Grinding wheel grooving: an innovative solution to increase grinding productivity

磨削是最基本和最昂贵的制造工艺之一，占工业化国家总加工费用的25%左右。世界上几乎所有的制造公司都依赖于磨削工艺来制造具有精确尺寸和高质量表面光洁度的部件。研磨对加拿大经济具有战略重要性，因为它对汽车、航空航天、造船、食品、能源和医疗等众多行业至关重要-但加拿大的研磨研究人员很少。 为了满足这一需求，我的研究计划的总体目标是促进对使用常规和超硬磨料砂轮的磨削过程的基本理解，并继续开发可以转移到加拿大工业的新型磨削技术，以提高磨削过程的生产率，可靠性和质量。例如，通过将新的冷却剂输送技术应用于磨削工艺，我的研究使一家加拿大航空航天公司显著提高了生产率。最近，我的研究小组发现，在平面（非轮廓）砂轮表面刻上螺旋形凹槽可以进一步提高磨削生产率，使材料去除率提高120%，同时仍然保持高质量的工件光洁度。我们还开发了相应的创新和实用的砂轮开槽系统，可以很容易地改造到现有的磨床（包括手动和计算机数控磨床），使其很容易转移到加拿大工业。 建议的研究的具体目标是建立在我成功的平面（非轮廓）砂轮开槽研究，使轮廓砂轮开槽。轮廓磨削允许将复杂形状加工成非常硬的材料，如超级合金，高碳钢和陶瓷。对成型砂轮进行开槽的能力将使开槽的切实好处能够应用于工业中更广泛的磨削应用，包括喷气发动机转子和叶片、齿轮、轴承滚道、钻头和刀具。 拟议研究的主要成果是： 1.创新实用的成型砂轮切槽解决方案 2.相应的磨削计算机模拟器，可以确定最佳的砂轮开槽几何形状、再开槽间隔和平面砂轮以及最终成形砂轮的工艺参数 我在这一领域有着坚实的成功记录，拟议中的砂轮切槽研究将继续为磨削技术的进步做出重大贡献，并将通过培训高素质的人才来建立和发展加拿大的专业知识。

Grinding is one of the most essential and costly manufacturing processes accounting for about 25% of the total machining expenditures in industrialized countries. Virtually every manufacturing company in the world relies on the grinding process to create components with precise dimensions and high-quality surface finishes. Grinding is of strategic importance to the Canadian economy because it is critical to myriad industries including the automotive, aerospace, shipbuilding, food, energy and medical industries – yet there are very few grinding researchers in Canada. To address this need, the overall goals of my research program are to contribute to the fundamental understanding of the grinding process using both conventional and super-abrasive grinding wheels and to continue to develop novel grinding technologies that can be transferred to Canadian industry to improve the productivity, reliability and quality of the grinding process. For example, by applying new coolant delivery techniques to the grinding process my research has enabled a Canadian aerospace company to significantly increase their productivity. Recently, my research group has discovered that inscribing spiral-shaped grooves around the surface of a flat (non-profile) grinding wheel can further improve grinding productivity by enabling up to 120% more material to be removed while still maintaining high-quality workpiece finishes. We have also developed a corresponding innovative and practical grinding wheel grooving system that can be readily retrofitted onto existing grinding machines (including both manual and computer numerical control grinders) making it easily transferrable to Canadian industry. The specific objective of the proposed research is to build upon my successful flat (non-profile) grinding wheel grooving research by enabling profile grinding wheels to be grooved. Profile grinding allows complex shapes to be machined into very hard materials such as superalloys, high-carbon steels and ceramics. The ability to groove profile wheels will enable the tangible benefits of grooving to become available to a much wider range of grinding applications in industry including jet engine rotors and blades, gears, bearing raceways, drill bits and cutters. Key outcomes of the proposed research are to develop: 1. innovative and practical grooving solutions for profile grinding wheels 2. corresponding grinding computer simulators that can determine optimal wheel grooving geometries, re-grooving intervals and process parameters for flat and, ultimately, profile grinding wheels I have a solid track record of success in this field and the proposed grinding wheel grooving research will continue to make significant contributions to the advancement of grinding technology and will establish and develop Canadian expertise through the training of highly-qualified personnel in this precision machining process.