Development and Key Technologies of Ultra-High Speed Grinding
Abstract
Ultra-High Speed Grinding (UHSG) is a new technology developed in the late 1980s and early 1990s, which has been developed rapidly in recent years and has become one of the most commonly used finishing methods in many machining fields. UHSG is a highly efficient grinding process with a high degree of abrasive utilization and high speed, capable of producing high-quality surface finish and accurately controlling the machined surface shape. This paper reviews the development and key technologies of UHSG, providing a reference for further application and development of UHSG.
Keywords: Ultra-High Speed Grinding; Abrasive utilization rate; Surface finish
1. Introduction
With the rapid development of manufacturing industry and the increasingly strict requirements of product quality, the traditional honing, lapping, polishing or grinding techniques can not meet the current needs, and the traditional finishing techniques have gradually been replaced by the new finishing technology of ultra-high speed grinding (UHSG). UHSG is a new kind of machining technology developed in the late 1980s and early 1990s, which has a high abrasive utilization rate and a very high efficiency. It is suitable for the processing of various metals, ceramics and other materials, and can produce high-quality surface finish and accurately control the machined surface shape. UHSG is widely used in many fields such as aerospace and automobile, bearing, cutting tools and optical components. This paper reviews the development status and key technologies of UHSG, providing references for further application and development of UHSG.
2. Historical Development and Current Development Status of UHSG
The key technologies of UHSG appeared in the late 1980s and early 1990s, becoming increasingly mature in the late 1990s and early 2000s. Since then, UHSG has been widely used in many industries and its research has also been continuously deepened and improved.
UHSG uses advanced grinding machines and abrasive tools to realize different grinding processes such as plunge grinding, oscillating grinding, reciporatory grinding, centerless grinding and other external grinding processes. The cutting speed of UHSG can reach up to several hundred meters per second, far higher than the normal grinding speed. A new type of abrasive tool and grinding wheel is used for UHSG – Superabrasive grinding wheel. It has high hardness, long wear resistance, can evenly transfer the cutting heat, and can control the temperature of grinding zone and grinding force to prevent thermal deformation of workpiece.
With the development of cutting and grinding tools, the research on grinding processes and optimization of grinding path in UHSG is also growing, and the research on grinding forces and getting the real-time information of the surface of the grinding zone is also gradually improved to better master the grinding condition and improve the surface finish accuracy. In addition, experimental studies on the thermal behavior of high speed grinding zone, as well as further study of grinding fluid, grinding magnetic field and high speed vibration adaptivity, are also being carried out.
3. Key Technologies of UHSG
3.1 Abrasive Wheel and Grinding Machine
UHSG uses special abrasive tool and grinding wheel to transfer the heat generated by the grinding process, ensure that the grinding force is evenly distributed on the grinding surface, and reduce the grinding force on the grinding area. Simultaneously, the abrasive tool and grinding wheels should have high efficiency, high wear resistance, large grinding capacity and other properties. Therefore, the abrasive tool and grinding wheel used in UHSG must have good properties, such as high hardness, good grindability, strong abrasiveness, good formability and thermal stability. In addition, appropriate grinding machines should be chosen for UHSG to realize different grinding processes with high efficiency and meet the demands of high production rate.
3.2 Grinding Path Optimization
The grinding path is essential to the UHSG. In order to obtain the required surface finish and shape tolerance, a reasonable grinding path should be chosen. On the basis of traditional grinding conditions, many unreasonable grinding procedures can be changed and optimized. The optimization of grinding path includes optimization of grinding procedure, grinding speed and grinding position. The optimization can improve the grinding efficiency, reduce grinding force and improve the accuracy of machined surface.
3.3 Grinding forces and temperature
In UHSG, the grinding forces are mainly composed of cutting forces, chip formation forces, chip–tool interaction forces, grinding zoning forces and grinding temperature. These grinding forces should be reasonably used to control the grinding zone temperature, so as to reduce the damage to the abrasive tools and grinding wheels and improve the processing quality. Experimental studies can be carried out to analyze the actual grinding forces and temperatures of UHSG to better determine the grinding parameters and obtain the required machined surface.
3.4 Grinding Fluid
The grinding fluid is an important factor in UHSG and plays an important role in cooling and lubrication of grinding zone. It can reduce the grinding temperature and grinding forces, thus reducing the grinding wear and improving the machining quality of UHSG. In addition, it can also reduce the grinding noise and generate better machined surface shape. However, the grinding fluid concentration, type, pH and temperature etc. should also be carefully chosen.
3.5 Research on Magnetic Grinding and Vibration Grinding Adaptability
The research on magnetic grinding and vibration grinding adaptability in UHSG mainly focuses on the effects of magnetic field strength and vibration frequency on the machined surface shape and the related pressure distribution and heat transfer. This research includes experimental study of machined surface shape under different magnetic field and vibration conditions, research on grinding pressure and heat transfer under different magnetic field and vibration conditions, and research on the optimization of grinding parameters under different conditions. The knowledge obtained from this research can effectively improve the machining accuracy and surface quality of UHSG.
4.Conclusion
Ultra-high speed grinding (UHSG) is a new finishing technology developed in the late 1980s and early 1990s, with a high abrasive utilization rate, high speed and high efficiency. It is suitable for the processing of various metals, ceramics and other materials, and can produce high-quality surface finish and accurately control the machined surface shape. This paper reviews the development and key technologies of UHSG, including abrasive wheel and grinding machine, grinding path optimization, grinding forces and temperature, grinding fluid, magnetic grinding and vibration grinding adaptability. The research and application of UHSG will be continuously deepened in the future and have a wide application prospect.
