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Modeling and evaluating of surface roughness prediction in micro-grinding on soda-lime glass considering tool characterization

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Abstract

The current research of micro-grinding mainly focuses on the optimal processing technology for different materials. However, the material removal mechanism in micro-grinding is the base of achieving high quality processing surface. Therefore, a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography is proposed in this paper. The differences of material removal mechanism between convention grinding process and micro-grinding process are analyzed. Topography characterization has been done on micro-grinding tools which are fabricated by electroplating. Models of grain density generation and grain interval are built, and new predicting model of micro-grinding surface roughness is developed. In order to verify the precision and application effect of the surface roughness prediction model proposed, a micro-grinding orthogonally experiment on soda-lime glass is designed and conducted. A series of micro-machining surfaces which are 78 nm to 0.98 μm roughness of brittle material is achieved. It is found that experimental roughness results and the predicting roughness data have an evident coincidence, and the component variable of describing the size effects in predicting model is calculated to be 1.5×107 by reverse method based on the experimental results. The proposed model builds a set of distribution to consider grains distribution densities in different protrusion heights. Finally, the characterization of micro-grinding tools which are used in the experiment has been done based on the distribution set. It is concluded that there is a significant coincidence between surface prediction data from the proposed model and measurements from experiment results. Therefore, the effectiveness of the model is demonstrated. This paper proposes a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography, which would provide significant research theory and experimental reference of material removal mechanism in micro-grinding of soda-lime glass.

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 100004, China

    Jun Cheng, Yadong Gong & Jinsheng Wang

Authors
  1. Jun Cheng
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  2. Yadong Gong
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  3. Jinsheng Wang
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Corresponding author

Correspondence to Jun Cheng.

Additional information

This project is supported by National Natural Science Foundation for Young Scholars of China(Grant No. 51205053), and National Natural Science Foundation of China(Grant No. 51075064)

CHENG Jun, born in 1981, is currently an lecturer at Northeastern University, China. He received his PhD degree from Northeastern University, China, in 2011. His research interests include micro precision process, grinding mechanism.

GONG Yadong, born in 1958, is currently a professor and a PhD candidate supervisor at Northeastern University, China. His main research interests include grinding mechanism, digital manufacturing.

WANG Jinsheng, born in 1981, is currently a superviser of a diamond tool company. He received his PhD degree from Northeastern University, China, in 2009. His main research interests is micro precision machining.

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Cheng, J., Gong, Y. & Wang, J. Modeling and evaluating of surface roughness prediction in micro-grinding on soda-lime glass considering tool characterization. Chin. J. Mech. Eng. 26, 1091–1100 (2013). https://doi.org/10.3901/CJME.2013.06.1091

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  • DOI: https://doi.org/10.3901/CJME.2013.06.1091

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