Prediction of grinding tool wear and lifetime by using a test bench

C. Vogt; S. Sinzinger; M. Rohrbacher; R. Rascher

doi:10.1117/12.2236212

30 June 2016 Prediction of grinding tool wear and lifetime by using a test bench

C. Vogt, S. Sinzinger, M. Rohrbacher, R. Rascher

Proceedings Volume 10009, Third European Seminar on Precision Optics Manufacturing; 100090Z (2016) https://doi.org/10.1117/12.2236212
Event: Third European Seminar on Precision Optics Manufacturing, 2016, Teisnach, Germany

Abstract

Optical surfaces are usually machined by grinding and polishing. To achieve short polishing times it is necessary to grind with best possible form accuracy and with low sub surface damages. This is possible by using very fine grained grinding tools for the finishing process. These however often show time dependent properties regarding cutting ability in conjunction with tool wear. For a successful grinding process the tools must show a constant chipping performance. A constant, at least predictable wear and cutting behavior is crucial for a deterministic machining. The paper describes the results of a testing series on a test bench for grinding tools. The test bench was presented for the first time on a SPIEConference in San Diego in August 2015 [1]. It is used to investigate the machining behavior of single grinding pellets on different materials under certain conditions, for example load and cutting speed. The bench is equipped with a linear measuring system and allows in-process-analyzing of material removal, tool wear and self-dressing effects. The gained data is used to determine suitable parameters for grinding processes, such as form grinding with ball-shaped tools or cup wheels and also gives information about tool wear and lifetime. This work describes a method to determine the characteristics of pellet grinding tools by tests conducted with a single pellet. The determination of the effective material removal rate and the derivation of the G-ratio are investigated. Especially the change from the newly dressed tool status via the quasi-stationary to the worn status of the tool is described. From the results of these tests the usability of a pellet grinding tool for a specific grinding task can be determined without testing a comparably expensive serial tool. The collected data can be stored and used in an appropriate data base for tool characteristics and be combined with useful applications.

Citation Download Citation

C. Vogt, S. Sinzinger, M. Rohrbacher, and R. Rascher "Prediction of grinding tool wear and lifetime by using a test bench", Proc. SPIE 10009, Third European Seminar on Precision Optics Manufacturing, 100090Z (30 June 2016); https://doi.org/10.1117/12.2236212

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