Quantitative model of dressing vitrified bonded grinding wheels

• Applicant: Professor Dr.-Ing. Fritz Klocke
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2011 to 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 190817249

The performance of grinding processes is significantly determined by the preparation of the grinding tools. Although dressing of vitrified bonded grinding wheels has been examined for decades and many correlations between the dressing parameters and the dressing results in terms of the grinding wheel condition and its process behavior are known, the dressing result cannot be described quantitatively yet. Existing models do only consider kinematic-geometric parameters, but this is insufficient to describe or explain the dressing process. Linke developed a model that also considers the dressing force and the collisions in the dressing process. However, in this approach, the description of the dressing result and thus the relationship between the developed parameters and the process behavior of the grinding wheel is not taken into account.These missing relationships were examined in the project funded by the DFG. It was possible to establish an analytical-empirical model for the dressing process that allows a quantitative prediction of the initial wear of the grinding wheel in particular. The project results enable a knowledge-based, targeted and reproducible setup of the grinding wheel for an optimized process and thus an optimized grinding result.The objective for the third year of research therefore is an extension of the model to other grinding wheel and dressing roller specifications to ensure wide applicability of the model.To achieve the objective, extensive dressing and grinding tests will be carried out in which the dressing roller specification on one hand and subsequently the grinding wheel specification on the other hand will be varied. The grinding wheel hardness, the grinding wheel grain size, the dressing roller grain size and the surface density of diamonds of the galvanic dressing roller will be investigated. By this procedure, the influence of the grinding wheel specification as well as the dressing roller specification on the wear behavior of the grinding wheel, on the workpiece roughness and on the effective surface roughness of the grinding wheel is systematically identified. Finally, the new findings will be implemented in the dressing model. The result is a dressing model that predicts the grinding wheel wear behavior, the workpiece roughness and the effective surface roughness of the grinding wheel as a function of the dressing parameters, considering the dressing roller specification and the grinding wheel specification.

• DFG Programme: Research Grants