Aspects of Precision Grinding (Part Roughness, Form Accurately, and a Basic Studyof the Brittle to Ductile Removal Transition)

摘要

Precision contour grinding as a method to produce complex shapes in steel,ceramics, and glass with submicron form accuracy and with roughness in the nanometer range is introduced. The machine and process aspects relevant for surface quality are discussed and an overview of the equipment used for the grinding experiments is given. Theoretical and experimental work regarding the influence of the process variables in the surface roughness profiles measured and roughness patterns observed on ground parts is emphasized. A good correlation exists between the theoretical predictions and the experimental findings, and a technique to avoid roughness patterns on ground surfaces is presented. A fundamental investigation of the conditions that determine the transition from ductile deformation to cracking is presented. Simulations are compared with the results of indentation experiments on glass. A fracture mechanics approach in conjunction with finite element calculations is shown to predict the threshold load for indentation cracking with reasonable accuracy. The influence of the dominant machine properties and process variables upon the form accuracy of ground parts is discussed. A model is used to study the influence of various parameters. The simulations are compared with experimental results.