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Depth of dressing optimization in CBN wheels of different friabilities using acoustic emission (AE) technique

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Abstract

Grinding is a manufacturing process that has the objective of granting the workpiece a high-quality surface and is located at the end of the sequence of machining processes. During grinding operation, the abrasive grains of the wheel surface are worn and the pores are filled with debris. This phenomenon makes the cutting tool less efficient to remove material and sometimes improper to be used if a process to correct the cutting surface is not applied to the tool. Dressing is defined as a conditioning process which gives shape to the wheel and has the purpose of improving its capacity to remove material. In this context, this work proposes the monitoring of the dressing process of CBN wheels through acoustic emission technique (AE) along with the processing of digital signals. Dressing tests were done in a cylindrical grinder with two types of CBN wheels and the surface after the process was evaluated through micrographs. The AE signals were acquired with a 2 MHz sampling rate. In sequence, statistics such as RMS (root mean square) and counts were applied to the sample signals and analyses in the frequency domain were done to select frequency bands that are more related to the dressing process. The results show that the counts’ analysis applied to the signals filtered in the selected bands is effective to detect the best moment to stop the dressing process.

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Acknowledgments

The authors would like to thank the following companies: Saint-Gobain Ceramic Materials-Surface Conditioning for the donation of the CBN abrasive grains and for its support to this research and Nikkon Cutting Tools Co. for providing the grinding wheels. The authors thank everyone for the support given to the research and opportunity for scientific and technological development.

Funding

The authors thank São Paulo Research Foundation (FAPESP-grant number 2015/10460-4 and 2017/18148-5), Coordination for the Improvement of Higher Level Education Personnel (CAPES), and National Council for Scientific and Technological Development (CNPq) for their financial support of this research.

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Authors and Affiliations

  1. Department of Electrical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, SP, Brazil

    Felipe Aparecido Alexandre & Paulo Roberto Aguiar

  2. Department of Mechanical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, SP, Brazil

    José Claudio Lopes, Lucas de Martini Fernandes, Luiz Eduardo de Angelo Sanchez, Hamilton José de Mello & Eduardo Carlos Bianchi

  3. Department of Control and Industrial Processes, Federal Institute of Education Science and Technology of Parana, Jacarezinho campus, Jacarezinho, PR, Brazil

    Fernando Sabino Fonteque Ribeiro

  4. Department of Electrical Engineering, University of Lins, Lins campus, Lins, SP, Brazil

    Breno Ortega Fernandez

  5. Saint-Gobain Surface Conditioning, Department of Ceramic Materials, Guarulhos, SP, Brazil

    Rodolfo Fischer Moreira de Oliveira

Authors
  1. Felipe Aparecido Alexandre
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  2. José Claudio Lopes
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Correspondence to Felipe Aparecido Alexandre.

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Alexandre, F.A., Lopes, J.C., de Martini Fernandes, L. et al. Depth of dressing optimization in CBN wheels of different friabilities using acoustic emission (AE) technique. Int J Adv Manuf Technol 106, 5225–5240 (2020). https://doi.org/10.1007/s00170-020-04994-8

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