High-speed grinding: from mechanism to machine tool

  • Yu-Long Wang ,
  • Yan-Bin Zhang ,
  • Xin Cui ,
  • Xiao-Liang Liang ,
  • Run-Ze Li ,
  • Ruo-Xin Wang ,
  • Shubham Sharma ,
  • Ming-Zheng Liu ,
  • Teng Gao ,
  • Zong-Ming Zhou ,
  • Xiao-Ming Wang ,
  • Yusuf Suleiman Dambatta ,
  • Chang-He Li
Expand
  • 1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, Shandong, People's Republic of China;
    2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan 250061, People's Republic of China;
    3. Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA, USA;
    4. State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, People's Republic of China;
    5. Department of Mechanical Engineering and Advanced Materials Science, Council of Scientific and Industrial Research (CSIR)-Central Leather Research Institute (CLRI), Regional Center for Extension and Development, Jalandhar 144021, India;
    6. Hanergy (Qingdao) Lubrication Technology Co., Ltd., Qingdao 266200, Shandong, People's Republic of China;
    7. Department of Mechanical Engineering, Ahmadu Bello University, Zaria, Nigeria

Received date: 2023-10-26

  Revised date: 2023-12-11

  Online published: 2025-02-26

Supported by

This research was financially supported by the Special Fund of Taishan Scholars Project (Grant No.tsqn202211179), the National Natural Science Foundation of China (Grant No. 52105457), the Youth Talent Promotion Project in Shandong (Grant No. SDAST2021qt12), the National Natural Science Foundation of China (Grant No. 52375447)

Abstract

High-speed grinding (HSG) is an advanced technology for precision machining of difficult-to-cut materials in aerospace and other fields, which could solve surface burns, defects and improve surface integrity by increasing the linear speed of the grinding wheel. The advantages of HSG have been preliminarily confirmed and the equipment has been built for experimental research, which can achieve a high grinding speed of more than 300 m/s. However, it is not yet widely used in manufacturing due to the insufficient understanding on material removal mechanism and characteristics of HSG machine tool. To fill this gap, this paper provides a comprehensive overview of HSG technologies. A new direction for adding auxiliary process in HSG is proposed. Firstly, the combined influence law of strain hardening, strain rate intensification, and thermal softening effects on material removal mechanism was revealed, and models of material removal strain rate, grinding force and grinding temperature were summarized. Secondly, the constitutive models under high strain rate boundaries were summarized by considering various properties of material and grinding parameters. Thirdly, the change law of material removal mechanism of HSG was revealed when the thermodynamic boundary conditions changed, by introducing lubrication conditions such as minimum quantity lubrication (MQL), nano-lubricant minimum quantity lubrication (NMQL) and cryogenic air (CA). Finally, the mechanical and dynamic characteristics of the key components of HSG machine tool were summarized, including main body, grinding wheel, spindle and dynamic balance system. Based on the content summarized in this paper, the prospect of HSG is put forward. This study establishes a solid foundation for future developments in the field and points to promising directions for further exploration.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00508-x

Cite this article

Yu-Long Wang , Yan-Bin Zhang , Xin Cui , Xiao-Liang Liang , Run-Ze Li , Ruo-Xin Wang , Shubham Sharma , Ming-Zheng Liu , Teng Gao , Zong-Ming Zhou , Xiao-Ming Wang , Yusuf Suleiman Dambatta , Chang-He Li . High-speed grinding: from mechanism to machine tool[J]. Advances in Manufacturing, 2025 , 13(1) : 105 -154 . DOI: 10.1007/s40436-024-00508-x

