Ioan D. Marinescu

Tribology of Abrasive Machining Processes

This book draws upon the science of tribology to understand, predict and improve abrasive machining processes. Pulling together information on how abrasives work, the authors, who are renowned experts in abrasive technology, demonstrate how tribology can be applied as a tool to improve abrasive machining processes. Each of the main elements of the abrasive machining system are looked at, and the tribological factors that control the efficiency and quality of the processes are described. Since grinding is by far the most commonly employed abrasive machining process, it is dealt with in particular detail. Solutions are posed to many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid wheel wear, vibrations, work-piece burn and high process costs. This practical approach makes this book an essential tool for practicing engineers. Uses the science of tribology to improve understanding and of abrasive machining processes in order to increase performance, productivity and surface quality of final products. A comprehensive reference on how abrasives work, covering kinematics, heat transfer, thermal stresses, molecular dynamics, fluids and the tribology of lubricants. Authoritative and ground-breaking in its first edition, the 2nd edition includes 30 per cent new and updated material, including new topics such as CMP (Chemical Mechanical Polishing) and precision machining for micro-and nano-scale applications.

Handbook of Lapping and Polishing

INTRODUCTION Ioan Marinescu From Craft to Science Importance of the Abrasive Problem Solving References FUNDAMENTALS OF LAPPING Eckart Uhlmann General Considerations Historical Development of Lapping Definition of Lapping and Classification of Lapping Processes Process Mechanisms and Subsurface Damage in Lapping Lapping Process as a Removal System Tool Specification Machine Settings Fundamentals of Planetary Kinematics Process Models and Simulation Symbols and Abbreviations References LAPPING OF DUCTILE MATERIALS Ioan Marinescu, Ion Benea, and Naga Jyothi Sanku Introduction Physics of the Process Mechanism of the Process References Bibliography LAPPING OF BRITTLE MATERIALS Ioan Marinescu, Ion Benea, and Mariana Pruteanu Introduction Background Information Nontraditional Lapping Processes ELID-Lap Grinding Materials, Experimental Setup, and Testing Procedure (Study Case) Experimental Results and Discussion References Bibliography Appendix A Appendix B LAPPING AND LAPPING MACHINES Toshiro K. Doi and Daizo Ichikawa Introduction Processing Principles of Lapping and Its Characteristics Lapping Machine Both-Sides Simultaneous Lapping Machine Equipped with a New Micromotion Mechanism Conclusions POLISHING TECHNOLOGY Toshiro K. Doi Polishing Principles Processing Accuracy and Damaged Layer Polishing Machines Mechanochemical Polishing and Chemical Mechanical Polishing Noncontact Polishing Magnetoabrasive Finishing Polishing Process Applying Electrophoretic Deposition Electroabrasive Mirror Polishing Process P-MAC Polishing Colloidal Silica Polishing References CHEMICAL MECHANICAL POLISHING AND ITS APPLICATIONS IN ULSI PROCESS Toshiro K. Doi Orientations and Role of CMP in Semiconductor Process Basic Concept of Planarization CMP Basic Technology of Planarization CMP The Study Case of Device Wafer Thin Film Magnetic Recording Heads CMP of Compound Semiconductor Wafers References INDEX

