Handbook ofMachining withGrinding Wheels DK4115_C000.fmPage iTuesday, November 14, 200612:02 PMMANUFACTURING ENGINEERING AND MATERIALS PROCESSINGA Series of Reference Books and TextbooksSERIES EDITORGeoffrey BoothroydBoothroyd Dewhurst, Inc.Wakefield, Rhode Island1. Computers in Manufacturing, U. Rembold, M. Seth, and J. S. Weinstein2. Cold Rolling of Steel, William L. Roberts3. Strengthening of Ceramics: Treatments, Tests, and DesignApplications, Harry P. Kirchner4. Metal Forming: The Application of Limit Analysis, Betzalel Avitzur5. Improving Productivity by Classification, Coding, and Data Base Standardization: The Key to Maximizing CAD/CAM and GroupTechnology, William F. Hyde6. Automatic Assembly, Geoffrey Boothroyd, Corrado Poli, and Laurence E. Murch7. Manufacturing Engineering Processes, Leo Alting8. Modern Ceramic Engineering: Properties, Processing, and Use in Design, David W. Richerson9. Interface Technology for Computer-Controlled ManufacturingProcesses, Ulrich Rembold, Karl Armbruster, and Wolfgang lzmann10. Hot Rolling of Steel, William L. Roberts11. Adhesives in Manufacturing, edited by Gerald L. Schneberger12. Understanding the Manufacturing Process: Key to SuccessfulCAD/CAM Implementation, Joseph Harrington, Jr.13. Industrial Materials Science and Engineering, edited by Lawrence E. Murr14. Lubricants and Lubrication in Metalworking Operations, Elliot S. Nachtman and Serope Kalpakjian15. Manufacturing Engineering: An Introduction to the Basic Functions, John P. Tanner16. Computer-Integrated Manufacturing Technology and Systems, Ulrich Rembold, Christian Blume, and Ruediger Dillman17. Connections in Electronic Assemblies, Anthony J. Bilotta18. Automation for Press Feed Operations: Applications and Economics, Edward Walker19. Nontraditional Manufacturing Processes, Gary F. Benedict20. Programmable Controllers for Factory Automation, David G. Johnson21. Printed Circuit Assembly Manufacturing, Fred W. Kear22. Manufacturing High Technology Handbook, edited by DonatasTijunelis and Keith E. McKee DK4115_C000.fmPage iiTuesday, November 14, 200612:02 PM23. Factory Information Systems: Design and Implementation for CIM Management and Control, John Gaylord24. Flat Processing of Steel, William L. Roberts25. Soldering for Electronic Assemblies, Leo P. Lambert26. Flexible Manufacturing Systems in Practice: Applications, Design, and Simulation, Joseph Talavage and Roger G. Hannam27. Flexible Manufacturing Systems: Benefits for the Low InventoryFactory, John E. Lenz28. Fundamentals of Machining and Machine Tools: Second Edition, Geoffrey Boothroyd and Winston A. Knight29. Computer-Automated Process Planning for World-ClassManufacturing, James Nolen30. Steel-Rolling Technology: Theory and Practice, Vladimir B. Ginzburg31. Computer Integrated Electronics Manufacturing and Testing, Jack Arabian32. In-Process Measurement and Control, Stephan D. Murphy33. Assembly Line Design: Methodology and Applications, We-Min Chow34. Robot Technology and Applications, edited by Ulrich Rembold35. Mechanical Deburring and Surface Finishing Technology, Alfred F. Scheider36. Manufacturing Engineering: An Introduction to the Basic Functions, Second Edition, Revised and Expanded, John P. Tanner37. Assembly Automation and Product Design, Geoffrey Boothroyd38. Hybrid Assemblies and Multichip Modules, Fred W. Kear39. High-Quality Steel Rolling: Theory and Practice, Vladimir B. Ginzburg40. Manufacturing Engineering Processes: Second Edition, Revised and Expanded, Leo Alting41. Metalworking Fluids, edited by Jerry P. Byers42. Coordinate Measuring Machines and Systems, edited by John A. Bosch43. Arc Welding Automation, Howard B. Cary44. Facilities Planning and Materials Handling: Methods andRequirements, Vijay S. Sheth45. Continuous Flow Manufacturing: Quality in Design and Processes, Pierre C. Guerindon46. Laser Materials Processing, edited by Leonard Migliore47. Re-Engineering the Manufacturing System: Applying the Theory of Constraints, Robert E. Stein48. Handbook of Manufacturing Engineering, edited by Jack M. Walker49. Metal Cutting Theory and Practice, David A. Stephenson and John S. Agapiou50. Manufacturing Process Design and Optimization, Robert F. Rhyder51. Statistical Process Control in Manufacturing Practice, Fred W. Kear52. Measurement of Geometric Tolerances in Manufacturing, James D. Meadows53. Machining of Ceramics and Composites, edited by Said Jahanmir, M. Ramulu, and Philip Koshy54. Introduction to Manufacturing Processes and Materials, Robert C. Creese DK4115_C000.fmPage iiiTuesday, November 14, 200612:02 PM55. Computer-Aided Fixture Design, Yiming (Kevin) Rong and Yaoxiang (Stephens) Zhu56. Understanding and Applying Machine Vision: Second Edition, Revised and Expanded, Nello Zuech57. Flat Rolling Fundamentals, Vladimir B. Ginzburg and Robert Ballas58. Product Design for Manufacture and Assembly: Second Edition, Revised and Expanded, Geoffrey Boothroyd, Peter Dewhurst, and Winston A. Knight59. Process Modeling in Composites Manufacturing, edited by Suresh G. Advani and E. Murat Sozer60. Integrated Product Design and Manufacturing Using GeometricDimensioning and Tolerancing, Robert Campbell61. Handbook of Induction Heating, edited by Valery I. Rudnev, Don Loveless, Raymond Cook and Micah Black62. Re-Engineering the Manufacturing System: Applying the Theory of Constraints, Second Edition, Robert Stein63. Manufacturing: Design, Production, Automation, and Integration,Beno Benhabib64. Rod and Bar Rolling: Theory and Applications, Youngseog Lee65. Metallurgical Design of Flat Rolled Steels, Vladimir B. Ginzburg66. Assembly Automation and Product Design: Second Edition, Geoffrey Boothroyd67. Roll Forming Handbook, edited by George T. Halmos68. Metal Cutting Theory and Practice: Second Edition, David A. Stephenson and John S. Agapiou69. Fundamentals of Machining and Machine Tools: Third Edition,Geoffrey Boothroyd and Winston A. Knight70. Manufacturing Optimization Through Intelligent Techniques, R. Saravanan71. Metalworking Fluids: Second Edition, Jerry P. Byers72. Handbook of Machining with Grinding Wheels, Ioan D. Marinescu,Mike Hitchiner, Eckart Uhlmann, W. Brian Rowe, and Ichiro Inasaki DK4115_C000.fmPage ivTuesday, November 14, 200612:02 PMIoan D. MarinescuMike HitchinerEckart UhlmannW. Brian RoweIchiro InasakiHandbook ofMachining withGrinding WheelsCRC Press is an imprint of theTaylor & Francis Group, an informa businessBoca Raton London New York DK4115_C000.fmPage vTuesday, November 14, 200612:02 PMCRC PressTaylor & Francis Group6000 Broken Sound Parkway NW, Suite 300Boca Raton, FL 33487-2742 2007 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa businessNo claim to original U.S. Government worksPrinted in the United States of America on acid-free paper10 9 8 7 6 5 4 3 2 1International Standard Book Number-10: 1-57444-671-1 (Hardcover)International Standard Book Number-13: 978-1-57444-671-5 (Hardcover)Tisbookcontainsinformationobtainedfromauthenticandhighlyregardedsources.Reprintedmaterialisquoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable eorts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microlming, and recording, or in any informa-tion storage or retrieval system, without written permission from the publishers.Forpermissiontophotocopyorusematerialelectronicallyfromthiswork,pleaseaccesswww.copyright.com(http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC) 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-prot organization that provides licenses and registration for a variety of users. For orga-nizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged.TrademarkNotice:Productorcorporatenamesmaybetrademarksorregisteredtrademarks,andareusedonlyfor identication and explanation without intent to infringe.Visit the Taylor & Francis Web site athttp://www.taylorandfrancis.comand the CRC Press Web site athttp://www.crcpress.com DK4115_C000.fmPage viTuesday, November 14, 200612:02 PM Preface Grinding,onceconsideredprimarilyanishingoperationinvolvinglowratesofremoval,hasevolved as a major competitor to cutting, as the term abrasive machining suggests. This is whatMilton Shaw, the man who is considered the great pioneer and father of American grinding, saidabout 10 years ago.Shaw led the development of grinding in the United States over the last 50 years.Wenamedthisbook HandbookofMachiningwithGrindingWheels becausethebordersbetweengrindingandotheroperationssuchassupernishing,lapping,polishing,andathoningare no longer distinct.Machining with grinding wheels extends from high-removal rate processesintothedomainsofultra-highaccuracyandsupernishing.Thisbookaimstoexploresomeofthe new transition operations, and for this reason we chose this title.This book presents a wide range of abrasive machining technology in fundamental and appli-cation terms. The emphasis is on why things happen as they do, rather than a how-to-do-it approach.The topics covered in this book cover a range of abrasive machining processes with grinding wheels,making this probably the most complete book regarding all kinds of grinding operations.The aim of this book is to present a unied approach to machining with grinding wheels thatwillbeusefulinsolvingnewgrindingproblemsofthefuture.Itshouldbeofvaluetoengineersand technicians involved in solving problems in industry and to those doing research on machiningwith grinding wheels in universities and research organizations.The team of authors are famous researchers who have devoted their entire lives doing researchin this eld and who are still actively contributing to new research and development. The authorsrepresentalargeregionoftheworldwhereabrasivemachiningwithgrindingwheelsaremostadvanced: United States, Great Britain, Japan, and Germany. I thank my co-authors for taking timefrom their busy activities to write and review this book over a period of 2 years.All the co-authors are my long-time friends, and with some of them, I have previously publishedor we are still in the process of nishing other books. Here is a short presentation of them.Professor Brian Rowe is considered the world father of Centerless Grinding in addition to othernotableresearchconcerninggrindingaspects:thermalanddynamicaspects,uid-lmbearings,etc.HeestablishedagreatlaboratoryandschoolinmanufacturingprocessesatLiverpoolJohnMooresUniversity.Asanemeritusprofessor,Brianisbusierthanbeforeretirement.Asheisanative English speaker, he spent a lot of time polishing our English in order to have a unitary book.I thank him for similar great work on our previous book, Tribology of Abrasive Machining Processes. ProfessorIchiroInasakiistheleadinggureinGrindinginJapan. AsdeanoftheGraduateSchoolofScienceandTechnologyatKeioUniversity,hedevelopedagreatlaboratorywithoutstanding research activities. His intelligent grinding wheel is featured in the Noritake Museumandrepresentsoneofhisbestaccomplishmentsandcontributions.HeledtheInternationalInsti-tution for Production Engineering Research in 2004/2005 as the president and was granted severalawards including an SME award. Ichiro-san and I have written two books: Handbook of CeramicGrinding and Polishing , and Tribology of Abrasive Machining