A Study on the Cutting Characteristics of Bottom Abrasive Grains in Helical Grinding Tools

Bochuan Chen; Xiaojin Shi; Songmei Yuan

doi:10.3390/ma17194814

A Study on the Cutting Characteristics of Bottom Abrasive Grains in Helical Grinding Tools

Bochuan Chen
, Xiaojin Shi
, Songmei Yuan^*

^*Corresponding author for this work

School of Mechanical Engineering and Automation

Beihang University

Research output: Contribution to journal › Article › peer-review

Abstract

Helical grinding is crucial for manufacturing small holes in hard-to-machine composite ceramics. This study introduces a geometric model of undeformed chips to analyze the cutting characteristics of abrasive grains on both the bottom and side edges of the tool. It reveals for the first time that the distribution of cutting grains—pure bottom-edge, pure side-edge, and mixed-edge—is influenced by the tool diameter and eccentricity. A novel calculation method for the distribution range (D_p) of pure bottom-edge grains is proposed, demonstrating that using a tool diameter at or below two-thirds of the target hole diameter effectively eliminates pure bottom-edge grains, improving chip evacuation, reducing chip adhesion, and optimizing cutting performance. Experimental validation on small holes in SiC_p/Al composites (65% volume fraction) confirmed these findings and provides practical guidance for optimizing cutting parameters and tool design.

Original language	English
Article number	4814
Journal	Materials
Volume	17
Issue number	19
DOIs	https://doi.org/10.3390/ma17194814
State	Published - Oct 2024

Keywords

bottom abrasive grain grinding characteristics
composite ceramics
helical grinding
kinematic analysis
pure bottom-edge grains

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10.3390/ma17194814

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@article{72f02610d4f8472191415b68f19ade97,

title = "A Study on the Cutting Characteristics of Bottom Abrasive Grains in Helical Grinding Tools",

abstract = "Helical grinding is crucial for manufacturing small holes in hard-to-machine composite ceramics. This study introduces a geometric model of undeformed chips to analyze the cutting characteristics of abrasive grains on both the bottom and side edges of the tool. It reveals for the first time that the distribution of cutting grains—pure bottom-edge, pure side-edge, and mixed-edge—is influenced by the tool diameter and eccentricity. A novel calculation method for the distribution range (Dp) of pure bottom-edge grains is proposed, demonstrating that using a tool diameter at or below two-thirds of the target hole diameter effectively eliminates pure bottom-edge grains, improving chip evacuation, reducing chip adhesion, and optimizing cutting performance. Experimental validation on small holes in SiCp/Al composites (65\% volume fraction) confirmed these findings and provides practical guidance for optimizing cutting parameters and tool design.",

keywords = "bottom abrasive grain grinding characteristics, composite ceramics, helical grinding, kinematic analysis, pure bottom-edge grains",

author = "Bochuan Chen and Xiaojin Shi and Songmei Yuan",

note = "Publisher Copyright: {\textcopyright} 2024 by the authors.",

year = "2024",

month = oct,

doi = "10.3390/ma17194814",

language = "英语",

volume = "17",

journal = "Materials",

issn = "1996-1944",

publisher = "Multidisciplinary Digital Publishing Institute (MDPI)",

number = "19",

}

TY - JOUR

T1 - A Study on the Cutting Characteristics of Bottom Abrasive Grains in Helical Grinding Tools

AU - Chen, Bochuan

AU - Shi, Xiaojin

AU - Yuan, Songmei

PY - 2024/10

Y1 - 2024/10

N2 - Helical grinding is crucial for manufacturing small holes in hard-to-machine composite ceramics. This study introduces a geometric model of undeformed chips to analyze the cutting characteristics of abrasive grains on both the bottom and side edges of the tool. It reveals for the first time that the distribution of cutting grains—pure bottom-edge, pure side-edge, and mixed-edge—is influenced by the tool diameter and eccentricity. A novel calculation method for the distribution range (Dp) of pure bottom-edge grains is proposed, demonstrating that using a tool diameter at or below two-thirds of the target hole diameter effectively eliminates pure bottom-edge grains, improving chip evacuation, reducing chip adhesion, and optimizing cutting performance. Experimental validation on small holes in SiCp/Al composites (65% volume fraction) confirmed these findings and provides practical guidance for optimizing cutting parameters and tool design.

AB - Helical grinding is crucial for manufacturing small holes in hard-to-machine composite ceramics. This study introduces a geometric model of undeformed chips to analyze the cutting characteristics of abrasive grains on both the bottom and side edges of the tool. It reveals for the first time that the distribution of cutting grains—pure bottom-edge, pure side-edge, and mixed-edge—is influenced by the tool diameter and eccentricity. A novel calculation method for the distribution range (Dp) of pure bottom-edge grains is proposed, demonstrating that using a tool diameter at or below two-thirds of the target hole diameter effectively eliminates pure bottom-edge grains, improving chip evacuation, reducing chip adhesion, and optimizing cutting performance. Experimental validation on small holes in SiCp/Al composites (65% volume fraction) confirmed these findings and provides practical guidance for optimizing cutting parameters and tool design.

KW - bottom abrasive grain grinding characteristics

KW - composite ceramics

KW - helical grinding

KW - kinematic analysis

KW - pure bottom-edge grains

UR - https://www.scopus.com/pages/publications/85206331641

U2 - 10.3390/ma17194814

DO - 10.3390/ma17194814

M3 - 文章

AN - SCOPUS:85206331641

SN - 1996-1944

VL - 17

JO - Materials

JF - Materials

IS - 19

M1 - 4814

ER -

A Study on the Cutting Characteristics of Bottom Abrasive Grains in Helical Grinding Tools

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Keywords

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