Figure - available from: The International Journal of Advanced Manufacturing Technology
This content is subject to copyright. Terms and conditions apply.
Source publication
Abrasive belt grinding is considered a flexible and precision machining method. The complicated contact status prevents the traditional simulation model from accurately predicting the machined surface topography, so this paper develops a new numerical simulation approach to solve this issue. The abrasive belt surface topography was detected using a...
Similar publications
The uniformity of the machining results in the rough polishing of optical components that determines the length of the subsequent fine polishing cycle. In this paper, full-calibre polishing of large-calibre flat optical components using the motion mode of the ring pendulum double-sided polisher is studied. The processing motion model of the ring pe...
![Measured and simulated surface roughness values [μm]](profile/Augustin-Goeroeg/publication/352032294/figure/tbl1/AS:1034913960693765@1623754124708/Measured-and-simulated-surface-roughness-values-mm_Q320.jpg)
The article deals with the simulation of single-oscillating grooves superfinishing. A model of the superfinishing tool was created according to the input information about the tool and the superfinishing process. Using this tool, a simulation of the cutting process was performed. The input parameters for the simulation were the cutting conditions,...
Coefficient of restitution is regarded as a dominating parameter in rockfall research. Generally, small-scale experiments were developed without considering interactions between boulder and slope. However, preimpact moving statuses are essential to evaluate rockfall behaviors. To reveal the effect of preimpact interactions on coefficient of restitu...
Mobile robots are expected to traverse on unstructured terrain, especially uneven terrain, or to climb obstacles or slopes. This paper analyzes one such passively–actively transformable mobile robot that is principally aimed at the above issue. A passive locomotion traverses on a rough and flat terrain; an active reconfiguration with an active susp...
Natural terrain is rarely flat. Substrate irregularities challenge walking animals to maintain stability, yet we lack quantitative assessments of walking performance and limb kinematics on naturally rough ground. We measured how continually rough 3D-printed substrates influence walking performance of Argentine ants by measuring walking speeds of wo...
Citations
... Those thermal variations may lead to minor thermal effects in the workpiece material by way of softening or thermal expansion, thus affecting the machining dynamics. During material removal, it forms chips and debris that have to be effectively cleared from the machining zone for effective tool-workpiece interaction [38][39][40]. This flexibility of the abrasive film allows the spaces between grains to act as chip storage reservoirs, avoiding clogging and hence retaining the cutting efficiency [41,42]. ...
This work investigates the contact between abrasive particles and workpieces in microfinishing processes with special consideration given to the determination of unit force, unit pressure, and grain, the forces exerted by individual abrasive grains. A detailed methodology was established for measuring the contact area, penetration depth, and circumferences of grain imprints at depths corresponding to multiples of the total height of the abrasive film, represented by the parameter Sz. The following depths were analyzed: 0.05 Sz, 0.15 Sz, 0.25 Sz, and 0.35 Sz. Results show that the areas closer to the central microfinishing zone bear the highest unit pressures and forces and, thus, contribute dominantly to material removal. It was further found that near the edges of the contact zone, the pressure and force have been reduced to lower material removal efficiency. The non-uniform geometry of abrasive particles was found to significantly affect contact mechanics, more at shallow depths of penetration, whereas the shape of the apex defines the nature of the interaction. A parabolic force and pressure distribution were evident for the irregular load distribution of the microfinishing area. The result brings out the need for further refinement in the design of the abrasive film and pressure distribution in order to achieve improvement in uniformity and efficiency during microfinishing. It would bring out valuable insights on how to improve the effectiveness of an abrasive film and ways of optimizing the process conditions. The results provide a founding stone for further advancement of knowledge in the grain–workpiece interaction, enabling better surface quality and more reliable microfinishing processes.
... Apart from that, the tool travels much slower compared to the workpiece, which provides better control over the surface finishing process [24,25]. Hence, the methodology of pressing an abrasive film against the workpiece surface is a crucial aspect of the process [26][27][28]. With superfinishing, unlike in any conventional machining process, the abrasive film is ...
