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Abrasives and Bonded Abrasives An abrasive is a small, hard particle having sharp edges and an irregular shape. Abrasives are capable of removing small amounts of material through a cutting process that produces tiny chips.
Abrasives and Bonded Abrasives Commonly used abrasives in abrasive machining are:
Conventional Abrasives
Aluminum Oxide Silicon Carbide
Superabrasives
Cubic boron nitride Diamond
Friability
Characteristic of abrasives. Defined as the ability of abrasive grains to fracture into smaller pieces, essential to maintaining sharpness of abrasive during use. High friable abrasive grains fragment more under grinding forces, low friable abrasive grains fragment less.
Abrasive Types
Abrasives commonly found in nature include:
Emery Corundum Quartz Garnet Diamond
Abrasive Types
Synthetically created abrasives include:
Aluminum oxide (1893) Seeded gel (1987) Silicon carbide (1891) Cubic-boron nitride (1970s) Synthetic diamond (1955)
Grinding Wheels
Large amounts can be removed when many grains act together. This is done by using bonded abrasives.
This is typically in the form of a grinding wheel. The abrasive grains in a grinding wheel are held together by a bonding material.
Bonding Abrasives
Bonding materials act as supporting posts or braces between grains. Bonding abrasives are marked with letters and numbers indicating:
Type of abrasive Grain size Grade Structure Bond type
Bond Types
Vitrified: a glass bond, most commonly used bonding material.
However, it is a brittle bond.
Bond Types
Reinforced Wheels: bond consisting of one or more layers of fiberglass.
Prevents breakage rather than improving strength.
Rubber: flexible bond type, inexpensive. Metal: different metals can be used for strength, ductility, etc.
Most inexpensive bond type.
(a)
(b)
Grinding Forces
A knowledge of grinding forces is essential for:
Estimating power requirements. Designing grinding machines and workholding fixtures and devices. Determining the deflections that the workpiece as well as the grinding machine may undergo. Deflections adversely affect dimensioning.
Grinding Forces
Forces in grinding are usually smaller than those in machining operations because of the smaller dimensions involved. Low grinding forces are recommended for dimensional accuracy.
Wear flats rub along the ground surface, creating friction, and making grinding very inefficient.
Tempering
Excessive heat, often times from friction, can soften the work-piece.
Burning
Excessive heat may burn the surface being ground. Characterized as a bluish color on ground steel surfaces.
Grain Fracture
Abrasive grains are brittle, and their fracture characteristics are important. Wear flat creates unwanted high temps. Ideally, the grain should fracture at a moderate rate so as to create new sharp cutting edges continuously.
Bond Fracture
The strength of the abrasive bond is very important! If the bond is too strong, dull grains cannot dislodge to make way for new sharp grains.
Hard grade bonds are meant for soft materials.
If too weak, grains dislodge too easily and the wear of the wheel increases greatly.
Soft grade bonds are meant for hard materials.
Grinding Ratio
G = (Volume of material removed)/ Volume of wheel wear) The higher the ratio, the longer the wheel will last. During grinding, the wheel may act soft or hard regardless of wheel grade.
Ex: pencil acting hard on soft paper and soft on rough paper.
Grinding Operations and Machines Surface Grinding Cylindrical Grinding Internal Grinding Centerless Grinding Creep-feed Grinding Heavy Stock Removal by Grinding Grinding fluids
Design Consideration for Grinding Part design should include secure mounting into workholding devices. Holes and keyways may cause vibration and chatter, reducing dimensional accuracy. Cylindrically ground pieces should be balanced. Fillets and radii made as large as possible, or relieved by prior machining.
Design Considerations for Grinding Long pieces are given better support in centerless grinding, and only the largest diameter may be ground in through-feed grinding. Avoid frequent wheel dressing by keeping the piece simple. A relief should be include in small and blind holes needing internal grinding.
Finishing Operations
Coated abrasives Belt Grinding Wire Brushing Honing Superfinishing Lapping Chemical-Mechanical Polishing Electroplating
Finishing Operations
Coated Abrasives have a more pointed and open structure than grinding wheels Belt Grinding high rate of material removal with good surface finish
Finishing Operations
Wire Brushing produces a fine or controlled texture Honing improves surface after boring, drilling, or internal grinding
Finishing Operations
Superfinishing very light pressure in a different path to the piece Lapping abrasive or slurry wears the pieces ridges down softly
Finishing Operations
Chemicalmechanical Polishing slurry of abrasive particles and a controlled chemical corrosive Electropolishing an unidirectional pattern by removing metal from the surface
Deburring Operations
Manual Deburring Mechanical Deburring Vibratory and Barrel Finishing Shot Blasting Abrasive-Flow Machining Thermal Energy Deburring Robotic Deburring
Deburring Operations
Vibratory and Barrel Finishing abrasive pellets are tumbled or vibrated to deburr Abrasive-flow Machining a putty of abrasive grains is forced through a piece
Deburring Operations
Thermal Energy Deburring natural gas and oxygen are ignited to melt the burr Robotic Deburring uses a force-feedback program to control the rate and path of deburring
Creep-feed grinding is an economical alternative to other machining operations. The use of abrasives and finishing operations achieve a higher dimensional accuracy than the solitary machining process. Automation has reduced labor cost and production times. The greater the surface-finish, the more operations involved, increases the product cost. Abrasive processes and finishing processes are important to include in the design analysis for pieces requiring a surface finish and dimensional accuracy.
