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Search Results (4)

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Keywords = abrasive filament brush

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15 pages, 11573 KiB  
Article
Image-Based Tool Characterization and DEM Simulation of Abrasive Brushing Processes
by Anton Hoyer and Eckart Uhlmann
Machines 2024, 12(3), 171; https://doi.org/10.3390/machines12030171 - 1 Mar 2024
Cited by 1 | Viewed by 2396
Abstract
Brushing with bonded abrasives is a finishing process used for deburring, edge rounding, and roughness reduction. However, due to the complex motion, chipping, and wear behavior of abrasive filaments, industrial brushing processes have historically relied on empirical knowledge. To gain a better understanding [...] Read more.
Brushing with bonded abrasives is a finishing process used for deburring, edge rounding, and roughness reduction. However, due to the complex motion, chipping, and wear behavior of abrasive filaments, industrial brushing processes have historically relied on empirical knowledge. To gain a better understanding of filament interactions, a physical model based on the discrete element method was developed to simulate process forces and contact areas. Filament patterns of round brushes were determined through the use of laser line triangulation and image processing. These filament patterns showed interlocked filaments and yielded more accurate results when used in brushing simulations than the oversimplified square patterns, which were used in previous research. Simulation confirms the occurrence of filament interactions, distinguishes between sweeping and striking filament motions, and reveals dynamic behavior at high brushing velocities that may increase undesirable tool wear. Full article
(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022)
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18 pages, 6304 KiB  
Article
Deliberate Surface Treatment of Zirconium Dioxide with Abrasive Brushing Tools
by Anton Hoyer and Eckart Uhlmann
Ceramics 2022, 5(4), 883-900; https://doi.org/10.3390/ceramics5040064 - 1 Nov 2022
Cited by 2 | Viewed by 2305
Abstract
Brushing with bonded abrasives is a flexible finishing process used to reduce the roughness of technical surfaces. Although industrially widespread, especially for the finishing of metallic surfaces, insufficient knowledge of the motion, the material removal, and the wear behavior of the abrasive filaments [...] Read more.
Brushing with bonded abrasives is a flexible finishing process used to reduce the roughness of technical surfaces. Although industrially widespread, especially for the finishing of metallic surfaces, insufficient knowledge of the motion, the material removal, and the wear behavior of the abrasive filaments complicates predictions of the work result. In particular, the reliable finishing of ceramics with bonded diamond grains proves difficult due to increased material removal rates, quickly leading to undesirable changes in the workpiece geometry. Based on technological investigations with abrasive brushing tools, this article provides insights into the surface finishing of zirconium dioxide with a focus on finding compromises between reduction in the surface roughness and alteration of the workpiece shape. Full article
(This article belongs to the Special Issue Advances in Ceramics)
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11 pages, 7038 KiB  
Article
Numerical and Experimental Research on the Brushing Aluminium Alloy Mechanism Using an Abrasive Filament Brush
by Xiuhua Yuan, Chong Wang, Qun Sun and Ling Zhao
Materials 2021, 14(21), 6647; https://doi.org/10.3390/ma14216647 - 4 Nov 2021
Cited by 2 | Viewed by 2133
Abstract
Abrasive filament brushes have been widely used in surface processes for a wide range of applications, including blending, edge-radiusing, and polishing. However, the associated brush mechanics of material removal is still not clear. In order to analyze the brush grinding of aluminium alloy, [...] Read more.
Abrasive filament brushes have been widely used in surface processes for a wide range of applications, including blending, edge-radiusing, and polishing. However, the associated brush mechanics of material removal is still not clear. In order to analyze the brush grinding of aluminium alloy, this paper constructed a kinematic model of a single filament, simulated the scratch process of a single abrasive grain, and investigated the brush force and material removal based on the finite element approach. The simulated result shows that the brush grinding can be changed from elastic–plastic deformation to chip formation when increasing the brush speed to 1000 r/min. The normal and tangential forces increase linearly and quadratically with the increase in the rotation speed (500–5000 r/min), respectively, and increase linearly with the increase in the penetration depth (0.1–1 mm), which is consistent with the experiment results. In addition, the amount of material removal initially increases with the increase in penetration depth, and then decreases. This paper provides a new approach to understanding the process of material removal and is helpful for the selection of reasonable brush parameters in the intelligent grinding control application. Full article
(This article belongs to the Special Issue Advances in Computational Materials Tribology)
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11 pages, 3072 KiB  
Article
Modeling of Contact Forces for Brushing Tools
by Eckart Uhlmann and Anton Hoyer
Ceramics 2021, 4(3), 397-407; https://doi.org/10.3390/ceramics4030029 - 9 Jul 2021
Cited by 5 | Viewed by 4776
Abstract
Brushing with bonded abrasives is a flexible finishing process used for the deburring and the rounding of workpiece edges as well as for the reduction of the surface roughness. Although industrially widespread, insufficient knowledge about the contact behavior of the abrasive filaments mainly [...] Read more.
Brushing with bonded abrasives is a flexible finishing process used for the deburring and the rounding of workpiece edges as well as for the reduction of the surface roughness. Although industrially widespread, insufficient knowledge about the contact behavior of the abrasive filaments mainly causes applications to be based on experiential values. Therefore, this article aims to increase the applicability of physical process models by introducing a new prediction method, correlating the contact forces of single abrasive filaments, obtained by means of a multi-body simulation, with the experimentally determined process forces of full brushing tools during the surface finishing of ZrO2. It was concluded that aggressive process parameters may not necessarily lead to maximum productivity due to increased tool wear, whereas less aggressive process parameters might yield equally high contact forces and thus higher productivity. Full article
(This article belongs to the Special Issue Advances in Ceramics)
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