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Publications (63)
Due to the continuously growing demands from high-added-value sectors such as aerospace, e-mobility or biomedical bound-abrasive technologies are the key to achieving extreme requirements. During grinding, energy is rapidly dissipated as heat, generating thermal fields on the ground part which are characterized by high temperatures and very steep g...
Smart manufacturing factories rely on the Internet of Things to drive changes to the machine-tool sector. Grinding processes play a leading role in the manufacturing of high added-value components for high-tech sectors. CBN and diamond grinding wheels are leading the next generation of advanced grinding. One of the critical points is the control of...
Superabrasive grinding of advanced materials parts with complex geometry is a critical issue for aerospace or energy industry. Likewise, conditioning of superabrasive is a key process in order to obtain the most effective grinding. While from industrial point of view the conditioning parameters and dressers are designed from the experience, from sc...
One of the most recent trends in industrial grinding is the use of customized grinding wheels, with the need to completely characterize abrasive grains and bond behavior. Thus, the main goal of the present research work was to evaluate the influence of the crystalline structure of abrasive grains on both the topography and wear of the grinding whee...
Grinding is a critical technology in the manufacturing of high added-value precision parts, accounting for approximately 20-25% of all machining costs in the industrialized world. It is a commonly used process in the finishing of parts in numerous key industrial sectors such as transport (including the aeronautical, automotive and railway industrie...
Dressing process is a critical issue for grinding process optimization. Depending on the grinding wheel material, shape or even the dimensional and geometrical tolerances of the workpiece and its surface roughness, dresser tool and dresser parameters have to be designed. Likewise, one of the problematic of dressers is the wear that they suffer. In...
Dressing is a critical issue for optimizing the grinding process. Dresser tool and dresser parameters must be designed according to the grinding wheel material, shape, or even the dimensional and geometrical tolerances of the workpiece and its surface roughness. Likewise, one of the problematic issues of dressers is the wear that they suffer. In or...
Grinding burn is one of the main problems in grinding and it is nowadays a matter of concern both for Academia and Industry. Research works along the last 50 years have shown that as much as 60-85% of the total consumed power is conducted to the workpiece in the form of heat. As a consequence, surface and subsurface temperature of the component ris...
Workpiece rejection originated by thermal damage is of great concern in high added-value industries, such as automotive or aerospace. Surface temperature control is vital to avoid this kind of damage. Difficulties in empirical measurement of surface temperatures in-process imply the measurement in points other than the ground surface. Indirect esti...
Diamantaketa prozesuaren eragin nabarmenetako bat, prozesu honek arteztutako piezaren gainazaleko akabera baldintzatzen duela da. Hain zuzen, zeharkako aitzinapena duen diamantaketa prozesuen eraginez, arteztutako piezen gainazalean helize itxurako markak agertu ohi dira. Gisa honetako markak agertzeak, eragin negatiboak ekar ditzake haien funtzio...
Manufacturing of grinding wheels is continuously adapting to new industrial requirements. New abrasives and new wheel configurations, together with wheel wear control allow for grinding process optimization. However, the wear behavior of the new abrasive materials is not usually studied from a scientific point of view due to the difficulty to contr...
Manufacturing of grinding wheels is continuously adapting to new industrial requirements. New abrasives and new wheel configurations, together with wheel wear control allow for grinding process optimization. However, the wear behavior of the new abrasive materials is not usually studied from a scientific point of view due to the difficulty to contr...
Wheel wear is a critical issue for grinding process optimization. This is why it receives so much attention both from Academia and industry. The development of new generations of abrasive wheels requires improving the understanding of the mechanisms involved in the loss of abrasive capacity of the wheels. In the case of alumina wheels, which are la...
Grinding process is a very important process in machining industry to manufacture high quality part. The correct preparation of grinding wheel involves dressing process taking importance to optimize grinding process. Due to the different dressing tools types, it is very difficult to find the most adequate tool for a particular application. In this...
Grinding process is a very important process in machining industry to manufacture high quality part. The correct preparation of grinding wheel involves dressing process taking importance to optimize grinding process. Due to the different dressing tools types, it is very difficult to find the most adequate tool for a particular application. In this...
Grinding technologies represent a critical step in the production of high added-value and high precision parts for strategic industrial sectors such as aerospace, automotive, biomedical, and wind generation. Whilst a number of factors related to the grinding wheel are important for optimizing the grinding process, there is no doubt that the wheel s...
In order to comply with strict environmental regulations, a current challenge for industry is the need to reduce, or, where possible, completely eliminate the use of cooling and lubricant fluids. In the case of a high added-value technology such as grinding (typical in aerospace, biomedical, and other high-tech sectors) the damaging effects of flui...
