Laser conditioning and structuring of grinding tools-a review

doi:10.1007/s40436-016-0167-0

Abstract

Abstract:

The conditioning of grinding tools is one of the most important factors for achieving an optimal grinding process. It influences the grinding forces and temperatures and, therefore, the achievable material removal rate, dimensional accuracy and the surface integrity of the workpiece. Furthermore, the roundness, profile accuracy and the wear of the grinding tools are strongly influenced by the conditioning process. The conditioning process should be matched to the abrasive type and the bonding of the grinding tool. Laser conditioning is a promising unconventional and non-contact method, which is able to condition all kinds of abrasives and bonding types. The main advantages of this novel method are no tool wear, good repeatability and controllability, high precision and a relatively short process time. Additionally, using this method grinding tools can be micro-structured. This paper reviews the literature on the laser conditioning of grinding tools, covering the associated setups, wheel conditioning and structuring mechanisms, and experimental results. It also discusses the technical barriers that have to be overcome before laser conditioning can be fully integrated into manufacturing.

Key words: Laser conditioning, Structuring, Dressing, Truing, Grinding tools, Grinding

Bahman Azarhoushang, Ali Zahedi. Laser conditioning and structuring of grinding tools-a review[J]. Advances in Manufacturing, 2017, 5(1): 35-49.

