Fritz Klocke on Grinding - Book Information

Contents
Symbols and Abbreviations ............................................................................ XIII
1 Introduction ........................................................................................................1
2 Principles of Cutting Edge Engagement...........................................................3
2.1 Cutting Edge Form.......................................................................................4
2.2 Cutting Edge Engagement ...........................................................................7
2.3 Distribution of Force and Energy in the Grinding Process ........................11
2.4 Grit and Bond Wear...................................................................................14
3 Structure and Composition of Grinding Wheels ...........................................17
3.1 Grit Material ..............................................................................................17
3.1.1 Natural Grit Materials ........................................................................17
3.1.2 Synthetic Grit Materials .....................................................................19
3.2 Bonds .........................................................................................................37
3.2.1 Resin Bonds........................................................................................38
3.2.2 Vitrified Bonds...................................................................................39
3.2.3 Metallic Bonds ...................................................................................40
3.2.4 Other bonds ........................................................................................40
3.2.5 Fillers and Additives ..........................................................................41
3.3 Tool Structure and Designation .................................................................42
3.3.1 Composition of Conventional Grinding Wheels ................................43
3.3.2 The Designation of Conventional Tools.............................................45
3.3.3 Composition of Superabrasive Grinding Wheels ...............................50
3.3.4 The Designation of Superabrasive Grinding Wheels .........................51
3.4 Tool Manufacture ......................................................................................54
3.4.1 The Manufacture of Tools with Conventional Abrasives...................54
3.4.2 The Manufacture of Superabrasive Grinding Wheels ........................58
3.5 Tool Testing...............................................................................................61
3.5.1 Hardness Testing ................................................................................62
3.5.2 Investigations in Grit Break-out .........................................................64
3.6 Abrasive Belts (Coated Abrasives) ............................................................66
3.6.1 Composition of Abrasive Belts ..........................................................66
3.6.2 The Manufacture and Structure of Abrasive Belts .............................66
VIII Contents
4 The Machinability of Various Materials ........................................................73
4.1 The Concept of “Machinability” in the Grinding Process ......................... 73
4.2 Influencing the Material Properties of Steels.............................................74
4.2.1 Material Properties as a Function of Carbon Content ........................74
4.2.2 The Influence of Alloying Elements on Material Properties..............77
4.2.3 Material Properties as a Function of Heat Treatment.........................79
4.3 The Structure of Various Steel Materials...................................................83
4.3.1 Case-Hardened Steels.........................................................................83
4.3.2 Heat-Treated Steels ............................................................................84
4.3.3 Nitrided Steels....................................................................................86
4.3.4 Roller Bearing Steels..........................................................................87
4.3.5 Tool Steels..........................................................................................88
4.3.6 Non-Corrosion, Fireproof and High-Temperature Steels...................89
4.4 Grinding Various Structural Components in Steels...................................91
4.5 Grinding Iron-Casting Materials................................................................92
4.6 Grinding Nickel-Based Materials ..............................................................94
4.6.1 Construction and Structure.................................................................94
4.6.2 Properties and Uses ............................................................................96
4.6.3 Grinding Behaviour – Influences on the Grinding Process ................96
4.7 Grinding Titanium Materials .....................................................................99
4.7.1 Construction and Structure.................................................................99
4.7.2 Properties and Uses ..........................................................................102
4.7.3 Grinding Behaviour – Influences on the Grinding Process ..............103
4.8. Grinding Brittle Materials.......................................................................105
4.8.1 The Machining Behaviour of Brittle Materials ................................106
4.8.2 Machining High-Performance Ceramics..........................................107
4.8.3 Glass Machining...............................................................................108
4.8.4 Silicon ..............................................................................................110
5 Cooling Lubricants.........................................................................................113
5.1 Principles of Cooling Lubricants in the Grinding Process.......................113
5.1.1 General Functions ............................................................................113
5.1.2 The Tribological System of Grinding...............................................114
5.1.3 Requirements of Cooling Lubricants in the Grinding Process .........114
5.2 Classification, Structure and Properties...................................................116
5.2.1 Oils...................................................................................................116
5.2.2 Emulsions.........................................................................................117
5.2.3 Aqueous Solutions ...........................................................................119
5.2.4 Use of Additives...............................................................................119
5.3 The Influence of Cooling Lubrication on the Grinding Process ..............120
5.3.1 Cooling Lubricant Type ...................................................................120
5.3.2 Cooling Lubricant Supply ................................................................123
5.4 Supervision, Maintenance and Disposal ..................................................129

6 Grinding ..........................................................................................................135
6.1 Preparation...............................................................................................135
6.1.1 Dressing Kinematics.........................................................................136
6.1.2 Sharpening........................................................................................142
6.1.3 Further Dressing Methods – Special Methods..................................146
6.1.4 Cleaning ...........................................................................................152
6.1.5 Dressing Variables and Effective Mechanisms – The Influence of
 Tool Preparation on the Grinding Process .......................................153

6.2 Parameters................................................................................................161

6.3. Methodological Variants according to DIN 8589...................................177
6.3.1 Introduction ......................................................................................177
6.3.2 External Cylindrical Grinding ..........................................................182
6.3.3 Internal Cylindrical Grinding ...........................................................210
6.3.4 Surface Grinding ..............................................................................212
6.3.5 Coated Abrasives..............................................................................215

6.4 Other Variants..........................................................................................227
6.4.1 Gear Grinding...................................................................................227
6.4.2 Gear Honing .....................................................................................248

6.5 Process Design.........................................................................................251
6.5.1 The Influence of Variables and Parameters on the Result................251
6.5.2 The Influence of the Grinding Tool on the Output...........................269
6.5.3 Multistage Processes ........................................................................273
6.5.4 Disturbances.....................................................................................280

6.6 Application Examples..............................................................................287
6.6.1 External Cylindrical Peripheral Plunge Grinding.............................287
6.2.2 External Form Grinding ...................................................................290
6.6.3 Internal Cylindrical Peripheral Plunge Grinding..............................293
6.6.4 Centreless Plunge Grinding..............................................................296
6.6.5 Surface Peripheral Plunge Grinding.................................................299


10 Process Monitoring.......................................................................................390
10.1 The Necessity of Process Monitoring ....................................................390
10.2 Sensors for Process Monitoring.............................................................392
10.2.1 Force Sensors .................................................................................392
10.2.2 Current Sensors ..............................................................................393
10.2.3 AE-Sensors.....................................................................................394
10.3 First Contact Control .............................................................................397
10.4 Collision Monitoring .............................................................................400
10.5 Dressing Monitoring..............................................................................401
10.6 Service Life Monitoring while Grinding Using AE...............................403
10.6.1 Monitoring Grinding Wheel Wear with the AE Effective Value ...403
10.6.2 Detecting Chattering ......................................................................404
10.6.3 Process Step Recognition as an Element of Reliable Monitoring ..405
10.7 Control of Workpiece Properties ...........................................................406
10.8 Reliability of Process Monitoring..........................................................408