skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.


Title: Influence of work-roll grinding error and high-fidelity corrective grinding in cold sheet rolling
Award ID(s):
1555531
PAR ID:
10359685
Author(s) / Creator(s):
; ; ;
Date Published:
Journal Name:
The International Journal of Advanced Manufacturing Technology
Volume:
120
Issue:
11-12
ISSN:
0268-3768
Page Range / eLocation ID:
7389 to 7413
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. Liquid jets in surrounding air face capillary and shear forces which eventually disintegrate the jet into droplets or spray. The instabilities developed in the flow inevitably break down an initial laminar (coherent) jet into a turbulent one. In the manufacturing process called grinding, one of the oldest approaches of shaping metals and other materials, liquid coolant jets are frequently used. A non-coherent or turbulent jet has a reduced flow rate due to cavitation, air entrapment and atomization of the fluid particles. The jet spread does not allow the coolant jet to effectively breach the high-speed rotating air layer, created by entrainment of air along the surface of rapidly rotating grinding wheel. The coherent, nearly columnal jet should be sufficiently long to maintain its initial velocity to penetrate the layer of air rotating with the grinding wheel. Thus, in many critical grinding applications, it is advised to use a coherent jet instead of a spray to eradicate defects of ground surface. In this study, we present simulations of liquid jet flows to see how the jet develops and breaks due to surface tension and shear forces. Creating an accurate model to predict liquid jet characteristics, especially for high-speed applications such as grinding wheel cooling would require wellresolving numerical grids and turbulence model selection. The problem being multi-phased with a density ratio of coolant-to-air being order of 1000 adds to the computational complexity. The presented numerical model and results are different compared to the previous simulations of liquid jets as the characteristics of jet disintegration are explored under conditions that closely resemble a grinding cooling application. Finite volume discretization of the flow domain and calculation of flow field characteristics were done by commercial software ANSYS Mesh and ANSYS Fluent modules, respectively. The numerical calculation and visualization of disintegration of free jet and the jet impinging into grinding wheel will be presented. 
    more » « less
  2. null (Ed.)
  3. This paper presents a study of the grinding of three different grades of silicon carbide (SiC) under the same conditions. Surface topography is analyzed using coherent scanning interferometry and scanning electron microscopy. The study provides a baseline understanding of the process mechanics and targets effective selection of process parameters for grinding SiC optics with near optical level surface roughness, thus reducing the need for post-polishing. Samples are raster and spiral ground on conventional precision machines with metal and copper-resin bonded wheels under rough, medium, and finish grinding conditions. Material microstructure and grinding conditions affect attainable surface roughness. Local surface roughness of less than 3 nm RMS was attained in both chemical vapor deposition (CVD) and chemical vapor composite (CVC) SiC. The tool footprint is suitable for sub-aperture machining of a large freeform optics possibly without the need for surface finish correction by post-polishing. Subsurface damage will be assessed in Part 2 of this paper series. 
    more » « less