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The Analysis of the Influence of Technological Parameters on the Grinding Temperature in the Single-Pass Grinding Process of Solid Carbide End Mill Flutes
 
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Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland
CORRESPONDING AUTHOR
Marcin Sałata   

Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland
 
 
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ABSTRACT
A method of the measurement of temperature and grinding force components during flute grinding of solid carbide end mills was presented. The tests were performed using two diamond grinding wheels: with a resin bond (S1) and with a metal bond (S2). A diamond grinding wheel of 1A1 type and a rectangular cross-section was used. An ultrafine grained carbide with a grain size of 0.2 to 0.5 μm, characterized by high hardness (1730 HV30) and very high tensile strength (4600 MPa) was used. The flutes were grinded in one pass, thus replacing rouging and finishing. The temperature of grinding was recorded using thermocouple type K, NiCr-Ni. The measurement of forces was conducted using a rotary piezoelectric dynamometer. Surface topography was recorded with the Alicona InfiniteFocus G4 microscope. The experiment was planned in Design-Expert 13 software. Mathematical models were developed, describing the relationships between the grinding speed and the feed rate as a function of the grinding temperature, grinding force and roughness parameters of the flute. For both grinding wheels, the Fn grinding force was recorded in the range of 28-110 N, the temperature in the range of 32-200°C and surface roughness Sa in the range of 0.31-0.76 μm. The best grinding result, in terms of low grinding forces and temperatures was achieved for the grinding wheel with the metal bond (S2). For the resin grinding wheel (S1), for the selected technological parameters, grinding burn occurred.