Processes .ProfessorEckartUhlmannisprofessoranddirectoroftheInstituteforMachine-ToolsandManagementatTechnicalUniversityofBerlin.Dr.UhlmannreceivedthischairedprofessorshipafteraverysuccessfulindustrialcareerwithHermes AbrasiveinGermany.Hismainresearchison one of these transition processes: grinding with lapping kinematics. As the head of his institute,one of the largest in Germany, he holds the leading position in research on all aspects of abrasivemachining with grinding wheels. A future book with Dr. Uhlmann will be also published this year, Handbook of Lapping and Polishing/CMP . DK4115_C000.fmPage viiTuesday, November 14, 200612:02 PM Dr. Mike Hitchiner is manager of Precision Technology at Saint-Gobain Abrasives, the largestgrinding wheel company in the world. Mike has devoted all his life to research, development, andpractical application of grinding processes. He started this activity during his Ph.D. studies at theUniversity of Oxford in England, and today he is considered Mr. CBN Grinding by the precision-grindingindustry.Hehasbroughtanimportantindustrialperspectivetothisbook,aswellashundreds of applications.Astheleadingauthor,myownexperienceinabrasive-machiningresearchcomplementsandwidelyextendstheexperienceoftheotherauthorsacrossindustrialandfundamentalareasofinvestigation.Myresearcheshaveparticularlyfocusedonnewandchallengingtechniquesofabrasive machining particularly for new materials. I have been fortunate to have studied the latesttechnologies developed in countries across the world rsthand and contributed to developing newtechniques for application in industry and in research. Themainpurposeofthisbookistopresentabrasive-machiningprocessesasasciencemorethan an art. Research and development on abrasive-machining processes have greatly increased thelevelofsciencecomparedto25yearsagowhenmanyaspectsofabrasivemachiningprocessesstill depended largely on the expertise of individual technicians, engineers, and scientists.Thebookhastwoparts:TheBasicProcessofGrindingandApplicationofGrindingProcesses.This structure allows us to present more about understanding of grinding behavior inthe rst part and more about industrial application in the second part. Ioan D. Marinescu Toledo, 2006 DK4115_C000.fmPage viiiTuesday, November 14, 200612:02 PM The Authors Ioan D. Marinescu is a professor of mechanical, industrial, and manufacturing engineering at theUniversity of Toledo. He is also the director of the Precision Micro-Machining Center of the Collegeof Engineering (www.eng.utoledo.edu/pmmc) of the same university. He has a Ph.D. in manufac-turingprocesses,anhonorarydoctoratefromUniversityofIashi,Romania,andisamemberofnumerous international professional organizations: JSPE, SME, ASME, ASPE, CIRP, IDA, ASAT,and NAMRI.ProfessorMarinescuisauthorofmorethan15booksandover300technicalandscienticpapers.Hehasgivenlecturesandworkshopsinmorethan40countriesaroundtheworld. Also,he is the executive director and cofounder of the American Society for Abrasive Technology.Tenyearsago,Dr.Marinescufoundedhisowncompany, AdvancedManufacturingSolutionsCo.,LLC,acompanythatspecializesinconsulting,R&D,manufacturing,andtrade(www.inter-ams.com). He is the president and CEO of this company. Mike Hitchiner obtained his doctorate in 1982 at the University of Oxford for research in grindingand machining with cubic boron nitride (CBN) and diamonds. After a another 3 years of universityresearch in diamonds and CBN, he joined Saint-Gobain Abrasives (SGA) and its afliate companiesin1985.Heworkedinitiallyonconventionalabrasivegrainmanufactureandadvancedceramicsbefore becoming R&D manager for vitried CBN in Europe in 1987. In 1989, he joined UniversalSuperabrasives (SGA) as technology manager for vitried CBN for the U.S. market. More recently,he has broadened his responsibilities as the technology manager for precision grinding applicationsfor North America, as well as projects throughout Asia and Europe. EckartUhlmann isthedirectoroftheFraunhofer-InstituteforProductionSystemsandDesignTechnology IPK and professor of machine tools and manufacturing technology at the Institute forMachineToolsandFactoryManagementoftheTechnicalUniversityinBerlin,Germany.Hereceived his doctorate in engineering on Creep Feed Grinding of High-Strength Ceramic Materials.Prior to his academic career, he served several years as vice-president and director of research anddevelopmentatHermesSchleifmittelGmbH&Co.,Hamburg,Germany.Inadditiontobeingaconsultant for various German and international companies, Dr. Uhlmann holds many professionalmemberships, including the Berlin Wissenschaftskommission, the Verein Deutscher Ingenieure, andtheInternationalInstitutionforProductionEngineeringResearch.Healsoholdsanhonorarydoctorate from Kolej Universiti Teknikal Kebangsaan, Malaysia. W. Brian Rowe gained 6 years of experience with Austin Motor Company, Birmingham, England,and another 6 years with Wickman Machine Tools, Coventry, England. He studied at the Universityof AstoninBirminghamearninganhonorsdegreeinmechanicalandproductionengineeringin1961.HeearnedaPh.D.forresearchonthemechanicsofcenterlessgrindingatManchesterUniversity in 1964 and became a doctor of science in 1976 for his wider research on tribology. Hebecametheheadofmechanicalengineeringin1973atLiverpoolPolytechnic(latertobecomeLiverpool John Moores University) and eventually became assistant rector responsible for corporateacademicdevelopment,strategicplanning,andfordevelopmentofresearch.In1992,herelin-quished his administrative responsibilities in order to focus on research. As director of the AdvancedManufacturingTechnologyResearchLaboratory(AMTREL),hebuiltupasignicantteamofresearchersthatworkedcloselywithindustryintheUnitedKingdom.AMTRELhasmade DK4115_C000.fmPage ixTuesday, November 14, 200612:02 PM contributionsacrossawidespectrumofmachinetooltechnologiesparticularlyinrelationtogrinding and grinding-machine design. He has supervised more than 40 Ph.D.s who have gone onto inuence manufacturing developments around the world. He thanks them for their contributionsin making his career highly rewarding. He has jointly published with them more than 250 scienticpapers,patents,andbooksincluding DesignofHydrostaticandHybridBearings in1982and Tribology of Abrasive Machining Processes in 2004. Ichiro Inasaki , Dean of the Faculty of Science and Technology, Keio University, has been dedicatedtoresearchworkinmanufacturingengineeringandmachinetooltechnologies.HecompletedhisdoctoratesatKeioUniversityin1969andhonoraryDr.-Ing.atHanoverUniversity,Germany,in1999.HeservesasfellowoftheJapanSocietyofMechanicalEngineers,theJapanSocietyofPrecisionEngineering,andtheSocietyofManufacturingEngineers,andservedaspresidentforCIRP between 2004 and 2005.As a positive part of his career, he has undertaken a role as editorofinternationaljournalsincludingthe InternationalJournalforManufacturingScienceandPro-duction, Machining Science and Technology , International Journal of Production Engineering andComputers , JournalofEngineeringManufacture(IMechE) ,and JournalofNanotechnologyandPrecision Engineering for years to date.His achievements and contributions to the world manufacturing engineering industries deserveappreciation and recognition, and awards were conferred on him by the Japan Society of MechanicalEngineers in 1969, 1987, 1997, and 1999, the Japan Society for Precision Engineering in 1992 and2005,theJapanSocietyforAbrasiveTechnologyin1980and1998,theJapaneseSocietyofTribologists in 2003, and the Society of Manufacturing Engineers (F. W. Taylor Research Medal)in2005.Hisdedicatedeffortshavebeencondensedinbooks,publicationsinjournals,andmorethan 300 papers in the eld of manufacturing engineering. DK4115_C000.fmPage xTuesday, November 14, 200612:02 PM Contents Part I The Basic Process of Grinding..........................................................................................................1 Chapter 1 Introduction...................................................................................................................31.1 From Craft to Science ..............................................................................................................31.2 Basic Uses of Grinding ............................................................................................................41.2.1 High Accuracy Required ..............................................................................................41.2.2 High Removal Rate Required ......................................................................................41.2.3 Machining of Hard Materials.......................................................................................41.3 Elements of the Grinding System............................................................................................41.3.1 The Basic Grinding Process.........................................................................................41.3.2 Four Basic Grinding Operations ..................................................................................51.4 The Importance of the Abrasive...............................................................................................61.5 Grinding Wheels for a Purpose................................................................................................71.6 Problem-Solving.......................................................................................................................71.6.1 Part I .............................................................................................................................71.6.2 Part II ............................................................................................................................8References ..........................................................................................................................................8 Chapter 2 Grinding Parameters.....................................................................................................92.1 Introduction...............................................................................................................................92.1.1 Wheel Life....................................................................................................................92.1.2 Redress Life................................................................................................................102.1.3 Cycle Time .................................................................................................................102.2 Process Parameters .................................................................................................................112.2.1 Uncut Chip Thickness or Grain Penetration Depth...................................................112.2.2 Wheel Speed...............................................................................................................112.2.3 Work Speed ................................................................................................................112.2.4 Depth of Cut ...............................................................................................................112.2.5 