References

[1] Gong P, Zhang YB, Li CH et al (2023) Residual stress generation in grinding: mechanism and modeling. J Mater Process Tech 324:118262. https://doi.org/10.1016/j.jmatprotec.2023.118262
[2] Cui X, Li CH, Yang M et al (2023) Enhanced grindability and mechanism in the magnetic traction nanolubricant grinding of Ti-6Al-4V. Tribol Int 186:108603. https://doi.org/10.1016/j.triboint.2023.108603
[3] Liu MZ, Li CH, Yang M et al (2023) Mechanism and enhanced grindability of cryogenic air combined with biolubricant grinding titanium alloy. Tribol Int 187:108704. https://doi.org/10.1016/j.triboint.2023.108704
[4] Cui X, Li CH, Zhang YB et al (2022) Grindability of titanium alloy using cryogenic nanolubricant minimum quantity lubrication. J Manuf Process 80:273-286
[5] Yang M, Kong M, Li CH et al (2023) Temperature field model in surface grinding: a comparative assessment. Int J Extreme Manuf 5(4):042011. https://doi.org/10.1088/2631-7990/ACF4D4
[6] Wang H, Huang LJ, Yao C et al (2015) Integrated analysis method of thin-walled turbine blade precise machining. Int J Precis Eng Manuf 16:1011-1019
[7] Zhao GL, Zhao B, Ding WF et al (2024) Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis. Int J Extrem Manuf 6(2):022007. https://doi.org/10.1088/2631-7990/ad16d6
[8] Wang BX, Zhao YJ, Liu GY et al (2023) Preventing thermal osteonecrosis through 3D printed ceramic grinding tool. Addit Manuf 78:103878. https://doi.org/10.1016/j.addma.2023.103878
[9] Huang WH, Yan JW (2023) Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review. Int J Extrem Manuf 5(1):012003. https://doi.org/10.1088/2631-7990/acab3f
[10] Liang XL, Liu CQ, Wang B et al (2023) Friction behaviors in the metal cutting process: state of the art and future perspectives. Int J Extrem Manuf 5(1):012002. https://doi.org/10.1088/2631-7990/ac9e27
[11] Song YX, Li CH, Zhou ZM et al (2024) Nanobiolubricant grinding: a comprehensive review. Adv Manuf 12(1) 1-42
[12] Choi YJ, Park KH, Hong YH et al (2013) Effect of ultrasonic vibration in grinding; horn design and experiment. Int J Precis Eng Manuf 14(11):1873-1879
[13] Sun C, Xiu SC, Hong Y et al (2020) Prediction on residual stress with mechanical-thermal and transformation coupled in DGH. Int J Mech Sci 179:105629. https://doi.org/10.1016/j.ijmecsci.2020.105629
[14] Yang L, Chu CH, Fu YC et al (2015) CFRP grinding wheels for high speed and ultra-high speed grinding: a review of current technologies and research strategies. Int J Precis Eng Manuf 16(12):2599-2606
[15] Li BZ, Ni JM, Yang JG et al (2014) Study on high-speed grinding mechanisms for quality and process efficiency. Int J Adv Manuf Tech 70:813-819
[16] Zhu Y (2021) Exploration of the application of ultra-high speed grinding technology in machinery manufacturing. Intern Combus Eng Parts 3:109-110
[17] Yuan JL, Deng ZH, Xiong WL et al (2010) Development and prospect of high-efficiency grinding technology and equipment. Aeronaut Manuf Tech 5:66-70
[18] Akilu S, Sharma KV, Baheta AT et al (2016) A review of thermophysical properties of water based composite nanofluids. Renew Sust Energ Rev 66:654-678
[19] Li C, Hu YX, Wei ZZ et al (2024) Damage evolution and removal behaviors of GaN crystals involved in double-grits grinding. Int J Extrem Manuf 6(2):025103. https://doi.org/10.1088/2631-7990/ad207f
[20] Zhao JS, Zhao B, Ding WF et al (2023) Grinding characteristics of MoS2-coated brazed CBN grinding wheels in dry grinding of titanium alloy. Chin J Mech Eng-En 36(1):109. https://doi.org/10.1186/s10033-023-00936-z