Handbook of advanced ceramics machining

DUCTILE GRINDING OF CERAMICS: MACHINE TOOL AND PROCESS H. Eda Ceramics and Metals Brittle Materials and Grinding In-Site Observation of Ductile Behavior in Ceramics Ductile-Mode Grinding of Ceramics Machine Tools for Ductile Grinding of Ceramics References DUCTILE-MODE ULTRA-SMOOTHNESS GRINDING OF FINE CERAMICS WITH COARSE-GRAIN-SIZE DIAMOND WHEELS H. Yasui Introduction Ductile-Mode Grinding with #140 Mesh Wheel Ultrasmoothness Grinding Conclusion References MECHANISMS FOR GRINDING OF CERAMICS S. Malkin and T.W. Hwang Introduction Indentation Fracture Mechanics Approach Machining Approach Concluding Remarks References GRINDING OF CERAMICS WITH ATTENTION TO STRENGTH AND DEPTH OF GRINDING DAMAGE J.E. Mayer Jr. Introduction Ceramic Materials Experimental Procedure Results and Discussion Conclusions References HIGHLY EFFICIENT AND ULTRAPRECISION FABRICATION OF STRUCTURAL CERAMIC PARTS WITH THE APPLICATION OF ELECTROLYTIC IN-PROCESS DRESSING GRINDING B.P. Bandyopadhyay, H. Ohmori, and A. Makinouchi Introduction ELID Grinding Principle Experimental Setup Results and Discussions Conclusions Acknowledgements References ELECTROLYTIC IN-PROCESS DRESSING GRINDING OF CERAMIC MATERIALS H. Ohmori and K. Katahira Introduction ELID Grinding Technique Efficient and Precision ELID Centerless Grinding of Zirconia Ceramics ELID Grinding Characteristics for the Machining of Optical Surface Quality for Ceramic Spherical Lens Molds ELID Grinding Characteristics and Surface Modifying Effects of Aluminum Nitride Ceramics Acknowledgements References HIGH-EFFICIENCY BELT CENTERLESS GRINDING OF CERAMIC MATERIALS AND HARDENED TOOL STEEL G. Dontu, D. Wu, and I.D. Marinescu Introduction Definition of the Problem Objectives Experiments for Ceramic Materials Results Preliminary Conclusions Experimental Plan for M7 Hardened Tool Steel Drill Bar The Problem Encountered and Possible Reasons Remaining Work Benefits to Companies Related Work Outside AMMC Related Work Inside AMMC AE MONITORING OF THE LAPPING PROCESS M. Pruteanu, R. Coman, and I.D. Marinescu Introduction Related Work Methodology Experimental Results Conclusions Remaining Work EFFECTIVENESS OF ELID GRINDING AND POLISHING C.E. Spanu and I.D. Marinescu Introduction Material Removal Mechanisms in Grinding of Ceramics and Glasses ELID Technique as Compared to Other Grinding Techniques Applications of ELID Technique Summary and Conclusions References MONO VERSUS POLYCRYSTALLINE DIAMOND LAPPING OF CERAMICS M. Pruteanu, I. Benea, and I.D. Marinescu Introduction Experimental Methodology Experimental Results Remaining Work References DOUBLE FRACTURE MODEL IN LAPPING OF CERAMICS I.D. Marinescu Introduction Double Fracture Model Experimental Procedures Conclusions DOUBLE SIDE GRINDING OF ADVANCED CERAMICS WITH DIAMOND WHEELS C.E. Spanu, I.D. Marinescu, and Mike Hitchiner Introduction Kinematical Model for the Double Side Grinding Operation Trajectory Simulation Experimental Validation Discussion of Results Conclusions References SUPER POLISHING OF MAGNETIC HEADS J. Ramirez-Salas and I.D. Marinescu Introduction Related Work Methodology Experimental Results Remaining Work LASER-ASSISTED GRINDING OF CERAMICS I.D. Marinescu and T.D. Howes Objectives Problem Statement Stock Removal Mechanism Conclusions Future Directions Bibliography TRIBOLOGICAL PROPERTIES OF ELID-GRINDING WHEEL BASED ON IN-PROCESS OBSERVATION USING A CCD MICROSCOPE TRIBOSYSTEM T. Kato, H. Ohmori, and I.D. Marinescu Introduction Experimental Method Experimental Result and Discussion Consideration for ELID-Grinding from the Viewpoint of Tribology Conclusions References DEVELOPMENTS IN MACHINING OF CERAMIC MATERIALS E. Uhlmann, S.-E. Holl, Th. Ardelt, and J. Laufer Introduction Honing Grinding with Lapping Kinematics Cooling Lubrication in Grinding of Ceramic Materials References ULTRASONIC MACHINING OF CERAMICS G. Spur, E. Uhlmann, E.-E. Holl, and N.-A. Daus Introduction Ultrasonic Technology Technology of Ultrasonic Lapping Ultrasonic-Assisted Grinding Process Comparison References INDEX

Detailed Study of Fluid Flow and Heat Transfer in the Abrasive Grinding Contact Using Computational Fluid Dynamics Methods

This paper introduces a set of research oriented computational fluid dynamics (CFD) 3D models used to simulate the fluid flow and heat transfer in a grinding process. The most important features of these models are described and some representative simulation results are presented, along with comparisons to published experimental data. Distributions of temperatures, pressures, velocities, and liquid volume fractions in and around the grinding region are obtained in great detail. Such results are essential in studying the influence of the fluid on the grinding process, as well as in determining the best fluid composition and supply parameters for a given application. The simulation results agree well with experimental global flow rates, temperature, and pressure values, showing the feasibility of CFD simulations in grinding applications.

Effect of different methods of cutting fluid application on turning of a difficult-to-machine steel (SAE EV-8)

In this study, different methods of cutting fluid application are used in turning of a difficult-to-machine steel (SAE EV-8). Initially, a semisynthetic cutting fluid was applied using a conventional method (i.e. overhead flood cooling), minimum quantity of cutting fluid, and pulverization. A lubricant of vegetable oil (minimum quantity of lubricant) was also applied using the minimum quantity method. Thereafter, a cutting fluid jet under high pressure (3.0 MPa) was singly applied in the following regions: chip–tool interface, top surface of the chip (between workpiece and chip) and tool–workpiece contact. Moreover, two other methods were used: an interflow between conventional application and chip–tool interface jet (combined method) and, finally, three jets simultaneously applied. In order to carry out these tests, it was necessary to set up a high-pressure system using a piston pump for generating a cutting fluid jet, a venturi for fluid application (minimum quantity of cutting fluid and minimum quantity of lubricant) and a nozzle for cutting fluid pulverization. The output variables analyzed included tool life, surface roughness, cutting tool temperature, cutting force, chip form, chip compression rate and machined specimen microstructure. Among the results, it can be observed that the tool life increases and the cutting force decreases with the application of cutting fluid jet, mainly when it is directed to the chip–tool interface. Excluding the methods involving jet fluid, the conventional method seems to be more efficient than other methods of low pressure, such as minimum quantity of volume and pulverization, when considering just the cutting tool wear.