Creep feed grinding is an abrasive finishing process characterized by low feed speeds (0.05-0.5 m/min) and very high depths of cut (0.1-30mm). Thanks to the extraordinary material removal rate provided together with a high shape accuracy obtained over complex profiles, this process has become the main competitor of milling. However, creep feed grin...
In this paper, the friction conditions of minimum coolant grinding (MCG) technology are deeply characterized. The MCG is a successful cooling/lubricating system that combines the application of minimum quantity of lubrication (MQL) and CO2 at low temperatures to create a frozen layer of oil able to reach the contact zone. This technique has previou...
Grinding is a critical machining process because it produces parts of high precision and high surface quality. Due to the semi-artisan production of the wheel, it is not possible to know in advance the performance of the wheel. One of the most useful parameters to characterize the grinding process is the specific grinding energy, which varies with...
Grind-hardening is a manufacturing process that uses the heat generated within the grinding zone in order to produce surface hardening. After the process, workpieces present dimensional inaccuracies and a poor surface finish. Thus, a finishing grinding operation has to be carried out. For a successful implementation of the whole process, two proble...
There is a growing interest in the machining of micro-holes with high aspect-ratio in difficult-to-machine alloys for the aerospace industry. Processes based on Electro Discharge Machining (EDM) and developed for the manufacture of both micro-electrode and micro-hole are actually used, but most of them involve micro-EDM machines. In this work, the...
The characterization of friction and tribological phenomena occurring in grinding requires reliable experimental input data. Up to now, existing test benches exhibit important limitations. Steep thermal gradients and elastic deformations of both machine structure, and rubbing elements are the main sources of inaccuracy cited in the literature. In t...
Grinding is an abrasive machining process characterized by producing high quality components for high added-value industries. Thermal damage is an undesired phenomenon that may ruin nearly finished products. The study of thermal damage requires understanding the mechanisms of heat partition between wheel and workpiece. In this work and original met...
Grinding is an advanced machining process for the manufacturing of valuable complex and accurate parts for high added value sectors such as aerospace, wind generation, etc. Due to the extremely severe conditions inside grinding machines, critical process variables such as part surface finish or grinding wheel wear cannot be easily and cheaply measu...
Electrical discharge milling-based processes are a good alternative for the manufacturing of micro-tools. However, some limitations must be considered both on the fields of process cost and control of surface characteristics. The inverse slab electrical discharge milling (ISEDM) process is an economic alternative to other high-precision high-cost m...
Grind-hardening is an innovative manufacturing process that takes advantage of the high amount of heat generated in the contact zone to produce a martensitic phase transformation in the subsurface layer of the workpiece. However, for a successful industrial implementation of the process, the closed loop control of the hardening depth is essential....
The grind-hardening process uses the heat generated within the grinding zone in order to produce surface hardening of the workpiece. However, after the process, workpieces present dimensional inaccuracies and poor surface roughness. Thus, a final grinding operation has to be performed. For an industrial implementation of the whole process, two prob...
Holes of 0.3-0.4 mm diameter and large depths are typical features in aerospace components of Ni-based and Ti-based alloys. The EDM process is a popular manufacturing method for this type of precision holes in difficult-to-machine materials. Optimization of this technology requires taking into account different aspects such as process parameters, e...
The EDM process is adequate for machining of narrow slots in low machinability materials, such as Ni based alloys used for aeronautical applications. This paper studies the influence of main process parameters involved in this process. The objective is to determine the effect of parameters related to the discharge process (current, pulse time and s...
Important research effort is currently being spent on reduction (if not complete removal) of lubricant consumption in machining operations. While scientific and industrial advances can be found in turning, milling and drilling technologies; advances in fluid reduction in grinding are still very limited. The main reason being abrasive processes gene...
Electrical discharge machining is a popular non-traditional machining
process, optimum for accurate machining of complex geometries in hard
materials. EDM has been used for decades for machining pieces for the
aeronautical industry, but surface integrity, and consequently the
reliability of the machined parts have been questioned for long time due...
The use of fluids in grinding is necessary to carry out an optimized process that avoids any kind of damage in the ground workpieces. However, the use of fluids in machining processes presents some problems as the economic one and the environmental one. The present work analyzes the industrial viability of a new solution to avoid the use of fluids...
Grinding is a stochastic process applied in the last stages of the manufacturing cycle. In last decades, grinding research has focused on prediction of thermal damage on ground workpiece since it is of considerable importance from both research and industrial perspectives. A number of numerical and analytical thermal models have been carried out so...
