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New Frontiers in Grinding Processes
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New Frontiers in Grinding Processes

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (20 May 2022) | Viewed by 8565

Special Issue Editors

Dr. James M. Griffin

E-Mail Website
Guest Editor
Non Destructive Testing and Manufacturing Engineering, Coventry University, Coventry CV1 5FB, UK
Interests: manufacturing mechatronics; non-destructive testing and machine learning
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Xun Chen

E-Mail Website
Guest Editor
General Engineering Research Institute, Liverpool John Moores University, Liverpool L3 3AF, UK
Interests: advanced manufacturing technology; intelligent sensing and process control; knowledge support systems
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Traditional grinding currently faces strong competition from a number of machining processes, such as hard turning. However, advanced grinding technology provides a superior finish and better productivity, thanks to many exciting developments in the fundamental understanding and application of associated new techniques. This Special Issue welcomes papers that push frontiers within the grinding community, where there is no alternative using other traditional machining techniques. Moreover, recently, there has been an increase in space-based transport, where they endure intense hostile environments, only permitting a modest amount of reusability when compared with their aero counterparts; new materials are being ground to address this problem, as well new grinding technologies used to machine such materials. Not just the material aspects are considered for the power plants but also the materials for airframes, such as composites or thin gauge, high strength-sheet metals. The manufacturing industry in particular has been faced with many difficult challenges of late, however at the same time it strives towards a net zero carbon manufacturing output.

Another area of expansion requiring innovation and development is that of precision micro grinding for MEMS devices, and these are continually becoming more complicated and minute. Papers will also be considered, where grinding is used as a finishing process from such semi-finish processes, such as 3D printing or waterjet. Finally, any aspect regarding significant improvements within grinding process will be considered.

Prof. Dr. James M. Griffin
Prof. Dr. Xun Chen
Guest Editors

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Keywords

  • fundamental investigation for understanding the mechanics of grinding
  • polishing using grinding technologies
  • grinding different materials
  • high removal rates grinding
  • sensors for the grinding condition monitoring
  • coolants and lubricants
  • flexible grinding control systems
  • grinding preparation and maintenance
  • micro and precision grinding technologies
  • grinding towards zero carbon manufacturing

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Published Papers (4 papers)