[21] Qian N, Chen JJ, Khan AM et al (2024) Towards sustainable grinding of difficult-to-cut alloys-a little longer a holistic review and trends. Chin J Mech Eng-En 37(1):23. https://doi.org/10.1186/s10033-024-01002-y
[22] Zhao HH, Gao XJ, Cai GQ (2006) Experimental study of impact chip formation mechanism in ultra-high speed grinding. China Mech Eng 42(9):43-47
[23] Zhao HH, Cai GQ, Gao XJ (2006) Research on grinding mechanism of natural marble by ultra-high speed impact grinding. China Mech Eng 7:677-680
[24] Zhao HH, Cai GQ (2004) Construction of impact chip formation model and mechanism research of ultra-high speed grinding. China Mech Eng 12:6-9
[25] Zhao HH, Gao XJ, Cai GQ (2006) Experimental study on chip formation mechanism due to shock of ultra-high speed grinding. China Mech Eng 42(9):43-47
[26] Zhang QL, To S, Zhao QL et al (2016) Surface generation mechanism of WC/Co and RB-SiC/Si composites under high spindle speed grinding (HSSG). Int J Refract Met H 56:123-131
[27] Yin JF, Xu JH, Ding WF et al (2021) Effects of grinding speed on the material removal mechanism in single grain grinding of SiCf/SiC ceramic matrix composite. Ceram Int 47(9):12795-12802
[28] Cheng Z, Xu JH, Ding WF (2011) Simulation study on chip formation process of titanium alloy TC4 grinding with single abrasive particle. Diamond Abrasives Eng 31(2):17-21
[29] Wang ML (2015) Study on material removel mechanism of ultra-high-speed grrinding. Dissertation, Taiyuan Universityof Technology
[30] Li DH (2013) Research on chip-formation mechanism of high-speed grinding for material of difficult machining. Dissertation, Donghua University
[31] Zhou H, Ding WF, Liu CJ (2019) Material removal mechanism of PTMCs in high-speed grinding when considering consecutive action of two abrasive grains. Int J Adv Manuf Tech 100(1/4):153-165
[32] Chen GP (2018) Study on dynamic characteristics and structure optimization of the high speed grinder. Dissertation, Hunan University
[33] Yeo SH, Ramesh K, Zhong ZW (2002) Ultra-high-speed grinding spindle characteristics upon using oil/air mist lubrication. Int J Mach Tool Manu 42(7):815-823
[34] Sun XY, Yao ZQ (2019) Research on thermal characteristics of high-speed grinding spindles and their influencing factors. Mod Mach Tool Autom Manuf Tech 11:17-21
[35] Liu Y, Ma YX, Meng QY et al (2018) Improved thermal resistance network model of motorized spindle system considering temperature variation of cooling system. Adv Manuf 6(4):384-400
[36] Liang JW (2021) Study and development of online dynamic balancing system for high speed grinder. Dissertation, Henan University of Technology
[37] Guo S, Zhang JQ, Jiang QH et al (2022) Surface integrity in high-speed grinding of Al6061T6 alloy. CIRP ANN-Manuf Techn 71(1):281-284
[38] Qiao GW, Zhang B, Guo S et al (2023) Surface morphology in high-speed grinding of TMCs fabricated by selective laser melting. J Manuf Process 97:200-209
[39] Yang L (2017) Fundamental research on the ultra-high speed grinding of nickel-based superalloy with CFRP wheels. Dissertation, Nanjing University of Aeronautics and Astronautics
[40] Lin T, Fu YC, Xu JH et al (2015) The influence of speed on material removal mechanism in high speed grinding with single grit. Int J Mach Tool Manu 89:192-201