TrendMD

References

1. Daneshi A, Jandaghi N, Tawakoli T (2014) Effect of dressing on internal cylindrical grinding. Procedia CIRP 14:37-41
2. Rowe WB (2014) Grinding wheel dressing. In:Rowe WB (ed) Principles of modern grinding technology, 2nd edn. William Andrew, Waltham, pp 63-82
3. Shih AJ (2000) An experimental investigation of rotary diamond truing and dressing of vitreous bond wheels for ceramic grinding. Int J Mach Tools Manuf 40:1755-1774
4. Wegener K, Hoffmeister HW, Karpuschewski B et al (2011) Conditioning and monitoring of grinding wheels. CIRP Ann Manuf Technol 60:757-777
5. Linke BS (2007) Wirkmechanismen beim Abrichten keramisch gebundener Schleifscheiben. Shaker, Aachen
6. Klocke F, Kuchle A (2009) Grinding, honing, lapping. Springer, Berlin
7. Kitzig H, Tawakoli T, Azarhoushang B (2016) A novel ultrasonicassisted dressing method of electroplated grinding wheels via stationary diamond dresser. Int J Adv Manuf Technol 86(1):1-8
8. Azarhoushang B, Rasifard A (2014) Das Abrichten als ein integraler Bestandteil des Schleifprozesses. Diam Bus 49:66-73
9. Marinescu ID (2007) Handbook of machining with grinding wheels. CRC, Boca Raton
10. Westkämper E (1995) Grinding assisted by Nd:YAG lasers. CIRP Ann Manuf Technol 44:317-320
11. Malkin S, Guo C (2008) Grinding technology:theory and applications of machining with abrasives. 2nd edn. Industrial Press, New York
12. Tawakoli T, Rasifard A (2011) Dressing of grinding wheels. In:Jackson JM, Davim PJ (eds) Machining with abrasives. Springer, US, Boston, pp 181-244
13. Zahedi A, Azarhoushang B, Akbari J et al (2016) Optimization and application of laser-dressed cBN grinding wheels. Adv Mater Res 1136:90-96
14. Schöpf M, Beltrami I, Boccadoro M et al (2001) ECDM (electro chemical discharge machining), a new method for trueing and dressing of metal bonded diamond grinding tools. CIRP Ann Manuf Technol 50:125-128
15. Wei C, Hu D, Xu K et al (2011) Electrochemical discharge dressing of metal bond micro-grinding tools. Int J Mach Tools Manuf 51:165-168
16. Pavel R, Pavel M, Marinescu I (2004) Investigation of predressing time for ELID grinding technique. J Mater Process Technol 149:591-596
17. Rabiey M (2011) Dry grinding with CBN wheels, the effect of structuring. Dissertation, Universität Stuttgart
18. Azarhoushang B (2011) Intermittent grinding of ceramic matrix composites:unterbrochenes Schleifen von keramischen Faserverbundwerkstoffen. Dissertation, Stuttgart University, Shaker Publication
19. Walter C, Komischke T, Kuster F et al (2014) Laser-structured grinding tools-generation of prototype patterns and performance evaluation. J Mater Process Technol 214:951-961
20. Tawakoli T (2014) Moderne schleiftechnologie und feinstbearbeitung 2014:neue entwicklungen und trends aus forschung und praxis. In:The seminar of moderne schleiftechnologie und feinstbearbeitung. Stuttgart, Volkan
21. Zahedi A, Azarhoushang B (2016) Strukturieren und profilieren mittels laser:moderne schleiftechnologie und feinstbearbeitung. In:The seminar of neue entwicklungen und trends aus forschung und praxis. Volkan
22. Tawakoli T, Rabiey M (2008) An innovative concept and its effects on wheel surface topography in dry grinding by resin and vitrified bond CBN wheel. Mach Sci Tech 12:514-528
23. Tawakoli T, Heisel U, Lee DH et al (2012) An experimental investigation on the characteristics of cylindrical plunge dry grinding with structured cBN wheels. Procedia CIRP 1:399-403
24. Nakayama K, Takagi J, Abe T (1977) Grinding wheel with helical grooves-an attempt to improve the grinding performance. CIRP Ann Manuf Technol 26:133-138
25. Azarhoushang B (2014) Das abrichten als integraler bestandteil des schleifprozesses:unkonventionelle Abrichtprozesse. Diam Bus 50:82-89
26. Kong MC, Miron CB, Axinte DA et al (2012) On the relationship between the dynamics of the power density and workpiece surface texture in pulsed laser ablation. CIRP Ann Manuf Technol 61:203-206
27. Yang J, Sun S, Brandt M et al (2010) Experimental investigation and 3D finite element prediction of the heat affected zone during laser assisted machining of Ti6Al4V alloy. J Mater Process Technol 210:2215-2222
28. Tangwarodomnukun V, Likhitangsuwat P, Tevinpibanphan O et al (2015) Laser ablation of titanium alloy under a thin and flowing water layer. Int J Mach Tools Manuf 89:14-28
29. Ahn DG, Byun KW (2009) Influence of cutting parameters on surface characteristics of cut section in cutting of Inconel 718 sheet using CW Nd:YAG laser. Trans Nonferrous Metals Soc China 19:s32-s39
30. Anderson M, Patwa R, Shin YC (2006) Laser-assisted machining of Inconel 718 with an economic analysis. Int J Mach Tools Manuf 46:1879-1891
31. Fabis PM (1996) Laser machining of CVD diamond:chemical and structural alteration effects. Surf Coat Technol 82:320-325
32. Butler-Smith PW, Axinte DA, Daine M (2011) Ordered diamond micro-arrays for ultra-precision grinding-an evaluation in Ti-6Al-4V. Int J Mach Tools Manuf 51:54-66
33. Kovalenko V, Yao J, Zhang Q et al (2013) Laser milling of the intractable materials. Procedia CIRP 6:504-509
34. Samant AN, Dahotre NB (2009) Laser machining of structural ceramics-a review. J Eur Ceram Soc 29:969-993