... This process, due to its precision and controlled cutting, remains ideal for the machining of difficult materials like Ti-6Al-4V and helps in extending components' lives by improving their operational properties. Hence, the methodology of pressing an abrasive film against the workpiece surface is a crucial aspect of the process [26][27][28]. With superfinishing, unlike in any conventional machining process, the abrasive film is pressed by an elastic element to ensure that the pressure is equally distributed over the whole area of contact ( Figure 1) [29][30][31][32]. ...
Ti–6Al–4V is the most commonly used alpha–beta titanium alloy, making it the most prevalent among all titanium alloys. The processed material is widely employed in aerospace, medical, and other industries requiring moderate strength, a good strength-to-weight ratio, and favorable corrosion resistance. A microfinishing process on the titanium alloy surface was conducted using abrasive films with grain sizes of 30, 12, and 9 μm. Superfinishing with abrasive films is a sequential process, where finishing operations are performed with tools of progressively smaller grains. The surface topography measurements of the workpiece were taken after each operation. The experiment was in the direction of developing a new surface smoothness coefficient considering the number and distribution of contact points so as to properly evaluate the quality of the surface finishing. The results showed that the finest-grain films gave the most uniform contact points, thus offering the best tribological characteristics; the 9 LF (micron lapping film) tools gave the smoothest surfaces (Sz = 2 µm), while the biggest-grain films, such as the 30 FF (micron microfinishing film), were less effective since large protrusions formed. This is a suitable study to explore the optimization paths for the superfinishing of titanium alloys, with implications for improving the performance and longevity of components in critical industrial applications.
... The honing stone was considered as an infinitely rigid body. • Belt grinding: Zou et al. [20] or Zhao et al. [21] adopted a similar strategy to Kersting et al.: a measured belt topography virtually scratching the workpiece surface. Movements were determined by the process kinematics and material was removed by a Boolean operation. ...
... Flexible abrasive films allow for adjustments in the width of the cutting zone [14], providing the capability to control the width of the microfinishing zone [15], the size and distribution of pressure, and the number of cutting edges in the processing zone [16]. The width of the cutting zone directly affects various phenomena occurring in the processing zone [17]. The length of the zone depends on the diameter hardness, and working surface shape of the pressure roller, as well as on the workpiece being processed. ...
... Materials 2024,17, 688 ...
In this study, the surface of new lapping films was analyzed, and the lapping finishing process was applied to RG7 tin bronze alloy. The research focused on examining lapping films with electrocorundum grains of nominal sizes 30, 12, and 9 μm, commonly used for achieving smooth surfaces. The manufacturing process involves placing abrasive grains and binder onto a polyester tape, resulting in a heterogeneous distribution of abrasive grains. The study investigates the impact of this random distribution on the performance of lapping films during material removal. Scanning electron microscopy was used to analyze the surface structure of abrasive films, revealing distinctive structures formed by the specific aggregation of abrasive grains. This study explores the influence of different nominal grain sizes on surface finish and aims to optimize lapping processes for diverse applications. The research also delves into microchip analysis, examining the products of the lapping film finishing process. Microchips were observed directly on the abrasive tool surface, revealing insights into their morphology and distribution. The chip segmentation frequency was determined, and they amounted to approximately 0.8 to 3 MHz; these are very high frequencies, which are unique for known chip-forming processes.
... Belt grinding is a kind of elastic grinding processing method, which consists of the belt abrasive particles being fixed on the ring carrier with a certain elastic material, such as a cloth base or paper base, through a binder [22,23]. The belt is tightened by using at least two polymer rubber wheels, as shown in Figure 1. ...