Equivalent Wheel Diameter .......................................................................................112.2.6 Active Grit Density ....................................................................................................122.2.7 Grit Shape Factor .......................................................................................................122.2.8 Force per Grit .............................................................................................................122.2.9 Specic Grinding Energy...........................................................................................122.2.10Specic Removal Rate ...............................................................................................122.2.11Grinding Power ..........................................................................................................132.2.12Tangential Grinding Force..........................................................................................142.2.13Normal Grinding Force ..............................................................................................142.2.14Coefcient of Grinding ..............................................................................................142.2.15Surface Roughness .....................................................................................................152.2.16 R T Roughness..............................................................................................................152.2.17 R A Roughness..............................................................................................................15 DK4115_C000.fmPage xiTuesday, November 14, 200612:02 PM 2.2.18 R z Roughness.............................................................................................................152.2.19 Material or Bearing Ratio.........................................................................................152.2.20 Peak Count ................................................................................................................152.2.21 Comparison of Roughness Classes...........................................................................152.2.22 Factors That Affect Roughness Measurements ........................................................152.2.23 Roughness Specications on Drawings....................................................................162.2.24 Stock Removal Parameter.........................................................................................172.2.25 Decay Constant ......................................................................................................172.2.26 G-Ratio......................................................................................................................172.2.27 P-Ratio.......................................................................................................................182.2.28 Contact Length..........................................................................................................182.2.29 Geometric Contact Length........................................................................................182.2.30 Real Contact Length .................................................................................................182.3 Grinding Temperatures ...........................................................................................................182.3.1Surface Temperature T ..............................................................................................182.3.2 Maximum Workpiece Surface Temperature .............................................................192.3.3 The C max Factor .........................................................................................................192.3.4 The Transient Thermal Property w ..........................................................................192.3.5 Workpiece Partition Ratio R w ...................................................................................192.3.6 Effect of Grinding Variables on Temperature ..........................................................192.3.7 Heat Convection by Coolant and Chips ...................................................................202.3.8 Control of Thermal Damage.....................................................................................20Appendix 2.1 Drawing Form and Prole Tolerancing..................................................................21References ........................................................................................................................................21 Chapter 3 Material Removal Mechanisms..................................................................................233.1 Signicance.............................................................................................................................233.1.1 Introduction.................................................................................................................233.1.2 Dening Basic Behavior ............................................................................................233.2 Grinding Wheel Topography..................................................................................................243.2.1 Introduction.................................................................................................................243.2.2 Specication of Single Cutting Edges .......................................................................243.3 Determination of Grinding Wheel Topography.....................................................................253.3.1 Introduction.................................................................................................................253.3.2 Static Methods............................................................................................................253.3.3 Dynamic Methods ......................................................................................................263.3.4 Kinematic Simulation Methods..................................................................................263.3.5 Measurement of Grinding Wheel Topography ..........................................................273.3.6 Roughness Measures ..................................................................................................273.3.7 Qualitative Assessment...............................................................................................283.3.8 Counting Methods ......................................................................................................283.3.9 Piezo and Thermoelectric Measurements ..................................................................283.3.10Photoelectric Method..................................................................................................283.3.11Mirror Workpiece Method..........................................................................................283.3.12Workpiece Penetration Method..................................................................................283.4 Kinematics of the Cutting Edge Engagement .......................................................................293.5 Fundamental Removal Mechanisms ......................................................................................313.5.1 Microplowing, Chipping, and Breaking ....................................................................313.6 Material Removal in Grinding of Ductile Materials .............................................................323.7 Surface Formation in Grinding of Brittle-Hard Materials ....................................................35 DK4115_C000.fmPage xiiTuesday, November 14, 200612:02 PM 3.7.1 Indentation Tests.........................................................................................................353.7.2 Scratch and Grinding Behavior of Brittle-Hard Materials ........................................353.7.2.1 Fine-Grained Materials ...............................................................................363.7.2.2 Coarse-Grained Materials ...........................................................................363.8 Energy Transformation...........................................................................................................41References ........................................................................................................................................42 Chapter 4 Grinding Wheels.........................................................................................................454.1 Introduction.............................................................................................................................454.1.1 Developments in Productivity....................................................................................454.1.2 System Development ..................................................................................................454.1.3 Conventional and Superabrasive Wheel Design........................................................454.2 Wheel Shape Specication.....................................................................................................464.2.1 Basic Shapes...............................................................................................................464.2.2 Hole Tolerances ..........................................................................................................484.2.3 Side and Diameter Tolerances....................................................................................494.3 Wheel Balance........................................................................................................................494.3.1 Introduction to Wheel Balance ..................................................................................494.3.2 Static and Dynamic Unbalance..................................................................................504.3.3 Automatic Wheel Balancers.......................................................................................524.3.4 Dynamic Balancing in Two Planes ............................................................................524.3.5 Coolant Unbalance .....................................................................................................534.4 Design of High-Speed Wheels...............................................................................................544.4.1 Trend toward Higher Speeds......................................................................................544.4.2 How Wheels Fail ........................................................................................................544.4.3 Hoop Stress and Radial Stress ...................................................................................544.4.4 Reinforced Wheels .....................................................................................................554.4.5 Segmented Wheels .....................................................................................................564.4.6 Segment