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Jha, Sunil
- Experimental Analysis of Brazed Diamond Dresser Using Single Grit Scratch on Zirconia Ceramic
Authors
1 Indian Institute of Technology Delhi, New Delhi, India., IN
Source
Manufacturing Technology Today, Vol 22, No 4 (2023), Pagination: 8-13Abstract
The overall performance of the grinding wheel is difficult to analyze, as it is a compilation of individual abrasive grit contributions. The single grit scratch test is useful to investigate the effect of the individual grit effect on the work material. A vacuum-brazed diamond dresser is developed for the single grit scratch experiment. Partially stabilized zirconia is used as work material to study the mechanics of material removal and mode of grit failure. The experiments were performed in dry conditions by varying the wheel speed, table feed, and depth of cut. The grit failure mechanism has been analyzed using a scanning electron microscope image and correlated with the induced force during the scratch test. The results show that the diamond microcracking was observed after 370 mm of grinding scratch marks. And the maximum tangential and normal force withstand by the diamond grit is 13.09 N and 19.65N, respectively.Keywords
Single Grit Scratch, Ceramics, Force Analysis.
References
- Anand, P., Arunachalam, N., & Vijayaraghavan, L. (2019). Evaluation of grinding strategy for bioceramic material through a single grit scratch test using force and acoustic emission signals. Journal of Manufacturing Processes, 37, 457-469. https://doi.org/10.1016/j.jmapro.2018.12.006
- Buhl, S., Leinenbach, C., Spolenak, R., & Wegener, K. (2013). Failure mechanisms and cutting characteristics of brazed single diamond grains. International Journal of Advanced Manufacturing Technology, 66(5-8), 775-786. https://doi.org/10.1007/s00170-012-4365-z
- Denkena, B., Wippermann, A., Busemann, S., Kuntz, M., & Gottwik, L. (2018). Comparison of residual strength behavior after indentation, scratching and grinding of zirconia-based ceramics for medical-technical applications. Journal of the European Ceramic Society, 38(4), 1760-1768. https://doi.org/10.1016/j. jeurceramsoc.2017.11.042
- Denry, I., & Kelly, J. R. (2008). State of the art of zirconia for dental applications. Dental Materials, 24(3), 299-307. https://doi.org/10.1016/j. dental.2007.05.007
- Flanders, L. A., Quinn, J. B., Wilson, O. C., & Lloyd, I. K. (2003). Scratch hardness and chipping of dental ceramics under different environments. Dental Materials, 19(8), 716-724. https://doi. org/10.1016/S0109-5641(03)00018-6
- Lee, S. K., Tandon, R., Readey, M. J., & Lawn, B. R. (2000). Scratch damage in zirconia ceramics. Journal of the American Ceramic Society, 83(6), 1428-1432. https://doi. org/10.1111/j.1151-2916.2000.tb01406.x
- Matsuo, T., Toyoura, S., Oshima, E., & Ohbuchi, Y. (1989). Effect of Grain Shape on Cutting Force in Superabrasive Single-Grit Tests. CIRP Annals - Manufacturing Technology, 38(1), 323-326. https://doi.org/10.1016/S0007-8506 (07)62714-0
- Naskar, A., Choudhary, A., & Paul, S. (2020). Wear mechanism in high-speed superabrasive grinding of titanium alloy and its effect on surface integrity. Wear, 462-463(September), 203475. https://doi.org/10.1016/j.wear.2020.203475
- Ohbuchi, Y., & Matsuo, T. (1991). Force and Chip Formation in Single-Grit Orthogonal Cutting with Shaped CBN and Diamond Grains. CIRP Annals - Manufacturing Technology, 40(1), 327-330. https://doi.org/10.1016/S0007-8506 (07)61998-2
- Development of CNC Machine Code and User Interface for a 3-Axis Pneumatically Configurable Polishing Machine
Authors
1 Indian Institute of Technology Delhi, New Delhi, IN
Source
Manufacturing Technology Today, Vol 22, No 2 (2023), Pagination: 50 - 55Abstract
The polishing of freeform surfaces finds applications in a variety of niche areas where the surface characteristics have a defining impact on functional capabilities of the product. Pneumatically Configurable Polishing (PCP) is a recent addition to the available technologies which can generate surface finish of nanometric scales on freeform surfaces. The manipulative ease and determinism in polishing force control offered by the PCP process allow it to finish complex surface profiles in a highly repeatable way. The automation code for a CNC PCP machine-tool is developed to ensure the accuracy in the finished parts being produced. The machine code for CNC interpolation and the parametric process control have been carried out in the Parker Automation Manager software. The user interface has been designed and deployed using the JMobile HMI software. The PAM Visualization allows the user defined part program to be loaded in the controller from an external removable disk. The exchange of tags and process variables between the controller and HMI has been done using the OPC UA platform. A part program created using a CAM software is employed to finish a sample workpiece. The developed CNC machine code is successfully tested and evaluated for its functional performance and process repeatability.