High-performance grinding has been converted from traditional manual grinding to robotic grinding over recent years. Accurate material removal is challenging for workpieces with complex profiles. Over recent years, digital processing of grinding has shown its great potential in the optimization of manufacturing processes and operational efficiency. Thus, quantification of the material removal process is an inevitable trend. This research establishes a three-dimensional model of the grinding workstation and designs the blade back arc grinding trajectory. A prediction model of the blade material removal depth (MRD) is established, based on the Adaptive Neuro-Fuzzy Inference System (ANFIS). Experiments were carried out using the Taguchi method to investigate how certain elements might affect the outcomes. An Analysis of Variance (ANOVA) was used to study the effect of abrasive belt grinding characteristics on blade material removal. The mean absolute percent error (MAPE) of the established ANFIS model, after training and testing, was 3.976%, demonstrating superior performance to the reported findings, which range from 4.373% to 7.960%. ANFIS exhibited superior outcomes, when compared to other prediction models, such as random forest (RF), artificial neural network (ANN), and support vector regression (SVR). This work can provide some sound guidance for high-precision prediction of material removal amounts from surface grinding of steam turbine blades.
... Moreover, applications of various types of regular (available in the commercial software) analysis methods, such as least-square-fitted polynomial planes, selected Gaussian (regression and robust) functions, median filter, spline approach, and fast Fourier transform scheme, were proposed for the evaluation of surface topography parameters from ISO 25178 standards. flexible grinding is required [25]. Moreover, ACF provides two-point correlated information about the spatial relation and dependence of data, indicating randomness or periodicity and isotropy or anisotropy of surface features can be received with this application [26]. ...
In this paper, the validity of the application of an autocorrelation function for resolving some surface topography measurement problems was presented. Various types of surfaces were considered: plateau-honed, honed with burnished dimples, ground, turned, milled, laser-textured, or isotropic. They were measured with stylus and non-contact (optical) methods. Extraction of selected features, such as form and waviness (defined as an L-surface) and high-frequency measurement noise (S-surface) from raw measured data, was supported with an autocorrelation function. It was proposed to select the analysis procedures with an application of the autocorrelation function for both profile (2D) and areal (3D) analysis. Moreover, applications of various types of regular (available in the commercial software) analysis methods, such as least-square-fitted polynomial planes, selected Gaussian (regression and robust) functions, median filter, spline approach, and fast Fourier transform scheme, were proposed for the evaluation of surface topography parameters from ISO 25178 standards.
... Belt grinding is a kind of elastic grinding processing method, which consists of the belt abrasive particles being fixed on the ring carrier with a certain elastic material, such as a cloth base or paper base, through a binder [18,19]. The belt is tightened by using at least two polymer rubber wheels, as shown in Fig. 1. ...
High-performance grinding has been converted from traditional manual grinding to robotic grinding over recent years. Accurate material removal is challenging for workpieces with complex profiles. Over recent years, digital processing of grinding has shown its great potential in the optimization of manufacturing processes and operational efficiency. Thus, quantification of the material removal process is an inevitable trend. This research establishes a three-dimensional model of the grinding workstation and designs the blade back arc grinding trajectory. A prediction model of the blade material removal rate (MRR) is established based on the Adaptive Neuro-Fuzzy Inference System (ANFIS). Experiments are carried out using the Taguchi method to investigate how certain elements might affect the outcomes. An Analysis of Variance (ANOVA) is used to study the effect of abrasive belt grinding characteristics on blade material removal. The mean absolute percent error (MAPE) of the established ANFIS model after training and testing is 3.976%, demonstrating superior performance to the reported findings, which range from 4.373 to 7.96%. ANFIS exhibits superior outcomes when compared to other prediction models, such as random forest(RF), artificial neural network (ANN), and support vector regression (SVR). This work can provide some sound guidance for high-precision prediction of material removal amounts from surface grinding of steam turbine blades.
... To model the evolution of surface roughness, Li et al. [18] combined the virtual abrasive belt topography and grinding kinematic process simulation; they incorporated the 3D Hertz contact model into the kinematics simulation to duplicate the actual contact conditions of multi-pass grinding. Zou et al. [19] used the belt's surface morphology and Johnson transform system to obtain the non-Gaussian surface morphology of the abrasive belt. The belt movement model was then established based on the grits vibration to predict the workpiece surface contour numerically but without considering the occurrence of macroscopic material removal during grinding and without explaining the evaluation criteria of the vibration amplitude. ...