[41] Zhan YJ (2013) Mechanisms research on high speed grinding of cemented carbide with vitrified diamond wheels. Dissertation, Huaqiao University
[42] Xiao P (2009) Study on surface integrity of titanium alloy TC4 in ultra high speed grinding process. Dissertation, Hunan University
[43] Yin L, Huang H, Ramesh K et al (2005) High speed versus conventional grinding in high removal rate machining of alumina and alumina-titania. Int J Mach Tool Manu 45(7):897-907
[44] Dai LZ, Chen GY, Shan ZZ (2021) Study on ultra-high speed nano-grinding of monocrystalline copper with V-shaped diamond abrasive grains based on molecular dynamics method. Diam Relat Mater 111:108224. https://doi.org/10.1016/j.diamond.2020.108224
[45] Li P, Chen SY, Jin T et al (2021) Machining behaviors of glass-ceramics in multi-step high-speed grinding: grinding parameter effects and optimization. Ceram Int 47(4):4659-4673
[46] Li Z, Ding WF, Shen L et al (2016) Comparative investigation on high-speed grinding of TiCp/Ti-6Al-4V particulate reinforced titanium matrix composites with single-layer electroplated and brazed CBN wheels. Chin J Aeronaut 29(5):1414-1424
[47] Zhang Z (2017) The investigations of high speed grinding mechanisms on AISI 1045 steel components with narrow deep groove structure. Dissertation, Taiyuan University of Technology
[48] Ren J, Hao MR, Lv M et al (2018) Molecular dynamics research on ultra-high-speed grinding mechanism of monocrystalline nickel. Appl Surf Sci 455:629-634
[49] Ma ZF (2019) Numerical and experimental analysis on high speed grinding Ti6Al4V with single grit. Dissertation, Taiyuan University of Technology
[50] Xu H (2012) Grinding temperature simulation research in high speed grinding of cemented carbides using finite element method. Dissertation, Hunan University
[51] Lu SX, Yang XX, Zhang JQ et al (2022) Rational thinking on removal mechanisms and processing damage of hard and brittle materials. Chin J Mech Eng-En 58(15):31-45
[52] Wang B, Liu ZQ, Su GS et al (2015) Brittle removal mechanism of ductile materials with ultrahigh-speed machining. J Manuf Sci Eng 137(6):061002. https://doi.org/10.1115/1.4030826
[53] Yang X, Zhang B (2019) Material embrittlement in high strain-rate loading. Int J Extrem Manuf 1(2):022003. https://doi.org/10.1088/2631-7990/ab263f
[54] Chen ZZ, Xu JH, Ding WF et al (2014) Grinding performance evaluation of porous composite-bonded CBN wheels for Inconel 718. Chin J Aeronaut 27(4):1022-1029
[55] Zhang YB (2018) Grinding mechanism, force prediction model and experimental validation of vegetable oil based nanofluids minimum quantity lubrication. Dissertation, Qingdao University of Technology
[56] Mao C, Wang JL, Zhang MJ et al (2023) Prediction of grinding force by an electroplated grinding wheel with orderly-micro-grooves. Chin J Mech Eng-En 36(1):116. https://doi.org/10.1186/s10033-023-00937-y
[57] Jin T, Cai GQ (1999) Strain rate strengthening of materials and size effects in grinding. Chin Mech Eng 10(12):1401-1403
[58] Jin T, Stephenson DJ (2006) Heat flux distributions and convective heat transfer in deep grinding. Inter J Mach Tool Manu 46(14)1862-1868
[59] Umbrello D, Micari F, Jawahir IS (2012) The effects of cryogenic cooling on surface integrity in hard machining: a comparison with dry machining. CIRP Ann-Manuf Techn 61(1):103-106
[60] Zhang B, Yin JF (2019) The “skin effect” of subsurface damage distribution in materials subjected to high-speed machining. Int J Extrem Manuf 1(1):012007. https://doi.org/10.1088/2631-7990/ab103b
