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Inventions
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Modern Grinding Technology and Systems 2019
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Modern Grinding Technology and Systems 2019

A special issue of Inventions (ISSN 2411-5134). This special issue belongs to the section "Inventions and Innovation in Advanced Manufacturing".

Deadline for manuscript submissions: closed (31 October 2020) | Viewed by 38486

Special Issue Editor

Prof. Dr. Brian Rowe

E-Mail Website
Guest Editor
Liverpool John Moores University, Liverpool, UK
Interests: grinding innovations; abrasive processes; abrasive tools; grinding machines; grinding systems; high removal rates; precision; grinding sensors; micro-grinding; flexible grinding systems; coolants and lubricants

Special Issue Information

Dear Colleagues,

Following on from the successful Special Issue produced in 2018, a new Special Issue will be produced in 2019. As previously, the Special Issue 2019 will feature a wide range of key innovations in the science and engineering of new grinding processes, abrasives, tools, machines, and systems for a range of important industrial topics. Topics will, not only feature well-known grinding processes and tools, but also innovations to solve new areas of application. Innovations may range from high-precision kinematics for grinding very large lenses and reflectors, through to medium-sized grinding machine processes, down to grinding very small components used in MEMS. Materials to be ground may include conventional engineering steels to aerospace materials, ceramics, and composites. Papers may also deal with novel topics, such as finishing of parts produced by 3D printing. Innovations may also include new features introduced into control systems to improve process efficiency or to integrate the grinding process more effectively into a wider manufacturing system. Papers will be welcomed that show significant improvements in any aspect of grinding processes, machines, materials, abrasives, wheel preparation, coolants and lubricants, and integration into modern manufacturing systems.

Prof. Dr. Brian Rowe
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Inventions is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Grinding innovations
  • Abrasive processes
  • Abrasive tools and wheel preparation
  • Grinding new materials
  • Grinding machines
  • Grinding systems and controls
  • High removal rates
  • High precision
  • Grinding sensors
  • Micro-grinding
  • Flexible grinding systems
  • Coolants and lubricants
  • Integration into the wider manufacturing system
  • AI in grinding systems

Published Papers (5 papers)

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Research

27 pages, 10955 KiB  
Article
The Effect of Grinding Wheel Contact Stiffness on Plunge Grinding Cycle
by Fukuo Hashimoto and Hiroto Iwashita
Inventions 2020, 5(4), 62; https://doi.org/10.3390/inventions5040062 - 16 Dec 2020
Viewed by 8191
Abstract
This paper presents the effect of grinding wheel contact stiffness on the plunge grinding cycle. First, it proposes a novel model of the generalized plunge grinding system. The model is applicable to all plunge grinding operations including cylindrical, centerless, shoe-centerless, internal, and shoe-internal [...] Read more.
This paper presents the effect of grinding wheel contact stiffness on the plunge grinding cycle. First, it proposes a novel model of the generalized plunge grinding system. The model is applicable to all plunge grinding operations including cylindrical, centerless, shoe-centerless, internal, and shoe-internal grinding. The analysis of the model explicitly describes transient behaviors during the ramp infeed and the spark-out in the plunge grinding cycle. Clarification is provided regarding the premise that the system stiffness is composed of machine stiffness and wheel contact stiffness, and these stiffnesses significantly affect productivity and grinding accuracy. The elastic deflection of the grinding wheel is accurately measured and formulas for representing the deflection nature under various contact loads are derived. The deflection model allows us to find the non-linear contact stiffness with respect to the normal load. The contact stiffnesses of four kinds of grinding wheels with different grades and bond materials are presented. Both cylindrical grinding and centerless grinding tests are carried out, and it is experimentally revealed that the time constant at ramp infeed and spark-out is significantly prolonged by reducing the grinding force. It is verified that a simulation of the grinding tests using the proposed model can accurately predict critical parameters like forces and machine deflection during plunge grinding operations. Finally, this paper provides a guideline for grinding cycle design in order to achieve the required productivity and grinding accuracy. Full article
(This article belongs to the Special Issue Modern Grinding Technology and Systems 2019)
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22 pages, 12101 KiB  
Article
The Design of an Infeed Cylindrical Grinding Cycle
by Fukuo Hashimoto
Inventions 2020, 5(3), 46; https://doi.org/10.3390/inventions5030046 - 28 Aug 2020
Cited by 2 | Viewed by 5215
Abstract
This paper synthesizes the design of an infeed cylindrical grinding system into a total system composed of the grinding mechanism and the grinding machine characteristics. The causalities between the grinding parameters and the machine structures are discussed, and the infeed grinding processes are [...] Read more.
This paper synthesizes the design of an infeed cylindrical grinding system into a total system composed of the grinding mechanism and the grinding machine characteristics. The causalities between the grinding parameters and the machine structures are discussed, and the infeed grinding processes are analyzed as outputs that represent responses to the inputs. These relationships are integrated into a block diagram with closed-loop feedback. A novel model exhibiting practical parameters such as grinding speed, infeed rate and MRR (Material Removal Rate) is proposed. The analysis of the grinding system derived a critical factor, the “grinding time contact,” which governs the transient behaviors of process parameters such as forces and machine deflection. The process parameters during the infeed cycle including spark-out grinding were investigated, and the formulas required for the cycle design are presented. Furthermore, to improve accuracy and productivity, the features of the cycle design are described and procedures for controlling size error and roundness are discussed. Finally, the model was verified with infeed grinding tests applied to both the chuck-type cylindrical and centerless grinding methods. Full article
(This article belongs to the Special Issue Modern Grinding Technology and Systems 2019)
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27 pages, 16170 KiB  
Article
Open-Source Grinding Machine for Compression Screw Manufacturing
by Jacob Franz and Joshua M. Pearce
Inventions 2020, 5(3), 26; https://doi.org/10.3390/inventions5030026 - 03 Jul 2020
Cited by 5 | Viewed by 14970
Abstract
Some of the most promising distributed recycling and additive manufacturing (DRAM) technical systems use fused particle fabrication (FPF) or fused granular fabrication (FGF), where compression screws force post-consumer waste plastic through a heated nozzle for direct 3D printing. To assist the technical evolution [...] Read more.
Some of the most promising distributed recycling and additive manufacturing (DRAM) technical systems use fused particle fabrication (FPF) or fused granular fabrication (FGF), where compression screws force post-consumer waste plastic through a heated nozzle for direct 3D printing. To assist the technical evolution of these systems, this study provided the details of an invention for a low-cost, easily replicable open-source grinding machine for compression screw manufacturing. The system itself can be largely fabricated using FPF/FGF following the self-replicating rapid prototyper (RepRap) methodology. This grinding machine can be made from a cordless cut-off grinder and < $155 in parts. The new invention is demonstrated to be able to cut custom screws with variable (i) channel depths, (ii) screw diameters, (iii) screw lengths, (iv) pitches, (v) abrasive disk thicknesses, (vi) handedness of the screws, (vii) and materials (three types of steel tested: 1045 steel, 1144 steel, and 416 stainless steel). The results show that the device is more than capable of replicating commercial screws as well as providing makers with a much greater flexibility to make custom screws. This invention enables the DRAM toolchain to become even more self-sufficient, which assists the goals of the circular economy. Full article
(This article belongs to the Special Issue Modern Grinding Technology and Systems 2019)
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Graphical abstract

