ± 0.0011 | µm³/µm² | 3.29 × 10−2 | yes |
Features parameters | |||||
Spd | 0.00025 ± 0.00001 | 0.00030 ± 0.00001 | 1/µm² | 7.70 × 10−3 | yes |
Spc | 0.045 ± 0.001 | 0.049 ± 0.000 | 1/µm | 1.20 × 10−4 | yes |
S10z | 2.9 ± 0.1 | 2.8 ± 0.1 | µm | 1.71 × 10−1 | no |
S5p | 1.76 ± 0.06 | 1.75 ± 0.04 | µm | 9.63 × 10−1 | no |
S5v | 1.18 ± 0.07 | 1.03 ± 0.04 | µm | 4.88 × 10−2 | yes |
Sda | 3463 ± 155 | 2844 ± 136 | µm² | 3.80 × 10−3 | yes |
Sha | 3475 ± 143 | 3060 ± 138 | µm² | 3.10 × 10−2 | yes |
Sdv | 104 ± 9 | 71 ± 6 | µm³ | 3.10 × 10−3 | yes |
Shv | 129 ± 10 | 83 ± 6 | µm³ | 4.90 × 10−4 | yes |
Functional parameters | |||||
Sk | 0.67 ± 0.01 | 0.69 ± 0.01 | µm | 3.07 × 10−1 | no |
Spk | 0.52 ± 0.02 | 0.36 ± 0.01 | µm | 9.99 × 10−6 | yes |
Svk | 0.33 ± 0.02 | 0.35 ± 0.01 | µm | 4.23 × 10−1 | no |
Smr1 | 11.8 ± 0.3 | 9.9 ± 0.2 | % | 9.99 × 10−6 | yes |
Smr2 | 89.3 ± 0.2 | 88.3 ± 0.2 | % | 4.90 × 10−3 | yes |
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Lipiński, D.; Banaszek, K.; Rypina, Ł. Analysis of the Cutting Abilities of the Multilayer Grinding Wheels—Case of Ti-6Al-4V Alloy Grinding. Materials 2022, 15, 22. https://doi.org/10.3390/ma15010022
Lipiński D, Banaszek K, Rypina Ł. Analysis of the Cutting Abilities of the Multilayer Grinding Wheels—Case of Ti-6Al-4V Alloy Grinding. Materials. 2022; 15(1):22. https://doi.org/10.3390/ma15010022
Chicago/Turabian StyleLipiński, Dariusz, Kamil Banaszek, and Łukasz Rypina. 2022. "Analysis of the Cutting Abilities of the Multilayer Grinding Wheels—Case of Ti-6Al-4V Alloy Grinding" Materials 15, no. 1: 22. https://doi.org/10.3390/ma15010022
APA StyleLipiński, D., Banaszek, K., & Rypina, Ł. (2022). Analysis of the Cutting Abilities of the Multilayer Grinding Wheels—Case of Ti-6Al-4V Alloy Grinding. Materials, 15(1), 22. https://doi.org/10.3390/ma15010022