Chemical Machining
Chemical machining
Uses chemical dissolution to dissolve material from the workpiece. Can be used on stones, most metals and some ceramics. Oldest of the advanced machining processes.
Chemical Machining
Chemical milling - shallow cavities are produced on
plates, sheets, forgings, and extrusions, generally for the overall reduction of weight. Can be used with depths of metal removal as large as 12 mm. Masking is used to protect areas that are not meant to be attacked by the chemical.
Chemical Machining
Chemical Blanking similar to the blanking of sheet metals with the exception that the material is removed by chemical dissolution rather than by shearing.
Printed circuit boards. Decorative panels. Thin sheet-metal stampings. Complex or small shapes.
Chemical Machining
Surface Roughness and Tolerance table
Chemical Machining
Photochemical blanking/machining
Modification of chemical milling. Can be used on metals as thin as .0025 mm.
Applications
Fine screens. Printed circuit boards. Electric-motor laminations. Flat springs. Masks for color televisions.
Chemical Machining
Chemical machining design considerations
No sharp corners, deep or narrow cavities, severe tapers, folded seam, or porous workpiece materials. Undercuts may develop. The bulk of the workpiece should be shaped by other processes prior to chemical machining.
Electrochemical Machining
Electrochemical machining (ECM)
An electrolyte acts as a current carrier which washes metal ions away from the workpiece (anode) before they have a chance to plate on the tool (cathode). The shaped tool is either solid or tubular. Generally made of brass, copper, bronze or stainless steel. The electrolyte is a highly conductive inorganic fluid.
Electrochemical Machining
Electrochemical machining cont.
The cavity produced is the female mating image of the tool shape.
Process capabilities
Generally used to machine complex cavities and shapes in high strength materials.
Design considerations
Not suited for producing sharp square corners or flat bottoms. No irregular cavities.
Electrochemical Machining
Electrochemical Machining
Pulsed electrochemical machining (PECM)
Refinement of ECM. The current is pulsed instead of a direct current. Lower electrolyte flow rate. Improves fatigue life. Tolerance obtained 20 to 100 micro-meters.
(a) (b)
Electrochemical Grinding
Electrochemical grinding (ECG)
Combines ECM with conventional grinding. Similar to a conventional grinder, except that the wheel is a rotating cathode with abrasive particles.
The abrasive particles serve as insulators and they remove electrolytic products from the working area.
Less then 5% of the metal is removed by the abrasive action of the wheel.
Components of operation
Shaped tool Electrode Workpiece Connected to a DC power supply Dielectric Nonconductive fluid
Common fluids
Mineral oils Distilled/Deionized water Kerosene Other clear low viscosity fluids are available which are easier to clean but more expensive
No-wear EDM is defined as the EDM process with reversed polarity using copper electrodes
Design considerations
Design so that electrodes can be simple/economical to produce Deep slots and narrow openings should be avoided Conventional techniques should be used to remove the bulk of material
Wire EDM
Similar to contour cutting with a bandsaw Typically used to cut thicker material
Up to 12 thick Also used to make punches, tools and dies from hard materials
Wire EDM
Wire
Usually made of brass, copper, or tungsten Range in diameter from 0.012 0.008 inches Typically used at 60% of tensile strength Used once since it is relatively inexpensive Travels at a constant velocity ranging from 6-360 in/min Cutting speed is measured in cross sectional area per unit time (varies with material)
18,000 mm^2/hour 28 in^2/hour
Wire EDM
Multiaxis EDM
Computer controls for controlling the cutting path of the wire and its angle with respect to the workpiece plane Multiheads for cutting multiple parts Features to prevent and correct wire breakage Programming to optimize the operation
The focus of optical energy on the surface of the workpiece melts and evaporates portions of the workpiece in a controlled manner
Works on both metallic and non-metallic materials
Important considerations include the reflectivity and thermal conductivity of the material The lower these quantities the more efficient the process
The surface produced is usually rough and has a heat affected zone (discussed in section 30.9)
Process capabilities also include welding, localized heat treating, and marking Very flexible process
Fiber optic beam delivery Simple fixtures Low setup times
Any adverse effects on the properties of the machined materials caused by the high local temperatures and heat affected zones should be investigated
Minimum hole diameter thus far is approximately 0.12 inches Maximum hole depth is approximately 1 inch
References
http://www.electricaldischargemachining.com/ http://www.belmont4edm.com/ http://www.texasairsonics.com/Cabinet%20Style.html