Tribology and Fundamentals of Abrasive Machining Processes

3rd Edition - November 10, 2021
Authors: Bahman Azarhoushang, Ioan D. Marinescu, W. Brian Rowe, Boris Dimitrov, Hitoshi Ohmori
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 2 3 7 7 7 - 9
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 2 3 7 7 8 - 6

This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of… Read more

Tribology and Fundamentals of Abrasive Machining Processes

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This new edition draws upon the fundamentals of abrasive machining processes and the science of tribology to understand, predict, and improve abrasive machining processes. Each of the main elements of the abrasive machining system is looked at alongside the tribological factors that control the efficiency and quality of the processes described. The new edition has been updated to include a variety of industrial applications. Grinding and conditioning of grinding tools are dealt with in particular detail, and solutions are proposed for many of the most commonly experienced industrial problems, such as poor accuracy, poor surface quality, rapid tool wear, vibrations, workpiece burn, and high process costs. The entire book has been rewritten and restructured, with ten completely new chapters. Other new features include:

Cover image
Title page
Table of Contents
Copyright
Dedication
List of contributors
About the authors
Preface to the first edition
Preface to the second edition
Preface to the third edition
Acknowledgments
Part One. Science of abrasive machining and tribology (introduction)
1. Abrasives
1.1. Introduction
1.2. Corundum
1.3. Silicon carbide
1.4. Diamond
1.5. Cubic boron nitride
1.6. Lapping and polishing abrasives
1.7. Abrasive sizes and shapes
2. Abrasive tools
2.1. Introduction
2.2. Bonded abrasives
2.3. Coated abrasives and abrasive belts
2.4. Loose abrasives and abrasive pastes
3. Abrasive machining processes
3.1. Introduction
3.2. Bonded and coated abrasive processes
3.3. Loose abrasive processes
4. Tribosystems of abrasive machining processes
4.1. Introduction
4.2. Tribological principles
4.3. Structure of tribomechanical processing
4.4. Tribosystems in abrasive machining
4.5. Modeling tribosystems of abrasive processes
4.6. Conclusions
Part Two. Principles of abrasive machining processes
5. Kinematics of bonded abrasive machining processes
5.1. Introduction
5.2. Chip thickness or grain penetration depth
5.3. Equivalent chip thickness
5.4. Cutting edge density
5.5. Grain spacing
5.6. Variability of active cutting edge density
5.7. Mean chip volume
5.8. Grain shapes
5.9. Geometric contact length
5.10. Kinematic contact length
5.11. Mean uncut chip cross-sectional area
5.12. Irregular grain spacing
5.13. Irregular grain protrusion
5.14. Contact times and tribological implications
6. Material removal mechanisms of bonded abrasive machining (forces, friction, and energy)
6.1. Introduction
6.2. Removal mechanism of ductile materials
6.3. Removal mechanism of brittle materials
6.4. Forces and power
6.5. Force ratio and friction coefficient
6.6. Specific energy
6.7. Size effect
6.8. Chip formation, sliding, and ploughing energies
6.9. Specific removal rate
6.10. Energy partition
7. Contact mechanics
7.1. Introduction
7.2. Contact area
7.3. Contact length
7.4. Smooth body analysis
7.5. Rough surface analysis
7.6. Experimental measurements of the roughness factor
7.7. Elastic stresses due to abrasion
7.8. Indentation mechanics approach
7.9. Summary
8. Grinding wheel macrodesign and microtopography
8.1. Introduction
8.2. Wheel body and shape
8.3. The importance of microtopography
8.4. Topographical definitions
8.5. Measurement techniques for grinding tool microtopography
8.6. Topography changes in grinding
9. Grinding tool conditioning
9.1. Introduction
9.2. Dressing, cleaning, and structuring
9.3. Dressing methods
9.4. Mechanical dressing processes
9.5. Tribology of mechanical dressing
9.6. Diamond types for dressing tools
9.7. Dressing with stationary diamond tools
9.8. Rotary dressing tools
9.9. Diamond form rollers
9.10. Diamond profile rollers
9.11. Diamond cup dresser
9.12. Continuous dressing
9.13. Crushing
9.14. Touch dressing
9.15. Cross-axis dressing
9.16. Wear and tool life of diamond dressing tools
9.17. Mechanical dressing of resin-, metal-, and hybrid-bonded grinding wheels
9.18. Sharpening
9.19. Removal mechanisms in mechanical dressing processes
9.20. Nonconventional conditioning processes
9.21. Summary
10. Principles of grinding processes
10.1. Overview of the grinding process
10.2. External cylindrical grinding between centers
10.3. External cylindrical centerless grinding
10.4. Surface grinding
10.5. Internal cylindrical grinding
11. Cutting temperature and energy partitioning in grinding
11.1. Introduction
11.2. Heat generation and dissipation
11.3. Measuring and estimating temperatures
11.4. Heat partitioning
11.5. Workpiece temperatures
11.6. Case studies
12. Kinematics and material removal mechanisms of loose abrasive machining
12.1. Introduction
12.2. Lapping
12.3. Polishing
12.4. Mass finishing and tumbling
12.5. Chemomechanical polishing
Part Three. Tool wear, induced surface integrity of workpiece material, and machineability of materials
13. Mechanisms of tool wear
13.1. Introduction
13.2. Wear types and mechanisms
13.3. Analysis of adhesive and abrasive wear
13.4. Abrasive tool loading or clogging
13.5. G-ratio
13.6. Tool wear and loading measurement
14. Thermal aspects of abrasive machining processes
14.1. Introduction
14.2. Grinding burn
14.3. Surface damage
14.4. Thermal softening
14.5. Rehardening
14.6. Crack formation
14.7. Microhardness
14.8. Residual stresses
14.9. Spheroidal swarf
15. Workpiece surface roughness
15.1. Introduction
15.2. Surface roughness parameters
15.3. Factors affecting surface roughness
15.4. Measurement of surface roughness
15.5. Application of acoustic emission to predict surface roughness behavior
16. Machinability of materials
16.1. Introduction
16.2. Metals
16.3. Structural aspects and machinability of nonmetals
16.4. Conclusions
Part Four. Process fluids and tribochemistry of abrasive machining
17. Process fluids for abrasive machining
17.1. Introduction
17.2. Types and classes of process fluids
17.3. Physical properties of process fluids
17.4. Chemical properties of process fluids
17.5. Tribological properties of process fluids
17.6. Biological properties of process fluids
17.7. Degradation of fluid properties during operation
17.8. Analysis of physicochemical and biological properties
17.9. Tribological and application characteristics
17.10. Selection of process fluids
17.11. Adjustment and maintenance of fluid properties in operation
17.12. Disposal of process fluids
17.13. Conclusions and recommendations
18. Fluid delivery
18.1. Introduction
18.2. The tasks and role of process fluid supply
18.3. Cooling and lubrication techniques
18.4. Process fluid delivery and supply system
18.5. Considerations and challenges of process fluid delivery
18.6. Fluid nozzles for high-performance grinding processes
19. Tribochemistry of abrasive machining
19.1. Introduction
19.2. Tribochemical behavior of abrasive tools
19.3. Tribochemical aspects of the workpiece material structure
19.4. Tribochemical aspects of dry abrasive machining
19.5. Tribochemical aspects of wet abrasive machining
19.6. Conclusions
Symbols and abbreviations
Index

