Grinding wheel grooving: innovative and feasible solutions for Canadian manufacturing industries to adopt to significantly reduce costly grinding-burn-induced waste and increase productivity and reliability

磨削加工过程是最基本和最昂贵的制造过程之一，约占工业国家机械加工总支出的25%。实际上，世界上每一家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，如齿轮，轴承和轴。然而，磨削是接近产品制造过程的最后阶段，由于磨削热损伤而报废工件组件的成本可能非常高。虽然制造商努力在更高的进给速率下进行更深的切削深度，以最大限度地提高生产率，但热损伤的风险导致许多生产磨削工艺在经过反复试验确定的过于保守的工艺参数下不是最优的。因此，需要磨削研究和专业知识，以便工业可以优化现有的磨削工艺并采用新的磨削技术。磨削过程对加拿大经济具有战略重要性，因为它对包括汽车、航空航天、造船、国防、医疗、能源、食品、电子和采矿在内的无数行业都至关重要，但加拿大的磨削研究人员却非常少。为了满足这些需求，我的研究计划的长期目标是开发新的研磨技术，可以转移到加拿大工业，以提高生产率，可靠性和质量。例如，我的研究使一家著名的加拿大航空航天制造公司通过将新颖的相干射流冷却剂输送技术应用于他们的磨削过程，从而显着提高了他们的生产率-在不到一年的时间内将废品率降低了50%。我的研究发现，在砂轮表面周围刻有螺旋形槽的磨削可以通过减少约50%的磨削力和功率（可能导致热损伤）来显着提高磨削效率，可靠性和生产率，并使高达300%的材料被移除。然而，在砂轮上形成凹槽的实际过程是有问题的，因此工业上还没有采用这种有前途的技术。因此，我的研究计划的短期目标是：1。开发和探索使用一种新的旋转金刚石修整槽系统，在平面和异形常规和超磨料砂轮上创建槽图案，作为加拿大工业采用的可行，实用和理想的解决方案。开发和验证基本的磨削计算机模拟工具，以确定最佳的砂轮开槽几何形状、速比和工艺参数。我在这一领域取得了良好的成功记录，提出的高度创新的磨削研究将在磨削技术方面取得重大进展，并通过培训这一精密加工过程中的高素质人才，创造加拿大的专业知识。

The grinding manufacturing process 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 worldwide relies on the grinding process to create components with precise dimensions and high-quality surface finishes such as gears, bearings and shafts. Grinding, however, is near the end of the product manufacturing process where the cost of scrapping a workpiece component due to grinding thermal damage can be extremely high. While manufacturers endeavor to take deeper depths of cut at higher feed rates to try to maximize productivity, the risk of thermal damage causes many production grinding processes to be suboptimal with overly conservative process parameters determined by trial-and-error. Grinding research and expertise is, therefore, needed so that industry can optimize existing grinding processes and adopt new grinding technologies. The grinding process is of strategic importance to the Canadian economy because it is critical to myriad industries including automotive, aerospace, shipbuilding, defense, medical, energy, food, electronics and mining - yet there are remarkably few grinding researchers in Canada. To address these needs, the long-term objectives of my research program are to develop new grinding technologies that can be transferred to Canadian industry to enhance productivity, reliability and quality. For example, my research enabled a prominent Canadian aerospace manufacturing company to significantly increase their productivity by applying novel coherent-jet coolant delivery techniques to their grinding processes - reducing their scrap rate in less than a year by 50%. My research has discovered that grinding with a spiral-shaped groove inscribed around the wheel surface can dramatically improve grinding efficiency, reliability and productivity by reducing grinding forces and power (which can lead to thermal damage) by ~50% and enabling up to 300% more material to be removed. The actual process of creating a groove on a grinding wheel, however, is problematic so industry has not adopted this promising technology. Therefore, the short-term objectives of my research program are to: 1. develop and explore the use of a new rotary diamond dresser grooving system to create groove patterns on flat and profiled conventional and super-abrasive grinding wheels as a feasible, practical and desirable solution for Canadian industry to adopt 2. develop and validate essential grinding computer simulation tools to determine optimal wheel grooving geometries, speed ratios and process parameters I have a solid track record of success in this field and the proposed highly-innovative grinding research will make significant advances in grinding technology and create Canadian expertise through the training of highly-qualified personnel in this precision machining process.