The use of abrasive belts for rail grinding has been recently proposed for removing surface roughness and extend the service life. The roughness of the grinding surface greatly affects the wheel-rail contact behavior and vibration of the rail coach. However, due to the nonlinear elastic contact with the surface and the randomness of the distribution of abrasion, the mechanism of surface roughness formation in abrasive belt rail grinding remains unclear. Thus, in this study, the surface topography was physically modeled, and a numerical calculation approach for determining the local roughness was developed. First, a two-dimensional (2D) digital filtering technology was proposed to quickly simulate the topography of a worn belt with the specified area through a sample abrasive belt surface. Second, combined with the previously proposed contact and material removal models, the time-varying cutting depth of local multi-abrasives was obtained by time-domain and spatial-domain discretization. Third, the envelope containing cutting edges was extracted to study the evolution of the local microscopic profile and the 2D roughness. Finally, the effectiveness of the proposed method was verified by performing grinding experiments, wherein the roughness values Ra and RSm were evaluated under different contact forces, belt speeds, and train speeds.
... To obtain minimally damaged surface layer in silicon wafers, Zhang et al. [7] proposed a new method of high-performance grinding by using developed diamond wheels. Zou et al. [8] developed a new numerical simulation approach to precisely predict the machined surface topography, and the result revealed that the errors between simulated and measured surface roughness were less than 5%. Those works are a great contribution to the traditional grinding and manufacturing, but the research on collision detection of them is lacked, which has a vital impact on grinding process and should not be disregarded. ...
A novel collision detection algorithm of abrasive belt grinding blade integrated disk (blisk) based on improved octree segmentation is proposed, to improve the accuracy and efficiency of collision detection while ensuring dimensional accuracy and surface quality. The traditional collision detection algorithm model is described in detail, among them, the collision detection model of the abrasive belt is obtained by establishing its Oriented Bounding Box (OBB), and the collision detection model of the blisk is established by the octree segmentation. Then, an improved octree segmentation based on k-means clustering method can be presented by analyzing the important factors that affect the collision detection; on this basis, an algorithm of collision detection for abrasive belt grinding blisk is given. Finally, algorithm verification and experimental verification are carried out based on a blisk with certain type, respectively. Compared with the traditional collision detection algorithm, the results with algorithm verification illustrate that the accuracy and efficiency of algorithm in this paper have promoted by 45% and 18.60%, respectively; and the results with experimental verification demonstrate that the accuracy and efficiency of algorithm in this paper have improved by 45% and 18.44%, respectively.
... Furthermore, after both finished abrasive processes, the root mean square (RMS) slopes RΔq decreases and oscillates slightly about 4° [9]. Therefore, the abrasive belt machining is considered a flexible and very precise superfinishing method [8][9][10][11]. ...
In automotive industries, the belt grinding (BG) is a mechanical manufacturing process by removing material using a tool called an abrasive belt. This technique enables high surface quality and reproducibility of high-precision mechanical parts to be achieved. The main objective of this paper is to provide a detailed account of the effect of superfinishing on the surface texture of 16MC5 casehardened steel by the belt grinding process under the alumina abrasive grains (Al2O3) with average sizes (60, 40, 30, 20 and 9 μm), respectively. The surface quality was characterized by one surface roughness parameter (Ra) and three parameters of the Abbott-Firestone curve (Rpk, Rk and Rvk) in order to determine the relationship between the grains size reduction and the surface texture. As all mechanical machining processes with undefined tool geometry (e.g. grinding, polishing, lapping,...etc.), experimental results obtained during measurements suggest a clear relationship between the reduction in abrasive grains size and the surface texture. The minimum quantity lubrication (MQL) also decreases the surface roughness; the lubrication addition helps to achieve better surface quality than the dry belt grinding.
