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Advanced Abrasive Processing Technology and Applications

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 September 2024 | Viewed by 3498

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Prof. Dr. Yufei Gao

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Guest Editor

School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: precision and ultra-precision abrasive machining; diamond wire saw slicing technology; semiconductor abrasive processing
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Special Issue Information

Dear Colleagues,

Abrasive processing technology has been widely used in the manufacture of many mission-critical components for various industrial areas, such as semiconductor chips, PV silicon solar cells, advanced optics, aerospace, automotive, telecommunications, etc. Most materials used in these fields, such as semiconductors, laser crystals, engineering ceramics, optical glass, superalloys, composite materials, etc., are difficult to process. The increasing degree of high-precision and high-efficiency requirements and the difficult-to-machine characteristic of advanced materials lead to numerous research challenges in different fields of abrasive processing technology, such as novel machining processes, processing mechanics, surface generation mechanisms, novel machine design, advanced sensing, machine metrology, machining process modeling and simulation, process monitoring, etc. This collection aims to summarize updates in the research on advanced abrasive processing technology and applications. The scope of this Special Issue includes, but is not limited to:

Precision and ultra-precision abrasive machining technology in semiconductor, optical, photovoltaic and other fields;
Basic theory of abrasive machining, such as sawing, grinding, lapping, etc.;
Modeling, simulation and optimization of the abrasive machining process;
High-speed and efficient abrasive processing technology;
Multi-energy-field-assisted composite abrasive machining technology;
Grinding technology for new materials;
Surface integrity of abrasive machining and its detection and control technology;
Abrasive processing tools and equipment;
Intelligent manufacturing technology and equipment for abrasive processing;
Other related processing technologies.

Dr. Yufei Gao
Guest Editor

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Keywords

precision/ultra-precision abrasive machining
sawing
grinding
lapping
material removal mechanism
machined surface integrity
difficult-to-machine materials
processing damage
processing monitoring

Published Papers (5 papers)

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Research

17 pages, 5304 KiB

Open AccessArticle

Experimental Investigation on Diamond Band Saw Processing of Resin Mineral Composites

by Jiahao Sun, Jianhua Zhang, Weizhou Gu, Yunfang Long and Chuanxin Guo

Materials 2024, 17(8), 1814; https://doi.org/10.3390/ma17081814 - 15 Apr 2024

Viewed by 538

Abstract

Resin mineral composite (RMC) is a new material with several times the damping properties of gray cast iron and great corrosion resistance. Due to its overall brittleness, sawing with a diamond band saw would be a suitable method. In this research, sawing experiments are carried out to study the sawing force characteristics of the material and its surface morphology during the processing. The results show that the feed force level is in the range of 3.5~5.5 N and the tangential force level is relatively low. The distribution of resin mineral components does not have a significant impact on the average sawing force but increases the fluctuation of the lateral force signal. The maximum fluctuation volume is 94.86% higher than other areas. Uneven lateral force, generated when diamond particles pass through the resin–mineral interface, is one of the causes of fluctuations. The machined surface of RMC has uniform strip scratches and a small number of pits. Maintaining a constant ratio of sawing speed to feed speed can result in approximately the same machined surface. A step structure with a height of about 10 μm appears at the interface of resin minerals. As a processing defect, it may affect the performance of RMC components in some aspects, which need a further precision machining processing. Full article

(This article belongs to the Special Issue Advanced Abrasive Processing Technology and Applications)

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17 pages, 9730 KiB

Open AccessArticle

Analysis of Grindability and Surface Integrity in Creep-Feed Grinding of High-Strength Steels

by Youkang Yin and Ming Chen

Materials 2024, 17(8), 1784; https://doi.org/10.3390/ma17081784 - 12 Apr 2024

Viewed by 389

Abstract

Creep-feed grinding of high-strength steel is prone to excessive wheel wear and thermal damage defects, which seriously affects the service performance of parts. To solve the above-mentioned issue, a creep-feed grinding test was carried out on high-strength steel using SG and CBN abrasive wheels. The grindability of high-strength steel was scrutinized in terms of grinding force, machining temperature and grinding specific energy. Moreover, the effects of operation parameters and grinder performances on the surface integrity of the workpiece such as surface morphology, roughness, residual stress and hardness were rigorously studied. The results indicate that, when the instantaneous high temperature in the grinding area reaches above the phase transition temperature of the steel, the local organization of the surface layer changes, leading to thermal damage defects in the components. The outstanding hardness and thermal conductivity of CBN abrasives are more productive in suppressing grinding burns than the high self-sharpening properties of SG grits and a more favorable machining response is achieved. The effects of thermal damage on the surface integrity of high-strength steel grinding are mainly in the form of oxidative discoloration, coating texture, hardness reduction and residual tensile stresses. Within the parameter range of this experiment, CBN grinding wheel reduces grinding specific energy by about 33% compared to SG grinding wheel and can control surface roughness below 0.8 µm. The weight of oxygen element in the burn-out workpiece accounts for 21%, and the thickness of the metamorphic layer is about 40 µm. The essential means of achieving burn-free grinding of high-strength steels is to reduce heat generation and enhance heat evacuation. The results obtained can provide technical guidance for high-quality processing of high-strength steel and precision manufacturing of high-end components. Full article

