Grinding wheel grooving: innovative and feasible solutions for Canadian manufacturing industries to adopt to significantly reduce costly grinding-burn-induced waste and increase productivity and reliability

砂轮开槽：加拿大制造业采用的创新且可行的解决方案，可显着减少昂贵的磨削烧伤浪费并提高生产率和可靠性

• 批准号: RGPIN-2020-07025
• 负责人: Bauer, Robert
• 金额: $ 1.97万
• 依托单位: Dalhousie University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=760137
• 关键词: Grinding; wheel; grooving; innovative; feasible

The grinding manufacturing process is one of the most essential and costly manufacturing processes accounting for about 25% of the total machining expenditures in industrialized countries. Virtually every manufacturing company worldwide relies on the grinding process to create components with precise dimensions and high-quality surface finishes such as gears, bearings and shafts. Grinding, however, is near the end of the product manufacturing process where the cost of scrapping a workpiece component due to grinding thermal damage can be extremely high. While manufacturers endeavor to take deeper depths of cut at higher feed rates to try to maximize productivity, the risk of thermal damage causes many production grinding processes to be suboptimal with overly conservative process parameters determined by trial-and-error. Grinding research and expertise is, therefore, needed so that industry can optimize existing grinding processes and adopt new grinding technologies. The grinding process is of strategic importance to the Canadian economy because it is critical to myriad industries including automotive, aerospace, shipbuilding, defense, medical, energy, food, electronics and mining - yet there are remarkably few grinding researchers in Canada. To address these needs, the long-term objectives of my research program are to develop new grinding technologies that can be transferred to Canadian industry to enhance productivity, reliability and quality. For example, my research enabled a prominent Canadian aerospace manufacturing company to significantly increase their productivity by applying novel coherent-jet coolant delivery techniques to their grinding processes - reducing their scrap rate in less than a year by 50%. My research has discovered that grinding with a spiral-shaped groove inscribed around the wheel surface can dramatically improve grinding efficiency, reliability and productivity by reducing grinding forces and power (which can lead to thermal damage) by ~50% and enabling up to 300% more material to be removed. The actual process of creating a groove on a grinding wheel, however, is problematic so industry has not adopted this promising technology. Therefore, the short-term objectives of my research program are to: 1. develop and explore the use of a new rotary diamond dresser grooving system to create groove patterns on flat and profiled conventional and super-abrasive grinding wheels as a feasible, practical and desirable solution for Canadian industry to adopt 2. develop and validate essential grinding computer simulation tools to determine optimal wheel grooving geometries, speed ratios and process parameters I have a solid track record of success in this field and the proposed highly-innovative grinding research will make significant advances in grinding technology and create Canadian expertise through the training of highly-qualified personnel in this precision machining process.

制造过程是最重要，最昂贵的制造过程之一，约占工业化国家总加工支出的25％。实际上，全世界的每个制造公司都依赖于磨削过程来创建具有精确尺寸和高质量表面饰面（例如齿轮，轴承和轴）的组件。但是，磨削接近产品制造过程的末尾，在该过程中，由于磨削损害而导致的工件组件的成本可能非常高。尽管制造商努力以更高的饲料速率进行更深的削减以尝试最大化生产率，但热损害的风险会导致许多生产磨削过程是次优的，而过度保守的过程参数由试验和错误确定。因此，需要磨削研究和专业知识，以便行业可以优化现有的研磨过程并采用新的研磨技术。磨削过程对加拿大经济至关重要，因为它对包括汽车，航空航天，造船，国防，医疗，能源，食品，电子，电子和采矿的无数行业至关重要 - 但加拿大的研究人员很少。为了满足这些需求，我的研究计划的长期目标是开发新的研磨技术，这些技术可以转移到加拿大行业，以提高生产率，可靠性和质量。例如，我的研究使一家著名的加拿大航空航天制造公司通过将新型的连贯射流冷却液交付技术应用于其磨削过程，从而大大提高了生产率 - 将不到一年的报废率降低了50％。我的研究发现，在车轮表面上刻有螺旋形的凹槽，可以通过降低研磨力和功率（可能导致热损害）降低约50％，并使高达300％，从而极大地提高磨削效率，可靠性和生产率更多的材料要去除。但是，在磨轮上创建凹槽的实际过程是有问题的，因此行业尚未采用这种有前途的技术。因此，我的研究计划的短期目标是：1。开发和探索使用新的旋转钻石梳妆台凹槽槽系统，以在平坦和剖析的传统和超级含糊的磨削轮上创建凹槽图案，作为可行，实用和实用和实用和实用和对于加拿大行业采用2的理想解决方案。开发和验证必不可少的磨削计算机模拟工具来确定最佳的车轮槽几何形状，速度比和过程参数，我在该领域的成功记录良好，并且提出的高度创新的磨削研究将使通过在这个精确的加工过程中培训高度合格的人员，在研磨技术方面取得了重大进步，并创造了加拿大的专业知识。