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

磨削加工是最基本和最昂贵的制造工艺之一，在工业化国家中约占机械加工总支出的25%。全球几乎每家制造公司都依赖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，磨削是在产品制造过程接近尾声的时候，由于磨削热损坏而报废零件的成本可能非常高。虽然制造商努力在更高的进给速度下进行更深的切割，以尝试最大限度地提高生产率，但热损坏的风险导致许多生产磨削工艺不是最优的，因为过于保守的工艺参数是通过反复试验确定的。因此，需要磨削研究和专业知识，以便行业能够优化现有的磨削工艺并采用新的磨削技术。研磨过程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、国防、医疗、能源、食品、电子和采矿等众多行业至关重要--然而，加拿大的研磨研究人员非常少。为了满足这些需求，我的研究计划的长期目标是开发新的磨削技术，这些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，我的研究使加拿大一家著名的航空航天制造公司通过将新颖的相干喷射冷却剂输送技术应用到磨削过程中，显著提高了生产率--在不到一年的时间里将废品率降低了50%。我的研究发现，在砂轮表面周围嵌入螺旋槽的磨削可以显著提高磨削效率、可靠性和生产率，因为磨削力和功率(可能导致热损伤)减少了约50%，并使材料的去除量增加了高达300%。然而，在砂轮上制造凹槽的实际过程是有问题的，因此工业界没有采用这项有前途的技术。因此，我的研究计划的短期目标是：1.开发和探索使用新的旋转钻石修整器沟槽系统，在平面和异形常规砂轮和超磨料砂轮上创建沟槽图案，作为加拿大工业采用的可行、实用和理想的解决方案。2.开发和验证基本的磨削计算机模拟工具，以确定最佳的砂轮沟槽几何形状、速度比和工艺参数我在该领域拥有坚实的成功记录，拟议的高度创新的磨削研究将通过培训该精密加工过程中的高素质人员，在磨削技术方面取得重大进步，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.