GREEN MACHINING ORIENTED TO DIMINISH DENSITY GRADIENT FOR MINIMIZATION OF DISTORTION IN ADVANCED CERAMICS

After sintering advanced ceramics, there are invariably distortions, caused in large part by the heterogeneous distribution of density gradients along the compacted piece. To correct distortions, machining is generally used to manufacture pieces within dimensional and geometric tolerances. Hence, narrow material removal limit conditions are applied, which minimize the generation of damage. Another alternative is machining the compacted piece before sintering, called the green ceramic stage, which allows machining without damage to mechanical strength. Since the greatest concentration of density gradients is located in the outer-most layers of the compacted piece, this study investigated the removal of different allowance values by means of green machining. The output variables are distortion after sintering, tool wear, cutting force, and the surface roughness of the green ceramics and the sintered ones. The following results have been noted: less distortion is verified in the sintered piece after 1 mm allowance removal; and the higher the tool wear the worse the surface roughness of both green and sintered pieces.

ELID Fine Grinding of SiC Bearing Rollers

Electrolytic in-process dressing (ELID) grinding is drawing more and more attention by the researchers for its smart method of in-process dressing of the grinding wheel. Many researches place emphasis on study of in-processing dressing and oxide layer. In this study, the effects of three grinding factors, including wheel speed, load applied on workpiece and eccentricity of three parts in one holder, on surface roughness (Ra) and material removal rate (MRR) were investigated in a single-side ELID grinding experiment. Each factor has three levels. The experimental results show that each factor has different influence: 1. Applied load is the main factor which significantly affects the Ra and MRR; 2. the speed of grinding wheel doesn’t show much influence; 3. eccentricity has a great influence on roughness but not on material removal rate.

The influence of wheel grain size on the surface roughness in ELID fine grinding of SiC ceramics

The demand for silicon carbide ceramics has increased significantly in the last decade due to its reliable properties. Sometimes, single side grinding is preferable over surface grinding, because it has the ability to produce flat surfaces. However, the manufacturing cost is still high because of the high tool wear and long machining time. Additionally, most of these grinding processes are followed by a lapping process. One of the ways to eliminate the lapping process is to use electrolysis in process dressing technique (ELID). Part of the solution also entails investigating the influence of different variables on the workpiece surface finish. This paper presents the influence of different grain size on roughness. In order to do this based on the experimental results, a full factorial experiment was developed for each grit size (wheel) on three levels of each variable: the spindle and wheel speed, the applied load and eccentricity. These four variables have been investigated for each grinding wheel mesh size and a model has been established for each wheel individually. The influence of using different grinding wheel mesh size is then founded.

Investigation on Surface Finishing of Components Ground with Lapping Kinematics: Lapgrinding Process

Over the last three decades, researchers have responded to the demands of industry to manufacture mechanical components with geometrical tolerance, dimensional tolerance, and surface finishing in nanometer levels. The new lapgrinding process developed in Brazil utilizes lapping kinematics and a flat grinding wheel dressed with a single-point diamond dresser in agreement with overlap factor (Ud) theory. In the present work, the influences of different Ud values on dressing (Ud = 1, 3 e 5) and grain size of the grinding wheel made of silicon carbide (SiC = 800, 600 e 300 mesh) are analyzed on surface finishing of stainless steel AISI 420 flat workpieces submitted to the lapgrinding process. The best results, obtained after 10 minutes of machining, were: average surface roughness (Ra) 1.92 nm; 1.19 µm flatness deviation of 25.4 mm diameter workpieces and mirrored surface finishing. Given the surface quality achieved, the lapgrinding process can be included among the ultra-precision finishing processes and, depending on the application, the steps of lapping followed by polishing can be replaced by the proposed abrasive process.

3-D CFD Parametric Study of the Impact of the Fluid Properties and Delivery Conditions on Flow and Heat Transfer in Grinding

Fluids have an important role in grinding. Correct fluid application results in enhanced process stability, better work piece quality, and tool life. This paper shows that Computational Fluid Dynamics (CFD) models can be used to simulate the fluid flow and heat transfer in a grinding process, replacing numerous experiments that are expensive, time-consuming, and have limited capabilities. The most important properties of created 3-D model are described, along with results obtained. The results show very detailed distributions of temperatures, pressures, and flow rates in and around the grinding region. The data obtained is essential in studying the influence of the grinding fluid on the grinding process, as well as in determining the best fluid composition and supply parameters for a given application. The results agree well with experimental global flow rates and temperature values and show the feasibility of 3-D CFD-based simulations in grinding applications. The parametric studies of influence of several fluid physical properties on useful flow rates and temperatures were presented as well.