35. Dhupal D, Doloi B, Bhattacharyya B (2008) Pulsed Nd:YAG laser turning of micro-groove on aluminum oxide ceramic (Al₂O₃). Int J Mach Tools Manuf 48:236-248
36. Fortunato A, Guerrini G, Melkote SN et al (2015) A laser assisted hybrid process chain for high removal rate machining of sintered silicon nitride. CIRP Ann Manuf Technol 64:189-192
37. Kang DW, Lee CM (2014) A study on the development of the laser-assisted milling process and a related constitutive equation for silicon nitride. CIRP Ann Manuf Technol 63:109-112
38. Zahedi A, Tawakoli T, Akbari J et al (2014) Conditioning of vitrified bond CBN grinding wheels using a picosecond laser. Adv Mater Res 1017:573-579
39. Gadag S (2011) Studying the mechanism of micromachining by short pulsed laser. Southern Methodist University, Dallas
40. Giridhar MS, Seong K, Schuelzgen A et al (2004) Femtosecond pulsed laser micromachining of glass substrates with application to microfluidic devices. Appl Opt 43:4584-4589
41. Varel H, Ashkenasi D, Rosenfeld A et al (1997) Micromachining of quartz with ultrashort laser pulses. Appl Phys A 65:367-373
42. Zahedi A, Tawakoli T, Azarhoushang B et al (2014) Picosecond laser treatment of metal-bonded CBN and diamond superabrasive surfaces. Int J Adv Manuf Technol 76:1479-1491
43. Chen G, Deng H, Zhou X et al (2015) Online tangential laser profiling of coarse-grained bronze-bonded diamond wheels. Int J Adv Manuf Technol 79(9):1477-1482
44. Wang XY, Wu YB, Wang J et al (2005) Absorbed energy in laser truing of a small vitrified CBN grinding wheel. J Mater Process Technol 164-165:1128-1133
45. Ramesh BN, Radhakrishnan V, Murti YVGS (1989) Investigations on laser dressing of grinding wheels-Part I:preliminary study. J Eng Ind 111:244
46. Ramesh BN, Radhakrishnan V (1989) Investigations on laser dressing of grinding wheels-Part II:grinding performance of a laser dressed aluminum oxide wheel. J Eng Ind 111:253
47. Ramesh BN, Radhakrishnan V (1995) Influence of dressing feed on the performance of laser dressed Al₂O₃ wheel in wet grinding. Int J Mach Tools Manuf 35:661-671
48. Xie XZ, Chen GY, Li LJ (2004) Dressing of resin-bonded superabrasive grinding wheels by means of acousto-optic Q-switched pulsed Nd:YAG laser. Opt Laser Technol 36:409-419
49. Hosokawa A, Ueda T, Yunoki T (2006) Laser dressing of metal bonded diamond wheel. CIRP Ann Manuf Technol 55:329-332
50. Khangar AA, Kenik EA, Dahotre NB (2005) Microstructure and microtexture in laser-dressed alumina grinding wheel material. Ceram Int 31:621-629
51. Chen G, Mei L, Zhang B et al (2010) Experiment and numerical simulation study on laser truing and dressing of bronze-bonded diamond wheel. Opt Lasers Eng 48:295-304
52. Timmer JH (2001) Laserkonditionieren von CBN-und Diamantschleifscheiben. Dissertation, Braunschweig University, Vulkan-Verl., Essen
53. Kang RK, Yuan JT, Zhang YP et al (2001) Truing of diamond wheels by laser. KEM 202-203:137-142
54. Chen M, Sun F, Lee Y et al (2003) Laser-assisted grinding wheel dressing (II)-experimental researches. J Mater Sci Technol 19:167-168
55. Chen X, Feng ZJ, Pashby IR (2004) A study on laser cleaning of Al₂O₃ grinding wheels. KEM 257-258:359-364
56. Jackson MJ, Robinson GM, Chen X (2006) Laser surface preparation of vitrified grinding wheels. J Mater Eng Perform 15(2):247-250
57. Dold C, Transchel R, Rabiey M et al (2011) A study on laser touch dressing of electroplated diamond wheels using pulsed picosecond laser sources. CIRP Ann Manuf Technol 60:363-366
58. Khangar A, Dahotre NB, Jackson MJ et al (2006) Laser dressing of alumina grinding wheels. J Mater Eng Perform 15(2):178-181
59. Rabiey M, Walter C, Kuster F et al (2012) Dressing of hybrid bond CBN wheels using short-pulse fiber laser. SV-JME 58:462-469
60. Walter C, Rabiey M, Warhanek M et al (2012) Dressing and truing of hybrid bonded CBN grinding tools using a short-pulsed fibre laser. CIRP Ann Manuf Technol 61:279-282
61. Khangar A, Dahotre NB (2005) Morphological modification in laser-dressed alumina grinding wheel material for microscale grinding. J Mater Process Technol 170:1-10
62. von Witzendorff P, Stompe M, Moalem A et al (2014) Dicing of hard and brittle materials with on-machine laser-dressed metalbonded diamond blades. Precis Eng 38:162-167
63. Guo B, Zhao Q, Fang X (2014) Precision grinding of optical glass with laser micro-structured coarse-grained diamond wheels. J Mater Process Technol 214:1045-1051
64. Walter C, Komischke T, Weingärtner E et al (2014) Structuring of CBN grinding tools by ultrashort pulse laser ablation. Procedia CIRP 14:31-36
65. Stutz GE, Marshall GF (2012) Handbook of optical and laser scanning, 2nd edn. CRC, Boca Raton
66. Azarhoushang B, Zahedi A (2016) Laserabrichten von superabrasiven Schleifwerkzeugen:moderne schleiftechnologie und feinstbearbeitung. In:The Seminar of Neue Entwicklungen und Trends aus Forschung und Praxis, Volkan
67. Jackson MJ, Khangar A, Chen X et al (2007) Laser cleaning and dressing of vitrified grinding wheels. J Mater Process Technol 185:17-23
68. Yung KC, Chen GY, Li LJ (2003) The laser dressing of resinbonded CBN wheels by a Q-switched Nd:YAG laser. Int J Adv Manuf Technol 22(7):541-546