The process of Wire Electrical Discharge Machining (WEDM) has experienced a dramatic growth in the last years. Together with the new requirements imposed by customer needs, globalization of the markets has brought about a new scenario in which competitiveness is the keyword. In the case of WEDM, it is only possible from a perspective that integrate...
This paper analyses the technological capabilities of a novel rotary (EDM) electrical discharge machining process for the manufacturing of high aspect ratio cylindrical micro-components. The process is called Inverse Electrical Discharge Grinding (ISEDM). An experimental analysis has been carried out on high speed steel (tool steel Vanadis 23), usi...
Manufacturing of micro-pins with diameter less than 1 mm is a field of great interest both in research and in industrial application. There is a wide variety of components of low-diameter cylindrical geometry for various applications, including precision products such as gear shafts, valves, shafts, and channels of micro-fluidic systems, parts for...
Grinding process using superabrasive metal-bonded wheels is unavoidably linked to long and inefficient truing and dressing processes. This document presents the application of electro-discharge dressing process as an alternative to form wheels. The accuracy of the process and its efficiency has been analyzed on wheels of different grit size. To do...
Temperature measurement in grinding has been a widely analyzed field in the study of the process. Temperatures in grinding are too difficult to measure due to the high gradients in the ground workpiece. A lot of different methods have been employed by many researches in the last years. In this paper the use of thermocouples is analyzed attending to...
The adaptation of universities to the European Higher Education Area (EHEA) plays an essential role in society, creating new knowledge, transferring it to students by means of new and more active methodologies aimed at learning that will enable students to put everything they learn into practice. However, such methodologies are not equally applicab...
The increased concern for environment and sustainability are pushing machining operations towards the reduction or even complete elimination of cutting fluids. Grinding is not excluded from this objective, but greater difficulties appear due to the nature of the material removal mechanisms. In this work, two approaches aiming at the optimization of...
The electrical discharge machining (EDM) process is a popular non-traditional machining process, but, although it is widely
used in industry, there is still a lack of scientific knowledge about its fundamentals. This paper discusses some aspects
of the discharge process at the sight of the results obtained with a previously developed thermal model,...
Important research efforts are being devoted to the analysis and optimization of grinding operations. Due to the large number of variables involved in the process, a deeper understanding of the nature of contact mechanics between wheel and workpiece is required. The possibility of a sound estimation of the actual contact length is a critical issue,...
Although there are already successful industrial experiences in other machining industries with the elimination of coolants, this is not so in the grinding industry due to the large amounts of generated heat that must be evacuated from the contact zone. In this work, a new approach to the elimination of fluids in grinding is presented. The technolo...
Superabrasive grinding is a high efficiency process used in special applications such as high speed grinding, creep feed grinding, and Quick-Point. Although the maximum efficiency is obtained by metallic bonded wheels due to their wear resistance, their hardness makes almost impossible to dress them properly. Vitrified bonded wheels are now being u...
In recent years, efforts have been put on modelling of the EDM process, being thermal modelling of the process one promising alternative. In a previous publication an original model of the EDM process was presented; even though predictions made by the proposed model show very high accuracy, there are still some aspects regarding the modelling of th...
Electrical Discharge Machining (EDM) is a non‐conventional machining process whose thermoelectric nature makes it suitable for the machining of any material, regardless of its hardness and of its brittleness, as long as it conducts electricity. Despite EDM is a popular process in industry, the fact that it involves phenomena of very distinct nature...
Taper-cutting is a common application of the wire electrical discharge machining (WEDM) process used for the production of
parts with complex geometry such as extrusion dies in wear-resistant materials, cutting dies, etc. During cutting, the wire
is subject to deformation, resulting in deviations in the inclination angle of machined parts. This fac...
The electrical discharge machining (EDM) process is optimum for accurate machining of complex geometries in hard materials, as those required in the tooling industry. It has become by far the most popular among the non-conventional machining processes. However, although a large number of EDM machines are sold every year, available knowledge of the...
The electrical discharge machining (EDM) process is, by far, the most popular amongst the non-conventional machining processes. The technology is optimum for accurate machining of complex geometries in hard materials, as those required in the tooling industry. However, although a large number of EDM machines are sold every year, scientific knowledg...
In this paper, the design and manufacturing of a CBN metal bonded grinding wheel electro discharge dresser is presented. It is known the difficulty of dressing this type of grinding wheels by conventional methods, therefore the dressing method presented is based in the Electro Discharge Machining (EDM) process. The difficulty in the dressing carrie...
Industrial application of superabrasive metallic-bond form-wheels is currently limited by problems arising when trying to recover geometrical accuracy after precision is lost due to wear. Literature shows this is a current field of research, and different configurations of the electrical discharge dressing process can be found. In this work an orig...