Jeffrey Badger, Ph.D. The Grinding Doc
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1 The following are the slides presented by Dr. Jeffrey A. Badger, The Grinding Doc, during the Cutting Tool Engineering Fast-Track Seminars series at IMTS in Chicago in 2010 Available at Available at
2 CTE Fast-Track Seminars at IMTS Jeffrey A. Badger, Ph.D. The Grinding Doc Monday 12:00-12:30 Switching to CBN Tuesday 12:00-12:30 High-performance Cooling Wednesday 12:00-12:30 Carbide Grinding Thursday 12:00-12:30 Power Monitoring Friday 12:00-12:30 High-performance Cooling Monday 12:00-12:30 Switching to CBN download 1: download 2: BadgerIMTS1.pdf BadgerIMTS2.pdf Available at Available at
3 CTE Fast-Track Seminars Jeffrey A. Badger, Ph.D. The Grinding Doc Monday 12:00-12:30 Switching to CBN Tuesday 12:00-12:30 High-performance Cooling Wednesday 12:00-12:30 Carbide Grinding Thursday 12:00-12:30 Power Monitoring Friday 12:00-12:30 High-performance Cooling Monday 12:00-12:30 Switching to CBN
4 In an ideal world. Normal Force Tangential Force
5 Dynamometer Force (N) Dynamometer Force (N) LVDT Displacement (mm) LVDT Displacement (mm) In an ideal world st forward pass 2 nd forward pass 3 rd forward pass 4 th forward pass F n LVDT F t Time (s) steady-state forces region of interest F n (normal force) Time (s) F t (tangential force) 150 X 100 t 50 table velocity - X/ t 0
6 F n : Normal Force F T : Tangential Force Dynamometer and LVDT signals to PC F n F t specimen specimen holder dynamometer LVDT A dynamometer measures forces in three directions table velocity Source: J. Badger, Ph.D. Thesis, Trinity College, Dublin.
7 Power = Heat Temperature Power (Watts) = Tangential Force (Newtons) x Wheel Speed (m/s) Power (Horsepower) = Tangential Force (lbs.) x Wheel Speed (sfpm) 10 kw 9.5 kw
8 The Grinding Doc s Grindometer 3-phase power from spindle motor 0.12
9 Power (kilowatts or HP) = voltage (in volts) X Current (in amps) voltage current For three-phase motor, measure the voltage with an alligator clip and the current with a Hall-effect transducer and you know the true power.
10 The Grinding Doc s Grindometer Dress before grinding Grinding of HSS with SG wheel, 4 flutes Therefore, the wheel is probably dulling
11 Yorän desh bårn, der ritt de gitt der gue. Årn desh, dee bårn desh, de umn Børk! Børk! Børk!! Norton s Field Instrumentation System, or F.I.S.
12 The Grinding Doc s Grindometer Grinding of Carbide on a Walter Machine
13 normalized power (P/P 0 ) The Grinding Doc s Grindometer 8 7 high-alloy PM grade poor cooling v c /v s = improved cooling v c /v s = amount of material removed (mm 3 /mm)
14 Power (kw) Grindometer Output L :14 original coolant setup side nozzles only modified coolant setup side nozzles + main nozzle Total Heat Heat to Workpiece Total Heat Heat to Workpiece Set 2: Side Nozzles Only Set 1: Side Nozzles + Main Nozzle time (s)
15 How wheels are usually evaluated How d that new trial wheel work out? Would you like to switch to this new wheel? It was ok. Parts looked ok. Nothing odd happened. Seemed alright. Not really. Lefty Bud Lefty The Salesman Bud The Button Pusher
16 power (kw) Wheel 1 Wheel 2 Wheel time (s) If all other parameters remain fixed and one wheel is generating more power than another wheel, by definition that wheel is generating more heat, and temperatures at the wheel-workpiece interface will be higher.
17 Reveals Unexpected Phenomena Are we really sparking out the way we think we are?
18 Centerless Troubleshooting
19
20 8.46 hz Unknown frequency 1.51 hz Reg wheel = 90 RPM = 1. 5 hz. Workpiece = 2431 RPM = 40.1 hz
21 124 Hz.
22 Cycle Time Reduction
23 Power (W) Power (W) Cycle Time Reduction time (s) time (s)
24 Temperatures and Grinding Burn P gr = 2.6 kw a eff R wp = 78% q = 123 W/mm 2 v pl l c T surface = 955 C
25 The Grinder s Toolbox by The Grinding Doc
26
27 temperature 1000 C 900 C 800 C 700 C 600 C 500 C 400 C 300 C 200 C 100 C 30 C T max,surface = 955 C Inputs: T rehardening = 850 C T RTS = 650 C T softening = 560 C 0.0 mm 0.1 mm 0.2 mm 0.3 mm 0.4 mm 0.5 mm 0.6 mm 0.7 mm 0.8 mm depth below ground surface Outputs: Depth of thermal softening: Depth of residual tensile stresses: Depth of rehardening burn: v s = 40 m/s d s = 400 mm d wp = 20 mm d eq = 19.0 v pl = 1.8 mm/min. w wp = 80 RPM k wp = 43 W/m K r wp = 7850 kg/m 3 c p,wp = 480 J/kg K v w = 84 mm/s Q = 1.9 mm 2 /s w = 25 mm Q = 47.1 mm 3 /s P = 2.6 kw e calc = 55 J/mm 3 l c = 0.65 mm t hs = 3.9 ms Aggr = 72 C 150 = 18.0 /mm 2 h max = 1.3 mm e chip = 13.8 J/mm 3 R ch,wp = 0.55 Pe = 1.20 R rp,wp = 0.9 R wp = q = 123 W/mm mm 1.2 mm 0.5 mm
28 s res (Mpa) non-nitrided portion of part nitrided portion of part ` ` ` ` ` ` 600 ` ` ` ` Predicted temperature(ºc)
29 Finally.. This is great. It s a magical black box that will tell me what to do so I don t have to think about my grinding operation. Bud Bud The Button Pusher
30 Want to learn more? 2007, reproduction prohibited The Grinding Doc s three-day High-Intensity Precision Grinding Course 15, 16, 17 November 2010 Chicago Hosted by Greenlee Diamond Tool Jeffrey Badger, Ph.D. 916 Jewell St. Austin, Texas USA (+1) badgerjeffrey@hotmail.com by Dr. Jeffrey A. Badger The Grinding Doc The Grinding Doc s Grindometer
31 CTE Fast-Track Seminars Jeffrey A. Badger, Ph.D. The Grinding Doc Monday 12:00-12:30 Switching to CBN Tuesday 12:00-12:30 High-performance Cooling Wednesday 12:00-12:30 Carbide Grinding Thursday 12:00-12:30 Power Monitoring Friday 12:00-12:30 High-performance Cooling Monday 12:00-12:30 Switching to CBN
32 CTE Fast-Track Seminars at IMTS Jeffrey A. Badger, Ph.D. The Grinding Doc Monday 12:00-12:30 Switching to CBN Tuesday 12:00-12:30 High-performance Cooling Wednesday 12:00-12:30 Carbide Grinding Thursday 12:00-12:30 Power Monitoring Friday 12:00-12:30 High-performance Cooling Monday 12:00-12:30 Switching to CBN download 1: download 2: BadgerIMTS1.pdf BadgerIMTS2.pdf Available at Available at
A Pictorial Odyssey. Grinding: An examination of the grinding process through the lens of an electron microscope. By Dr.
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