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Research

13 pages, 5203 KiB  
Article
Fabrication of Cylindrical Microlens Array on RB-SiC Moulds by Precision Grinding with MAWJ-Textured Diamond Wheels
by Fukang Su, Zhenzhong Zhang, Peng Yao, Hanwen Yu, Hongyu Xing, Mengran Ge and Yanhua Zhao
Appl. Sci. 2022, 12(14), 6893; https://doi.org/10.3390/app12146893 - 7 Jul 2022
Cited by 2 | Viewed by 2097
Abstract
Cylindrical microlens array (CMA) is applied widely in imaging, sensing, and laser machining fields. Among the many techniques for machining CMA, moulding is considered a mass-production method with low-cost and good accuracy. Aimed at the present problems in the machining of CMA moulds, [...] Read more.
Cylindrical microlens array (CMA) is applied widely in imaging, sensing, and laser machining fields. Among the many techniques for machining CMA, moulding is considered a mass-production method with low-cost and good accuracy. Aimed at the present problems in the machining of CMA moulds, which include low processing efficiency and the prediction of the surface topography, this paper focused on the fabrication of CMA on RB-SiC moulds by precision grinding with micro-abrasive water jet (MAWJ) textured diamond wheels. The combined rough–fine grinding strategy for ceramic mould materials was proposed. The grinding experiments of CMA were carried out. The ultra-precision grinding method was optimized to obtain high shape accuracy and a high-quality surface of RB-SiC moulds. It was found that by using MAWJ-textured diamond wheels, the profile error in the peak-to-valley value (PV) of the CMA moulds can be further reduced to 6.7 μm by using the combined rough–fine strategy grinding process. Full article
(This article belongs to the Special Issue New Frontiers in Grinding Processes)
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22 pages, 17431 KiB  
Article
Analysis of Acoustic Emissions for Determination of the Mechanical Effects of Scratch Tests
by Timothy Devenport, Bernard Rolfe, Michael Pereira and James M. Griffin
Appl. Sci. 2022, 12(13), 6724; https://doi.org/10.3390/app12136724 - 2 Jul 2022
Cited by 1 | Viewed by 1651
Abstract
Acoustic Emission (AE) is a promising technique for measuring tool wear online and in real time. In this work, scratch tests were conducted to better understand the “pre-wear” AE response based on loading conditions that were not sufficient to generate galling. The scratch [...] Read more.
Acoustic Emission (AE) is a promising technique for measuring tool wear online and in real time. In this work, scratch tests were conducted to better understand the “pre-wear” AE response based on loading conditions that were not sufficient to generate galling. The scratch tests used the same type of indenter against two different sheet materials: aluminum and steel. The results showed that AE parameters such as the mean frequency, Centroid frequency and Shannon entropy outperformed other frequency domain techniques by discriminating between the two sheet materials in scratch tests. From the literature, the frequency region of interest was expected to be sub 300 kHz. However, in this study, activity below this threshold was found to be noise, whereas distinct frequencies were found at much higher frequencies than expected. These results are compared against single grit “SG” tests of both mild steel- and nickel-based superalloys to allow comparison of the two test methods and materials used. This comparison showed that the SG tests excited the acoustic emission in ways in which the scratch tests did not. Another factor when using acoustic emissions to monitor sheet metal forming is the differences obtained in energy–frequency mapping, where many report the galling phenomena between a certain amplitude and frequency range. Such results are specific to the setup and the materials/geometries used. Further work presented here compares different scratch tests where energy–frequency mapping is different for different materials/geometries. Full article
(This article belongs to the Special Issue New Frontiers in Grinding Processes)
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18 pages, 8737 KiB  
Article
Crack Propagation Behavior of Fused Silica during Cyclic Indentation under Incremental Loads
by Koji Kosai, Yugang Zhao and Jiwang Yan
Appl. Sci. 2022, 12(13), 6589; https://doi.org/10.3390/app12136589 - 29 Jun 2022
Viewed by 2158
Abstract
Fused silica is an important optical material with important applications, where the surface must be precisely machined without subsurface damage. In this study, multi-cyclic indentations under incremental loads were performed on fused silica using two kinds of indenters to clarify the mechanisms of [...] Read more.
Fused silica is an important optical material with important applications, where the surface must be precisely machined without subsurface damage. In this study, multi-cyclic indentations under incremental loads were performed on fused silica using two kinds of indenters to clarify the mechanisms of crack generation and propagation induced by precision grinding. It was found that incremental loading cyclic nanoindentation induced various patterns of subsurface cracking and surface spalling. Four kinds of surface spalling were identified at different locations around an indent, the temporal formation mechanisms of which were clarified by microscopic observation and topographical measurement. Load–displacement curve analysis demonstrated that incremental propagation of lateral cracks during early indentation cycles caused large-scale brittle fractures during later cycles. Compared with a Berkovich indenter, a cube-corner indenter caused more significant brittle fractures and surface spalling. The findings in this study will deepen the understanding of subsurface damaging mechanism of fused silica and other brittle solids caused by cyclic tool-workpiece interactions in grinding and other mechanical machining processes. Full article
(This article belongs to the Special Issue New Frontiers in Grinding Processes)
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15 pages, 4086 KiB  
Article
Frictional Behaviour of the Microstructural Surfaces Created by Cylindrical Grinding Processes
by Haoyang Cao, Xun Chen, Haolin Li and Chao Shen
Appl. Sci. 2022, 12(2), 618; https://doi.org/10.3390/app12020618 - 10 Jan 2022
Cited by 4 | Viewed by 1845
Abstract
Cylindrical surface grinding can create defined textural patterns on a component with high quantity. This paper presents an experimental investigation of the frictional behaviours of ground cylindrical microstructural surfaces under a well lubrication condition. It shows that the coefficient of friction (COF) of [...] Read more.
Cylindrical surface grinding can create defined textural patterns on a component with high quantity. This paper presents an experimental investigation of the frictional behaviours of ground cylindrical microstructural surfaces under a well lubrication condition. It shows that the coefficient of friction (COF) of microstructural surface is influenced by different workload and rotation speed. The results reveal that conventional surface roughness parameters do not present the influence of surface microstructure on friction performance well. However, the paper presents an interesting discovery that the friction behaviour of microstructural surfaces created by grinding could be controlled by combining dressing and grinding conditions. Such a discovery provides a logic way to reduce surface friction for energy efficiency applications. A few functional relationships have been established to illustrate the influence of microstructural features on friction. It was found that the ground microstructural surface could improve friction performance up to 20% compared to the smoother surfaces without defined surface textural patterns. Full article
(This article belongs to the Special Issue New Frontiers in Grinding Processes)
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