13 pages, 3434 KiB  
Article
Dynamic Rounding Stability in Through-Feed Centerless Grinding
by Fukuo Hashimoto
Inventions 2020, 5(2), 17; https://doi.org/10.3390/inventions5020017 - 29 Apr 2020
Cited by 2 | Viewed by 3928
Abstract
The through-feed method in centerless grinding allows manufacturers to produce cylindrical parts at much higher levels of productivity than can be achieved with in-feed grinding, so it has been extensively employed in industry. However, its rounding mechanism is not yet well understood due [...] Read more.
The through-feed method in centerless grinding allows manufacturers to produce cylindrical parts at much higher levels of productivity than can be achieved with in-feed grinding, so it has been extensively employed in industry. However, its rounding mechanism is not yet well understood due to the complexity of the through-feed process. This paper presents the fundamental parameters, such as material removal rates, forces, and so on in the through-feed grinding, and analyses on the grinding system with feedback loops, including regenerative functions and the machine dynamic functions. Further, the characteristic roots of the system, representing the number of waves and the growth rates of the harmonics in roundness, are identified at each grinding position from entry to exit. To evaluate the grinding process stability, a rounding stability index (RSI) was proposed. It was demonstrated that the analytical tool modeled in this paper can identify the optimum operational conditions by the RSI for achieving desired grinding productivity and accuracy. Finally, the model is verified with grinding tests, and the nm-order roundness obtained by the tests is shown. Full article
(This article belongs to the Special Issue Modern Grinding Technology and Systems 2019)
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18 pages, 6394 KiB  
Article
Characterization of Material Properties Based on Inverse Finite Element Modelling
by Mikdam Jamal and Michael N. Morgan
Inventions 2019, 4(3), 40; https://doi.org/10.3390/inventions4030040 - 02 Aug 2019
Cited by 5 | Viewed by 5573
Abstract
This paper describes a new approach that can be used to determine the mechanical properties of unknown materials and complex material systems. The approach uses inverse finite element modelling (FEM) accompanied with a designed algorithm to obtain the modulus of elasticity, yield stress [...] Read more.
This paper describes a new approach that can be used to determine the mechanical properties of unknown materials and complex material systems. The approach uses inverse finite element modelling (FEM) accompanied with a designed algorithm to obtain the modulus of elasticity, yield stress and strain hardening material constants of an isotropic hardening material model, as well as the material constants of the Drucker–Prager material model (modulus of elasticity, cap yield stress and angle of friction). The algorithm automatically feeds the input material properties data to finite element software and automatically runs simulations to establish a convergence between the numerical loading–unloading curve and the target data obtained from continuous indentation tests using common indenter geometries. A further module was developed to optimise convergence using an inverse FEM analysis interfaced with a non-linear MATLAB algorithm. A sensitivity analysis determined that the dual spherical and Berkovich (S&B) approach delivered better results than other dual indentation methods such as Berkovich and Vickers (B&V) and Vickers and spherical (V&S). It was found that better convergence values can be achieved despite a large variation in the starting parameter values and/or material constitutive model and such behaviour reflects the uniqueness of the dual S&B indentation in predicting complex material systems. The study has shown that a robust optimization method based on a non-linear least-squares curve fitting function (LSQNONLIN) within MATLAB and ABAQUS can be used to accurately predict a unique set of elastic plastic material properties and Drucker–Prager material properties. This is of benefit to the scientific investigation of properties of new materials or obtaining the material properties at different locations of a part which may be not be similar because of manufacturing processes (e.g., different heating and cooling rates at different locations). Full article
(This article belongs to the Special Issue Modern Grinding Technology and Systems 2019)
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