(This article belongs to the Special Issue Advanced Abrasive Processing Technology and Applications)

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17 pages, 32623 KiB

Open AccessArticle

Superfinishing with Abrasive Films Featuring Discontinuous Surfaces

by Katarzyna Tandecka, Wojciech Kacalak, Maciej Wiliński, Michał Wieczorowski and Thomas G. Mathia

Materials 2024, 17(7), 1704; https://doi.org/10.3390/ma17071704 - 08 Apr 2024

Cited by 1 | Viewed by 372

Abstract

This study introduces innovative designs for abrasive tools aimed at enhancing surface finishing processes. Prototypes consisting of non-continuous abrasive films with discontinuous surface carriers and abrasive layers were developed to improve the efficiency and effectiveness of the smoothing process. Four distinct abrasive films with varying nominal grain sizes were fabricated to explore the versatility and efficacy of the prototypes. The results indicate that the incorporation of carrier irregularities significantly influences surface finishing processes, leading to improvements in material removal efficiency and surface quality. Longitudinal discontinuities facilitate faster removal of irregularities from workpiece materials, reducing the risk of deep scratches on surfaces. Additionally, this study highlights the importance of tool motion patterns in optimizing material removal processes and ensuring surface quality. The integration of carrier irregularities with additional oscillatory tool motion shows promise for further improving surface quality. These findings advance our understanding of abrasive machining processes and provide valuable insights for optimizing abrasive tool designs and machining strategies for enhanced surface finishing. Full article

(This article belongs to the Special Issue Advanced Abrasive Processing Technology and Applications)

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20 pages, 11683 KiB

Open AccessArticle

Study on Grinding-Affected Layer of Outer-Ring Inner Raceway of Tapered Roller Bearing

by Dameng Cheng, Guangdi Jin, Yufei Gao, Panling Huang, Zhenyu Shi and Yuanchao Tang

Materials 2023, 16(22), 7219; https://doi.org/10.3390/ma16227219 - 17 Nov 2023

Viewed by 695

Abstract

In the grinding of bearing raceways, the coupling effect between grinding force and heat in the contact area between the grinding wheel and the workpiece causes changes in the material structure and mechanical properties of the raceway surface layer, which can lead to the formation of a grinding-affected layer. The grinding-affected layer has a significant impact on the service performance and fatigue life of bearings. In order to improve the ground surface quality of the outer-ring inner raceway of tapered roller bearings and optimize the processing parameters, this paper presents a study on the grinding-affected layer. A finite element simulation model for grinding the outer-ring inner raceway of the tapered roller bearing was established. The grinding temperature field was simulated to predict the affected-layer thickness during raceway grinding. The correctness of the model was verified through grinding experiments using the current industrial process parameters of bearing raceway grinding. The research results indicate that the highest grinding temperature of the outer-ring inner raceway of the tapered roller bearing is located near the center of the grinding arc area on the thin end edge. As the workpiece speed and grinding depth decrease, the highest grinding temperature decreases, and the dark layer thickness of the grinding-affected layer decreases or even does not occur. The research results can provide theoretical guidance and experimental reference for grinding the raceway of tapered roller bearings. Full article

(This article belongs to the Special Issue Advanced Abrasive Processing Technology and Applications)

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23 pages, 5610 KiB

Open AccessArticle

On Characterization of Shear Viscosity and Wall Slip for Concentrated Suspension Flows in Abrasive Flow Machining

by Can Peng, Hang Gao and Xuanping Wang

Materials 2023, 16(20), 6803; https://doi.org/10.3390/ma16206803 - 22 Oct 2023

Viewed by 989

Abstract

In the realm of abrasive flow machining (AFM), precise finishing and maintaining dimensional accuracy have remained challenging due to non-uniformities in the AFM process and complexities associated with the abrasive media’s shear viscosity and wall slip behavior. By addressing these challenges, this study introduces a comprehensive framework, combining theoretical foundations, measurement techniques, and experimental setups. Utilizing capillary flow, a novel compensation strategy is incorporated within the Mooney method to counter entrance pressure drop effects. This enhanced capillary flow method emerges as a promising alternative to the conventional Cox–Merz empirical rule, enabling precise characterization of wall slip behavior and shear viscosity, particularly at elevated shear rates. The abrasive media exhibit a Navier nonlinear wall slip, as highlighted by the Mooney method. Rigorous verification of the proposed methodologies and models against supplemental experiments showcases a high degree of congruence between predicted and observed results, emphasizing their accuracy and broad application potential in AFM. This research illuminates the intricacies of the abrasive media’s behavior, accentuating the need for meticulous characterization, and provides a robust foundation for genuine modeling and predictions in material removal within AFM. Full article

(This article belongs to the Special Issue Advanced Abrasive Processing Technology and Applications)

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