Design..........................................................................................................564.4.7 Abrasive Layer Depth ................................................................................................574.4.8 Recent Development of High-Speed Conventional Wheels......................................584.4.9 Safety of Segmented Wheel Designs.........................................................................594.4.10Speed Rating of Grinding Wheels .............................................................................604.5 Bond Life................................................................................................................................614.6 Wheel Mount Design .............................................................................................................614.6.1 A Conventional Wheel Mount ...................................................................................624.6.2 Use of Blotters............................................................................................................624.6.3 Clamping Forces.........................................................................................................624.6.3.1 Clamping Force to Compensate for the Weight of the Wheel...................624.6.3.2 Clamping Force for Unbalance of the Wheel ............................................634.6.3.3 Clamping Force for Motor Power Surge....................................................634.6.3.4 Clamping Force for Reaction of Wheel to Workpiece...............................634.6.4 High-Speed Wheel Mounts ........................................................................................644.6.5 The Single-Piece Wheel Hub.....................................................................................644.6.6 Direct Mounting on the Spindle ................................................................................644.6.7 CFRP Wheel Hubs .....................................................................................................664.6.8 Electroplated Wheels..................................................................................................664.6.9 Aluminum Hubs .........................................................................................................684.6.10Junker Bayonet Style Mounts ....................................................................................68 DK4115_C000.fmPage xiiiTuesday, November 14, 200612:02 PM 4.6.11HSK Hollow Taper Mount .........................................................................................684.6.12Titanium Hub Design.................................................................................................704.7 Wheel Design and Chatter Suppression ................................................................................714.7.1 The Role of Damping.................................................................................................714.7.2 Forced and Self-Excited Vibrations ...........................................................................714.7.2.1 Forced Vibrations ........................................................................................714.7.2.2 Self-Excited Vibration.................................................................................714.7.3 Damped Wheel Designs and Wheel Compliance......................................................724.7.4 Wheel Frequency and Chatter....................................................................................734.7.5 Summary.....................................................................................................................73References ........................................................................................................................................73 Chapter 5 The Nature of the Abrasive........................................................................................755.1 Introduction.............................................................................................................................755.2 Silicon Carbide .......................................................................................................................755.2.1 Development of SiC...................................................................................................755.2.2 Manufacture of SiC....................................................................................................755.2.3 Hardness of SiC..........................................................................................................755.3 Alumina (Alox)-Based Abrasives ..........................................................................................765.4 Electrofused Alumina Abrasives ............................................................................................765.4.1 Manufacture................................................................................................................765.4.2 Brown Alumina ..........................................................................................................775.4.3 White Alumina............................................................................................................775.4.4 Alloying Additives......................................................................................................785.4.5 Pink Alumina..............................................................................................................785.4.6 Ruby Alumina.............................................................................................................795.4.7 Zirconia-Alumina .......................................................................................................795.4.8 Single Crystal White Alumina ...................................................................................795.4.9 Postfusion Processing Methods..................................................................................795.4.10Postfusion Heat Treatment .........................................................................................795.4.11Postfusion Coatings....................................................................................................795.5 Chemical Precipitation and/or Sintering of Alumina ............................................................795.5.1 Importance of Crystal Size.........................................................................................795.5.2 Microcrystalline Grits.................................................................................................805.5.3 Seeded Gel Abrasive ..................................................................................................805.5.4 Application of SG Abrasives......................................................................................805.5.5 Sol Gel Abrasives .......................................................................................................805.5.6 Comparison of SG and Cubitron Abrasives ..............................................................815.5.7 Extruded SG Abrasive................................................................................................815.5.8 Future Trends for Conventional Abrasives ................................................................825.6 Diamond Abrasives.................................................................................................................825.6.1 Natural and Synthetic Diamonds ...............................................................................825.6.2 Origin of Diamond .....................................................................................................835.6.3 Production Costs.........................................................................................................835.6.4 Three Forms of Carbon..............................................................................................845.6.5 The Shape and Structure of Diamond .......................................................................855.6.6 Production of Synthetic Diamond..............................................................................855.6.7 Controlling Stone Morphology ..................................................................................855.6.8 Diamond Quality Measures........................................................................................86 DK4115_C000.fmPage xivTuesday, November 14, 200612:02 PM 5.6.9 Diamond Coatings.....................................................................................................865.6.10 Polycrystalline Diamond (PCD) ...............................................................................875.6.11 Diamond Produced by Chemical Vapor Deposition (CVD) ....................................885.6.12 Structure of CVD Diamond......................................................................................885.6.13 Development of Large Synthetic Diamond Crystals................................................885.6.14 Demand for Natural Diamond..................................................................................895.6.15 Forms of Natural Diamond.......................................................................................895.6.16 Hardness of Diamond ...............................................................................................895.6.17 Wear Resistance of Diamond ...................................................................................905.6.18 Strength of Diamond.................................................................................................905.6.19 Chemical Properties of Diamond .............................................................................905.6.20 Thermal Stability of Diamond..................................................................................915.6.21 Chemical Afnity of Diamond .................................................................................925.6.22 Effects of Chemical Afnity in Manufacture...........................................................925.6.23 Effects of Chemical Afnity in Grinding.................................................................925.6.24 Grinding Steels and Cast Irons with Diamond ........................................................925.6.25 Thermal Properties....................................................................................................925.7 CBN........................................................................................................................................935.7.1 Development of CBN ...............................................................................................935.7.2 Shape and Structure of CBN....................................................................................935.7.3 Types of CBN Grains ...............................................................................................945.7.4 Microcrystalline CBN...............................................................................................955.7.5 Sources and Costs of