Bahman Azarhoushang

Bahman Azarhoushang has been a Professor of Mechanical and Medical Engineering at Furtwangen University (Germany) since 2013, where he also serves as the Head of the Center for Excellence in Machining. There he has access to various modern CNC machine tools and measuring devices. He has published more than 160 publications in various languages (with more than 60 publications in peer-reviewed journals) and lectured at numerous national and international conferences. He has authored several books and patents in the field of abrasive and precision machining. He is the editor of various international journals and co-authored the 3rd edition of ‘Tribology and Fundamentals of Abrasive Machining Processes’ (Elsevier). He teaches courses in Manufacturing Engineering, Machine Tools, Production Metrology, and Precision Manufacturing. His main research areas are conditioning (mechanical and nonmechanical dressing) and grinding (high-speed, high-efficiency grinding; nonconventional grinding), precision machining, tribology, innovative tools, the creation of extremely fine surfaces and structures, and process optimization.

Affiliations and expertise

Professor of Mechanical and Medical Engineering, Furtwangen University, Furtwangen im Schwarzwald, Germany

Ioan D. Marinescu

Ioan D. Marinescu is Professor and Director of the Precision Micromachining Center at The University of Toledo, Ohio, USA, and CEO of Advanced Manufacturing Solutions, LLC. His research interests include manufacturing processes, grinding, tribology, advanced materials, and machining of brittle materials.

Affiliations and expertise

Professor and Director, Precision Micromachining Center, The University of Toledo, Toledo, OH, USA

W. Brian Rowe

W. Brian Rowe is Consulting Director and Emeritus Professor of Mechanical Engineering at Liverpool John Moores University, Liverpool, UK. He is also former Director of the Advanced Manufacturing Technology and Tribology Research Laboratory. Professor Rowe is a widely respected researcher in the fields of tribology and grinding. He has authored many books on grinding and grinding machine technology, also on bearing analysis and design.

Affiliations and expertise

Consulting Director and Emeritus Professor of Mechanical Engineering at Liverpool John Moores University, Liverpool, UK

Boris Dimitrov

Boris Dimitrov is a Consulting Engineer in mechanics and chemistry, former Chief Scientist of the Romanian Research Institute of Applied Mechanics, and a former member of the Romanian Institute for Precision Mechanics in Bucharest.

Affiliations and expertise

Romanian Research Institute for Applied Mechanics and Institute for Precision Mechanics, Bucharest, Romania

Hitoshi Ohmori

Hitoshi Ohmori is Chief Scientist at the Materials Fabrication Laboratory, RIKEN, Wakō, Saitama, Japan.

Affiliations and expertise

Chief Scientist, Materials Fabrication Laboratory, RIKEN, Wakō, Saitama, Japan

Life Sciences

Physical Sciences & Engineering

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Health

Tribology and Fundamentals of Abrasive Machining Processes

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Institutional subscription on ScienceDirect

Bahman Azarhoushang

Ioan D. Marinescu

W. Brian Rowe

Boris Dimitrov

Hitoshi Ohmori