[1]	Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding. An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels [J]. Advances in Manufacturing, 2020, 8(2): 160-176.
[2]	Ping Zhou, Zi-Guang Wang, Ying Yan, Ning Huang, Ren-Ke Kang, Dong-Ming Guo. Sensitivity analysis of the surface integrity of monocrystalline silicon to grinding speed with same grain depth-of-cut [J]. Advances in Manufacturing, 2020, 8(1): 97-106.
[3]	Xiao-Liang Shi, Shi-Chao Xiu, Hui-Ling Su. Residual stress model of pre-stressed dry grinding considering coupling of thermal, stress, and phase transformation [J]. Advances in Manufacturing, 2019, 7(4): 401-410.
[4]	Shi-Jie Dai, Xiao-Qiang Li, Hui-Bo Zhang. Research on temperature field of non-uniform heat source model in surface grinding by cup wheel [J]. Advances in Manufacturing, 2019, 7(3): 326-342.
[5]	V. G. Ladeesh, R. Manu. Effect of machining parameters on edge-chipping during drilling of glass using grinding-aided electrochemical discharge machining (G-ECDM) [J]. Advances in Manufacturing, 2018, 6(2): 215-224.
[6]	Sandip Kunar, B. Bhattacharyya. Investigation on surface structuring generated by electrochemical micromachining [J]. Advances in Manufacturing, 2017, 5(3): 217-230.
[7]	Zi-Li Xu, Song Lu, Jun Yang, Yong-Hui Feng, Chun-Tai Shen. A wheel-type in-pipe robot for grinding weld beads [J]. Advances in Manufacturing, 2017, 5(2): 182-190.
[8]	Mustafa Bakkal, Erdinç Serbest, İlker Karipçin, Ali T. Kuzu, Umut Karagüzel, Bora Derin. An experimental study on grinding of Zr-based bulk metallic glass [J]. Advances in Manufacturing, 2015, 3(4): 282-291.