CBN.......................................................................................955.7.6 Wurtzitic Boron Nitride ............................................................................................955.7.7 Hardness of CBN......................................................................................................965.7.8 Wear Resistance of CBN..........................................................................................965.7.9 Thermal and Chemical Stability of CBN.................................................................975.7.10 Effect of Coolant on CBN........................................................................................975.7.11 Effect of Reactivity with Workpiece Constituents ...................................................985.7.12 Thermal Properties of CBN......................................................................................985.8 Grain Size Distributions .........................................................................................................985.8.1 The ANSI Standard...................................................................................................985.8.2 The FEPA Standard...................................................................................................995.8.3 Comparison of FEPA and ANSI Standards..............................................................995.8.4 US Grit Size Number................................................................................................995.9 Future Grain Developments ...................................................................................................995.10 Postscript.................................................................................................................................99References ......................................................................................................................................100 Chapter 6 Specication of the Bond.........................................................................................1036.1 Introduction...........................................................................................................................1036.2 Single-Layer Wheels ............................................................................................................1036.3 Electroplated (EP) Single-Layer Wheels .............................................................................1036.3.1 Structure of an EP Layer ........................................................................................1036.3.2 Product Accuracy ....................................................................................................1036.3.3 Wear Resistance of the Bond..................................................................................1036.3.4 Grit Size and Form Accuracy .................................................................................1046.3.5 Wheel Wear Effects in Grinding ............................................................................1046.3.6 Grit Size and Form-Holding Capability.................................................................1056.3.7 Wheel Break-In Period ...........................................................................................105 DK4115_C000.fmPage xvTuesday, November 14, 200612:02 PM 6.3.8 Summary of Variables Affecting Wheel Performance ...........................................1076.3.9 Effect of Coolant on Plated Wheels .......................................................................1076.3.10 Reuse of Plated Wheels ..........................................................................................1076.4 Brazed Single-Layer Wheels................................................................................................1076.5 Vitried Bond Wheels for Conventional Wheels ................................................................1086.5.1 Application of Vitried Bonds................................................................................1086.5.2 Fabrication of Vitried Bonds ................................................................................1086.5.3 Structure and Grade of Conventional Vitried Wheels..........................................1096.5.4 Mixture Proportions ................................................................................................1106.5.5 Structure Number....................................................................................................1106.5.6 Grade of Conventional Vitried Wheels ................................................................1106.5.7 Fracture Wear Mode of Vitried Wheels ...............................................................1116.5.8 High Porosity Vitried Wheels...............................................................................1126.5.9 Multiple Pore Size Distributions ............................................................................1136.5.10 Ultrahigh Porosity Vitried Wheels .......................................................................1136.5.11 Combining Grade and Structure.............................................................................1136.5.12 Lubricated Vitried Wheels ....................................................................................1136.6 Vitried Bonds for Diamond Wheels ..................................................................................1146.6.1 Introduction.............................................................................................................1146.6.2 Hard Work Materials...............................................................................................1146.6.3 Low Chemical Bonding..........................................................................................1146.6.4 High Grinding Forces .............................................................................................1146.5.5 Diamond Reactivity with Air at High Temperatures .............................................1146.6.6 Porous Vitried Diamond Bonds............................................................................1156.7 Vitried Bonds for CBN......................................................................................................1156.7.1 Introduction.............................................................................................................1156.7.2 Requirements for Vitried CBN Bonds .................................................................1166.7.3 CBN Wheel Structures............................................................................................1166.7.4 Grades of CBN Wheels ..........................................................................................1166.7.5 Firing Temperature..................................................................................................1166.7.6 Thermal Stress.........................................................................................................1186.7.7 Bond Mix for Quality .............................................................................................1186.8 Resin Bond Wheels ..............................................................................................................1186.9 Plastic Bonds ........................................................................................................................1196.10 Phenolic Resin Bonds ..........................................................................................................1196.10.1 Introduction.............................................................................................................1196.10.2 Controlled Force Systems.......................................................................................1196.10.3 Abrasive Size ..........................................................................................................1206.10.4 Benets of Resilience .............................................................................................1206.10.5 Phenolic Resin Bonds for Superabrasive Wheels ..................................................1216.10.6 Wheel Marking Systems for Resin Bonds .............................................................1216.11 Polyimide Resin Bonds ........................................................................................................1216.11.1 Introduction.............................................................................................................1216.11.2 Cost Developments and Implications .....................................................................1216.11.3 Induced Porosity Polyimide....................................................................................1216.12 Metal Bonds .........................................................................................................................1226.12.1 Introduction.............................................................................................................1226.12.2 Bronze Alloy Bonds................................................................................................1226.12.3 Porous Metal Bonds................................................................................................1226.12.4 Crush-Dressing........................................................................................................1226.12.5 High-Porosity Impregnated Metal Bonds...............................................................124 DK4115_C000.fmPage xviTuesday, November 14, 200612:02 PM 6.13 Other Bond Systems.............................................................................................................1246.13.1 Rubber .....................................................................................................................1246.13.2 Shellac .....................................................................................................................1246.13.3 Silicate.....................................................................................................................124References ......................................................................................................................................124 Chapter 7 Dressing....................................................................................................................1277.1 Introduction...........................................................................................................................1277.2 Traverse Dressing of Conventional Vitried Wheels with Stationary Tools ......................1277.2.1 Nomenclature ..........................................................................................................1277.2.2 Single-Point Diamonds ...........................................................................................1287.2.3 Diamond Size..........................................................................................................1287.2.4 Scaif Angle..............................................................................................................1297.2.5 