Forecasting and examples of abrasive tool improvement for centerless steel grinding

The present work is aimed at enhancing the grinding efficiency of abrasive tools by designing and selecting their optimal characteristics. To that end, regularities in the process of defect-free grinding of workpieces made of hard-tomachine corrosion-resistant stainless steel of 12Х18Н10Т grade, nickel alloy of ХН60ВТ grade, structural steel of 30ХГСА grade, and complex-alloyed steel of 12Х2НВФА grade are studied by simulation modeling in the DEFORM software environment. The temperature in the cutting zone is selected as a criterion determining the quality indicators of the grinding process. The research methodology is based on the theory of metal cutting. It was established that each of the investigated abrasive tools, i.e., 1 25A F60 O6V, 1 25A F60 Q6V, 1 25A F80 O6V, and 1 25A F80 N7V is characterized by its rational field of application. For the “Pin” workpiece, the economic effect achieved due to elimination of scrap caused by grinding burns on the ground surface amounted to 18,095 RUB. In terms of the Ra parameter, an improved roughness of the machined surface can be achieved by small cutting depths (from 0.05 mm to 0.25 mm) in combination with a driving wheel speed of up to 108 min-1. The required accuracy of machining can be achieved by cutting depths of up to 0.25 mm in combination with a driving wheel speed of 86 min-1. Hence, a new methodology for designing and selection of abrasive tools is proposed. This methodology ensures minimal softening of the ground material, as well as the required surface roughness, accuracy of workpiece dimensions, and machining performance. In future research, coarser-grained (F40, F36) abrasive tools should be investigated.

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