Keywords
Parker PAC 320 Controller, Pneumatically Configurable Polishing (PCP), CNC Machine Code, JMobile StudioReferences
- Alam, Z., Iqbal, F., & Jha, S. (2015). Automated control of three axis CNC ball end magneto- rheological finishing machine using PLC. International Journal of Automation and Control, 9(3), 201-210. https://doi.org/10.1504/ IJAAC.2015.070956
- Cao, Z. C., & Cheung, C. F. (2016). Multi-scale modeling and simulation of material removal characteristics in computer-controlled bonnet polishing. International Journal of Mechanical Sciences, 106, 147-156. https://doi.org/10.1016/ j.ijmecsci.2015.12.011
- Kumar Singh, A., Jha, S., & Pandey, P. M. (2011). Design and development of nanofinishing process for 3D surfaces using ball end MR finishing tool. International Journal of Machine Tools and Manufacture, 51(2), 142-151. https:// doi.org/10.1016/j.ijmachtools.2010.10.002
- Lin, B., Li, K. L., Cao, Z. C., & Huang, T. (2019). Modeling of pad surface topography and material removal characteristics for computer- controlled optical surfacing process. Journal of Materials Processing Technology, 265, (October 2018), 210-218. https://doi.org/10.1016/j. jmatprotec.2018.10.027
- Mohammad, A. E. K., Hong, J., & Wang, D. (2018). Design of a force-controlled end-effector with low-inertia effect for robotic polishing using macro-mini robot approach. Robotics and Computer-Integrated Manufacturing, 49, (November 2016), 54-65. https://doi. org/10.1016/j.rcim.2017.05.011
- Verma, T., Chawla, O., & Jha, S. (2022). Mathematical modelling for prediction of surface roughness in Pneumatically Configurable Polishing process. Wear, 504-505, (March), 204434. https://doi. org/10.1016/j.wear.2022.204434
- Xu, P., Cheung, C. F., Wang, C., & Zhao, C. (2020). Novel hybrid robot and its processes for precision polishing of freeform surfaces. Precision Engineering, 64, (January), 53-62. https://doi. org/10.1016/j.precisioneng.2020.03.013
- Effect of Applied Pneumatic Pressure on the Polishing Spot Size and the Total Normal Force in Pneumatically Configurable Polishing
Authors
1 Indian Institute of Technology Delhi, New Delhi, IN
Source
Manufacturing Technology Today, Vol 22, No 2 (2023), Pagination: 56 - 60Abstract
The present study pertains to a compliant polishing technique called Pneumatically Configurable Polishing (PCP) which uses the precise inflation of a thin elastomeric diaphragm or membrane using pneumatic pressure for generating nano level surface finish on substrate surfaces. The PC polishing tool which has a cup shape is made to contact the workpiece surface such that its flexible nature can adapt itself to the macro features on the workpiece. This inflated tool-work contact leads to the entrapment of the hard abrasives preplaced in the interface zone in the form of a slurry. The rotary motion of the tool along with the relative motion between the workpiece and tool, help to generate an improved surface finish in the interface area. The area of the finishing zone is an important outcome of the polishing regime because it defines the dimensions of the area which will be affected by the tool. It also helps to estimate the time needed for polishing a large area. Also, the force transmitted to the workpiece surface is an important measure to estimate the functional life of the tool. In the current study, the variation of the spot size and total normal force are modelled mathematically in terms of the physical and geometrical properties of the tool as well as the applied fluid pressure. The Hertz theory of contact is used to model the contact conditions in the polishing interface zone. The model studies the effect of pneumatic pressure on membrane inflation and its influence on the area of the polishing spot at varying working gaps. The effect of the applied fluid pressure is studied on the normal force experienced by the workpiece, and the results obtained from the model are validated with experimental verification under identical polishing conditions. The values obtained experimentally show a close agreement with the theoretical results obtained from the model.
Keywords
Surface Finish, Compliant Polishing, Polishing Spot Size, Mathematical ModelReferences
- Cao, Z., & Fai, C. (2016). International journal of mechanical sciences multi-scale modeling and simulation of material removal characteristics in computer-controlled bonnet polishing. International Journal of Mechanical Sciences, 106,147-156.https://doi.org/10.1016/j.ijmecsci. 2015.12.011
- Jha, S., & Jain, V. K. (2004). Design and development of the magnetorheological abrasive flow finishing (MRAFF) process. International Journal of Machine Tools and Manufacture, 44(10), 1019-1029. https://doi.org/10.1016/j. ijmachtools.2004.03.007
- Singh, A. K., Jha, S., & Pandey, P. M. (2011). International journal of machine tools & manufacture design and development of nanofinishing process for 3D surfaces using ball end MR finishing tool. International Journal of Machine Tools and Manufacture, 51(2), 142-151. https://doi.org/10.1016/j. ijmachtools.2010.10.002
- Verma, T., Chawla, O., & Jha, S. (2022). Mathematical modelling for prediction of surface roughness in pneumatically configurable polishing process. Wear, 504-505, (July), 204434. https:// doi.org/10.1016/j.wear.2022.204434
- Zhang, J., Wang, H., Kumar, A. S., & Jin, M. (2020). Experimental and theoretical study of internal finishing by a novel magnetically driven polishing tool. International Journal of Machine Tools and Manufacture, 153, (March), 103552. https://doi.org/10.1016/j.ijmachtools. 2020.103552
- Zhu, W., & Beaucamp, A. (2020). International Journal of Machine Tools and Manufacture Compliant grinding and polishing : A review. International Journal of Machine Tools and Manufacture, 158, (July), 103634. https://doi. org/10.1016/j.ijmachtools.2020.103634