Cooling....................................................................................................................1297.2.6 Dressed Topography................................................................................................1307.2.7 Dressing Feed and Overlap Ratio...........................................................................1307.2.8 Dressing Depth........................................................................................................1317.2.9 Dressing Forces.......................................................................................................1317.2.10 Dressing Tool Wear.................................................................................................1317.2.11 Rotationally Adjustable Tools.................................................................................1327.2.12 Prole Dressing Tools.............................................................................................1327.2.13 Synthetic Needle Diamonds ...................................................................................1337.2.14 Natural Long Diamond Blade Tools ......................................................................1347.2.15 Grit and Cluster Tools.............................................................................................1357.2.16 Form Blocks............................................................................................................1357.3 Traverse Dressing of Superabrasive Wheels with Stationary Tools....................................1377.3.1 Introduction.............................................................................................................1377.3.2 Jig Grinding.............................................................................................................1377.3.3 Toolroom Grinding .................................................................................................1377.4 Uniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond Tools ...........1387.4.1 Introduction.............................................................................................................1387.4.2 Crush or Dressing Speed Ratio ..............................................................................1387.4.3 Single-Ring Diamond and Matrix Diamond Discs................................................1397.4.4 Dressing Conditions for Disc Dressers ..................................................................1407.4.5 Synthetic Diamond Discs .......................................................................................1417.4.6 Sintered and Impregnated Rolls .............................................................................1417.4.7 Direct-Plated Diamond Rolls..................................................................................1417.4.8 Cup-Shaped Tools ...................................................................................................1417.5 Uniaxial Traverse Dressing of Vitried CBN Wheels with Rotary Diamond Tools ..........1427.5.1 Introduction.............................................................................................................1427.5.2 Dressing Depth........................................................................................................1427.5.3 Crush Ratio .............................................................................................................1437.5.4 The Dressing Affected Layer..................................................................................1437.5.5 Touch Dressing .......................................................................................................1447.5.6 Truer Design for Touch Dressing...........................................................................1477.5.7 Impregnated Truers .................................................................................................1477.5.8 Traverse Rotary Truers Using Needle Diamonds ..................................................1497.6 Cross-Axis Traverse Dressing with Diamond Discs ...........................................................1497.6.1 Introduction.............................................................................................................1497.6.2 Traverse Rate...........................................................................................................150 DK4115_C000.fmPage xviiTuesday, November 14, 200612:02 PM 7.7 Diamond Form-Roll Dressing..............................................................................................1507.7.1 Manufacture and Design ..........................................................................................1507.7.2 Reverse Plating.........................................................................................................1537.7.3 Inltrated Rolls.........................................................................................................1537.7.4 Reverse Plated Rolls.................................................................................................1547.7.5 Dress Parameters for Form Rolls.............................................................................1547.7.6 Dress Parameters for Form CBN Wheels................................................................1587.7.7 Handling Diamond Rolls..........................................................................................1597.8 Truing and Conditioning of Superabrasive Wheels.............................................................160References ......................................................................................................................................165 Chapter 8 Grinding Dynamics ..................................................................................................1678.1 Introduction...........................................................................................................................1678.1.1 Loss of Accuracy and Productivity..........................................................................1678.1.2 A Need for Chatter Suppression..............................................................................1678.2 Forced and Regenerative Vibrations ....................................................................................1678.2.1 Introduction...............................................................................................................1678.2.2 Forced Vibration .......................................................................................................1688.2.3Regenerative Vibration .............................................................................................1688.3 The Effect of Workpiece Velocity........................................................................................1688.4 Geometrical Interference between Grinding Wheel and Workpiece...................................1708.5 Vibration Behavior of Various Grinding Operations ...........................................................1708.6 Regenerative Self-Excited Vibrations ..................................................................................1728.6.1 Modeling of Dynamic Grinding Processes..............................................................1728.6.2 Grinding Stiffness and Grinding Damping..............................................................1728.6.3 Contact Stiffness.......................................................................................................1748.6.4 Dynamic Compliance of the Mechanical System ...................................................1758.6.5 Stability Analysis......................................................................................................1768.7 Suppression of Grinding Vibrations.....................................................................................1788.7.1 Suppression of Forced Vibrations ............................................................................1788.7.2 Suppression of Self-Excited Chatter Vibrations ......................................................1798.8 Conclusions...........................................................................................................................183References ......................................................................................................................................184 Chapter 9 Grinding Wheel Wear...............................................................................................1859.1 Three Types of Wheel Wear.................................................................................................1859.1.1 Introduction...............................................................................................................1859.2 Wheel Wear Mechanisms.....................................................................................................1859.2.1 Abrasive Wheel Wear ...............................................................................................1859.2.2 Adhesive Wheel Wear ..............................................................................................1859.2.3 Tribochemical Wheel Wear ......................................................................................1869.2.4 Surface Disruptions ..................................................................................................1869.2.5 Diffusion...................................................................................................................1869.3 Wear of the Abrasive Grains ................................................................................................1869.3.1 Types of Grain Wear ................................................................................................1869.3.2 A Combined Wear Process.......................................................................................1869.3.3 Grain Hardness and Temperature.............................................................................1879.3.4 Magnitude of the Stress Impulses............................................................................1879.3.5 Growth of Grain Flats ..............................................................................................187 DK4115_C000.fmPage xviiiTuesday, November 14, 200612:02 PM 9.3.6 Grain Splintering ......................................................................................................1889.3.7 Grain Break-Out .......................................................................................................1899.3.8 Bond Softening.........................................................................................................1899.3.9 Effect of Single Grain Forces ..................................................................................1899.3.10Wear by Deposition..................................................................................................1919.4 Bond Wear ............................................................................................................................1919.4.1 