[61] Wu ZW, Fan WA, Qian C et al (2023) Contact mechanism of rail grinding with open-structured abrasive belt based on pressure grinding plate. Chin J Mech Eng-En 36(1):42. https://doi.org/10.1186/s10033-023-00862-0
[62] Liu XB, Zhang B, Deng ZH (2002) Grinding of nanostructured ceramic coatings: surface observations and material removal mechanisms. Int J Mach Tool Manu 42(15):1665-1676
[63] Wang B, Liu ZQ, Song QH et al (2016) Proper selection of cutting parameters and cutting tool angle to lower the specific cutting energy during high speed machining of 7050-T7451 aluminum alloy. J Clean Prod 129:292-304
[64] Ma W, Chen X, Shuang F (2017) The chip-flow behaviors and formation mechanisms in the orthogonal cutting process of Ti6Al4V alloy. J Mech Phys Solids 98:245-270
[65] Zhang YQ, Lu Y, Hao H (2004) Analysis of fragment size and ejection velocity at high strain rate. Int J Mech Sci 46(1):27-34
[66] Dai JB, Ding WF, Zhang LC et al (2015) Understanding the effects of grinding speed and undeformed chip thickness on the chip formation in high-speed grinding. Int J Adv Manuf Tech 81:995-1005
[67] Li LY, Zhang YB, Cui X et al (2023) Mechanical behavior and modeling of grinding force: a comparative analysis. J Manuf Process 102:921-954
[68] Xia J (2020) Experimental and simulation research on ultra-high speed grinding of nickel-based superalloys based on single abrasive grain. Dissertation, Nanjing University of Aeronautics and Astronautics
[69] Fan ZL (2018) Simulation and experimental study on grinding mechanism of high-speed grinding AISI 1045 steel with single abrasive grain. Dissertation, Taiyuan University of Technology
[70] Liu CJ (2018) Removal mechanism of particulate reinforced titanium matrix composites in high-speed grinding. Dissertation, Nanjing University of Aeronautics and Astronautics
[71] Fu DK, Ding WF, Yang SB et al (2017) Formation mechanism and geometry characteristics of exit-direction burrs generated in surface grinding of Ti-6Al-4V titanium alloy. Int J Adv Manuf Tech 89:2299-2313
[72] Yu J, Liu Z, Wu Y et al (2015) Simulation study of high-speed grinding of alloy steel 20CrMo with single grits. Manuf Tech Mach Tool 12:97-102
[73] Cheng Z, Xu J, Ding W et al (2011) Simulation study of chip formation process in single grit grinding of titanium alloy TC4. Diamond Abrasives Eng 31(2):17-21
[74] Holmquist TJ, Johnson GR (2011) A computational constitutive model for glass subjected to large strains, high strain rates and high pressures. J Appl Mech-t ASME 78(5):051003. https://doi.org/10.1115/1.4004326
[75] Johnson GR, Holmquist TJ (1994) An improved computational constitutive model for brittle materials. Am Inst Phys Conf Proc 309(1):981-984
[76] Wang B, Liu ZQ, Cai YK et al (2021) Advancements in material removal mechanism and surface integrity of high speed metal cutting: a review. Int J Mach Tool Manu 166:103744. https://doi.org/10.1016/j.ijmachtools.2021.103744
[77] Andrade U, Meyers M, Vecchio K et al (1994) Dynamic recrystallization in high-strain, high-strain-rate plastic deformation of copper. Acta Mater 42(9):3183-3195
[78] Fu XL, Ai X, Zhang S et al (2006) Constitutive equation for 7050 aluminum alloy at high temperatures. Mater Sci Forum 532/533:125-128
[79] Calamaz M, Coupard D, Girot F (2008) A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti-6Al-4V. Int J Mach Tool Manu 48(3/4):275-288