Introduction...............................................................................................................1919.4.2 Balancing Grain and Bond Wear .............................................................................1919.5 Assessment of Wheel Wear..................................................................................................1929.5.1 Microtopography ......................................................................................................1929.5.2 Prole Wear ..............................................................................................................192References ......................................................................................................................................193 Chapter 10 Coolants ..................................................................................................................19510.1 Introduction.........................................................................................................................19510.2 Basic Properties of Grinding Fluids ...................................................................................19510.2.1 Basic Properties ....................................................................................................19510.2.2 Basic Requirements ..............................................................................................19510.2.3 Secondary Requirements ......................................................................................19510.3 Types of Grinding Fluids....................................................................................................19610.4 Base Materials.....................................................................................................................19710.4.1 Introduction...........................................................................................................19710.4.2 Water-Based and Oil-Based Fluids ......................................................................19810.4.3 Rinsing Capacity...................................................................................................19810.4.4 Lubricating Capability..........................................................................................19910.5 Additives .............................................................................................................................19910.6 Application Results.............................................................................................................20110.7 Environmental Aspects........................................................................................................20110.8 The Supply System.............................................................................................................20110.8.1 Introduction...........................................................................................................20110.8.2 Alternative Cooling Lubricant Systems ...............................................................20210.8.3 Fluid Supply System Requirements.....................................................................20210.9 Grinding Fluid Nozzles.......................................................................................................20310.9.1 Basic Types of Nozzle System.............................................................................20310.9.2 The Jet Nozzle......................................................................................................20410.9.3 The Shoe Nozzle ..................................................................................................20410.9.4 Through-the-Wheel Supply ..................................................................................20510.9.5 Minimum Quantity Lubrication Nozzles .............................................................20510.9.6 Auxiliary Nozzles .................................................................................................20610.10Inuence of the Grinding Fluid in Grinding......................................................................20610.10.1Conventional Grinding .........................................................................................20610.10.2Inuence of the Fluid in Grinding Brittle-Hard Materials..................................20710.10.3High-Speed and High-Performance Grinding......................................................209References ......................................................................................................................................213 Chapter 11 Monitoring of Grinding Processes .......................................................................21711.1 The Need for Process Monitoring ......................................................................................21711.1.1 Introduction ..........................................................................................................21711.1.2 The Need for Sensors ..........................................................................................217 DK4115_C000.fmPage xixTuesday, November 14, 200612:02 PM 11.1.3 Process Optimization ...........................................................................................21711.1.4 Grinding Wheel Wear...........................................................................................21711.2 Sensors for Monitoring Process Variables..........................................................................21811.2.1 Introduction ..........................................................................................................21811.2.2 Force Sensors .......................................................................................................21911.2.3 Power Measurement .............................................................................................22211.2.4 Acceleration Sensors............................................................................................22311.2.5 AE Systems ..........................................................................................................22311.2.6 Temperature Sensors ............................................................................................22611.3 Sensor for Monitoring the Grinding Wheel .......................................................................22811.3.1 Introduction ..........................................................................................................22811.3.2 Sensors for Macrogeometrical Quantities ...........................................................23011.3.3 Sensors for Microgeometrical Quantities ............................................................23011.4 Sensors for Monitoring the Workpiece...............................................................................23311.4.1 Introduction ..........................................................................................................23311.4.2 Contact-Based Workpiece Sensors for Macrogeometry......................................23311.4.3 Contact-Based Workpiece Sensors for Microgeometry ......................................23411.4.4 Contact-Based Workpiece Sensors for Surface Integrity....................................23511.4.5 Noncontact-Based Workpiece Sensors ................................................................23711.5 Sensors for Peripheral Systems ..........................................................................................24011.5.1 Introduction ..........................................................................................................24011.5.2 Sensors for Monitoring of the Conditioning Process..........................................24011.5.3 Sensors for Coolant Supply Monitoring..............................................................242References ......................................................................................................................................244 Chapter 12 Economics of Grinding..........................................................................................24712.1 Introduction.........................................................................................................................24712.2 A Grinding Cost Comparison Based on an Available Grinding Machine ........................24712.2.1 Introduction ..........................................................................................................24712.2.2 Aeroengine Shroud Grinding Example ...............................................................24712.3 A Cost Comparison Including Capital Investment ............................................................24912.3.1 Introduction ..........................................................................................................24912.3.2 Automotive Camlobe Grinding Example ............................................................24912.4 Cost Comparison Including Tooling...................................................................................25012.4.1 Introduction ..........................................................................................................25012.4.2 Effect of Tooling Costs in Camlobe Grinding ....................................................25012.5 Grinding as a Replacement for Other Processes................................................................25112.5.1 Introduction ..........................................................................................................25112.5.2 Fine Grinding as a Replacement for Lapping.....................................................25112.5.3 High-Speed Grinding with Electroplated CBN Wheels to Replace Turn Broaching..................................................................................25212.6 Multitasking Machines for Hard-Turning with Grinding ..................................................25212.7 Summary .............................................................................................................................253References ......................................................................................................................................253 Part II Application of Grinding Processes................................................................................................255 DK4115_C000.fmPage xxTuesday, November 14, 200612:02 PM Chapter 13 Grinding of Ductile Materials................................................................................25713.1 Introduction.........................................................................................................................25713.1.1 Grindability ..........................................................................................................25713.1.2 Effect of Chip Form.............................................................................................25713.1.3 Chemical Reactivity.............................................................................................25713.2 Cast Irons ............................................................................................................................25813.2.1 Gray Cast Iron......................................................................................................25813.2.2 White Cast Iron....................................................................................................25813.2.3 Malleable Cast Iron..............................................................................................25913.2.4 Nodular or Ductile Cast Iron...............................................................................25913.3 Steels ...................................................................................................................................25913.3.1 Plain Carbon Steels..............................................................................................25913.3.2 Alloy Steels ..........................................................................................................26013.3.3 Tool Steels............................................................................................................26013.3.4 Stainless Steels.....................................................................................................26213.4 Heat-Resistant Superalloys .................................................................................................26313.4.1 Precipitation-Hardened Iron-Based Alloys ..........................................................26413.4.2 Nickel-Based Alloys.............................................................................................26413.4.3 Cobalt-Based Alloys.............................................................................................26413.4.4 Titanium ...............................................................................................................264References ......................................................................................................................................265 Chapter 14 Grinding of Ceramics.............................................................................................26714.1 Introduction.........................................................................................................................26714.1.1 Use of Ceramic Materials ....................................................................................26714.1.2 Machining Hard Ceramics ...................................................................................26714.1.3 Wheel-Dressing Requirements.............................................................................26714.1.4 ELID Grinding .....................................................................................................26814.1.5 Advantages of ELID............................................................................................26814.2 Background on Ceramic Materials.....................................................................................26814.2.1 History..................................................................................................................26814.2.2 Structure ...............................................................................................................26814.2.3 Ceramic Groups ...................................................................................................26914.2.4 Ceramic Product Groups......................................................................................26914.2.5 Application of ZTA Ceramics..............................................................................27014.2.6 Grinding of Ceramics...........................................................................................27014.3 Diamond Wheels for Grinding Ceramics...........................................................................27114.3.1 The Type of Diamond Abrasive...........................................................................27114.3.2 Types of Diamond Wheel ....................................................................................27114.3.3 Wheel Truing and Dressing .................................................................................27314.4 Physics of Grinding Ceramics ............................................................................................27414.5 ELID Grinding of Ceramics ...............................................................................................27814.5.1 Mechanism of ELID Grinding Technique...........................................................27814.5.2 Research Studies on ELID...................................................................................28014.5.3 Summary on ELID Grinding ...............................................................................282References ......................................................................................................................................282 DK4115_C000.fmPage xxiTuesday, November 14, 200612:02 PM Chapter 15 Grinding Machine Technology...............................................................................28515.1 The Machine Base ..............................................................................................................28515.1.1 Introduction ..........................................................................................................28515.1.2 Cast Iron Bases ....................................................................................................28515.1.3 Reuse of Cast Bases.............................................................................................28515.1.4 Welded Bases .......................................................................................................28515.1.5 Damping in Machine Tools..................................................................................28715.1.6 Large Mass Bases ................................................................................................28715.1.7 Tuned Mass Dampers...........................................................................................28715.1.8 Composite Material Bases ...................................................................................28715.1.9 Granite Bases .......................................................................................................28815.2 Foundations .........................................................................................................................28815.3 Guideways ...........................................................................................................................29015.3.1 Introduction ..........................................................................................................29015.3.2 Denition of Axes ................................................................................................29015.4 Slideway Congurations .....................................................................................................29015.4.1 Introduction ..........................................................................................................29015.4.2 The Flat and Vee Way..........................................................................................29115.4.3 The Double Vee Slideway....................................................................................29115.4.4 Dovetail Slideway ................................................................................................29115.4.5 Plain Slideway Materials .....................................................................................29315.5 Hydrostatic Slideways.........................................................................................................29415.5.1 Hydrostatic Bearing Principle..............................................................................29415.5.2 Plane-Pad Hydrostatic Slideway Congurations.................................................29415.5.3 Plane-Pad Hydrostatic Flowrate...........................................................................29415.5.4 Hydrostatic Slideway Materials and Manufacture ..............................................29415.5.5 Round Hydrostatic Slideways..............................................................................29515.5.6 Diaphragm-Controlled Hydrostatic Slideways ....................................................29515.5.7 Self-Compensating Hydrostatic Slideways..........................................................29615.6 Recirculating Rolling Element Slideways..........................................................................29715.7 Linear Axis Drives and Motion Control.............................................................................29915.7.1 Introduction ..........................................................................................................29915.7.2 Hydraulic Drives ..................................................................................................29915.7.3 Electrohydraulic Drives........................................................................................29915.7.4 Ac Servo- and Ballscrew Drives..........................................................................29915.8 Elements of AC Servodrive Ballscrew Systems ................................................................29915.8.1 The Ballscrew.......................................................................................................29915.8.2 The Ballnut...........................................................................................................30115.8.3 AC Servomotors ...................................................................................................30215.8.4 Encoders ...............................................................................................................30315.8.5 Resolvers ..............................................................................................................30515.9 Linear Motor Drive Systems ..............................................................................................30515.9.1 Introduction ..........................................................................................................30515.9.2 A Linear Motor System.......................................................................................30515.9.3 Laser Interferometer Encoders for Linear Motor Drives ....................................30615.10Spindle Motors and Grinding Wheel Drives......................................................................30715.11Drive Arrangements for Large Conventional Wheels ........................................................30715.11.1 Rolling Element Spindle Bearings for Large Wheels.........................................30715.11.2 Hydrodynamic Spindle Bearings for Large Wheels............................................30915.11.3 Hydrostatic Spindle Bearings for Large Wheels.................................................310 DK4115_C000.fmPage xxiiTuesday, November 14, 200612:02 PM 15.12 Drive Arrangements for Small Wheel Spindle Units ........................................................31215.12.1