[80] Sheikh-Ahmad JY, Bailey JA (1995) A constitutive model for commercially pure titanium. J Eng Mater Technol 117(2):139-144
[81] Li GH, Wang MJ, Duan CZ (2009) Adiabatic shear critical condition in the high-speed cutting. J Mater Process Tech 209(3):1362-1367
[82] Wang XY, Huang CZ, Zou B et al (2013) Dynamic behavior and a modified Johnson-Cook constitutive model of Inconel 718 at high strain rate and elevated temperature. Mater Sci Eng A 580:385-390
[83] Ugodilinwa NE, Khoshdarregi M, Ojo OA (2019) Analysis and constitutive modeling of high strain rate deformation behavior of Haynes 282 aerospace superalloy. Mater Today Commun 20:100545. https://doi.org/10.1016/j.mtcomm.2019.100545
[84] Wang B, Liu ZQ, Song QH et al (2019) A modified Johnson-Cook constitutive model and its application to high speed machining of 7050-T7451 aluminum alloy. J Manuf Sci Eng 141(1):011012. https://doi.org/10.1115/1.4041915
[85] Liu CJ, Ding WF, Yu TY et al (2018) Materials removal mechanism in high-speed grinding of particulate reinforced titanium matrix composites. Precis Eng 51:68-77
[86] Wu SX, Gong X, Ni YQ et al (2022) Material removal and surface damage in high-speed grinding of enamel. J Mech Behav Biomed 136:105532. https://doi.org/10.1016/j.jmbbm.2022.105532
[87] Setti D, Sinha MK, Ghosh S et al (2015) Performance evaluation of Ti-6Al-4V grinding using chip formation and coefficient of friction under the influence of nanofluids. Int J Mach Tool Manu 88:237-248
[88] Doyle ED, Dean SK (1980) An insight into grinding from a materials viewpoint. CIRP Ann-Manuf Techn 29(2):571-575
[89] Doyle ED, Aghan RL (1975) Mechanism of metal removal in the polishing and fine grinding of hard metals. Metall Mater Trans B 6:143-147
[90] Xia J, Ding WF, Qiu B et al (2020) 3D simulation study on the chip formation process of nickel-based high-temperature alloy high-speed ultra-high-speed grinding. Diamond Abrasives Eng 40(6):58-69
[91] Sun JG, Li C, Zhou ZM et al (2023) Material removal mechanism and force modeling in ultrasonic vibration-assisted micro-grinding biological bone. Chin J Mech Eng-En 36(1):129. https://doi.org/10.1186/s10033-023-00957-8
[92] Liu XC, Chen F, Zhao C et al (2016) Simulation and research of single abrasive cutting based on DEFORM-3D. Mach Des Manuf 10:69-73
[93] Yao CF, Wang T, Xiao W et al (2014) Experimental study on grinding force and grinding temperature of Aermet 100 steel in surface grinding. J Mater Process Tech 214(11):2191-2199
[94] Sun S, Brandt M, Dargusch MS (2009) Characteristics of cutting forces and chip formation in machining of titanium alloys. Int J Mach Tool Manu 49(7/8):561-568
[95] Liu YF, Wang D, Chen X (2016) Experimental study of grinding force and specific grinding energy for high-speed grinding of 18CrNiMo7-6. Manuf Tech Mach Tool 8:94-97
[96] Patidar A, Kumar MA, Kumar Chaudhary A (2021) High speed super abrasive grinding of sintered yttria stabilised zirconia (YSZ) using single layer electroplated diamond grinding wheels. Mater Today Proc 45:4660-4665
[97] Wang XM, Song YX, Li CH et al (2023) Nanofluids application in machining: a comprehensive review. Int J Adv Manuf Tech 1-52
[98] Sun C, Hong Y, Xiu SC et al (2023) Surface strengthening mechanism of the active grinding carburization. Tribol Int 185:108569. https://doi.org/10.1016/j.triboint.2023.108569
[99] Rowe WB (2001) Thermal analysis of high efficiency deep grinding. Int J Mach Tool Manu 41(1):1-19
Outlines

/