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Kolbers Lai Fulin Machinery (Shanghai) Co., Ltd. (KSMS) is part of the Joint Grinding Group. The Joint Grinding Group has eight well-known brands (Stuart, Short, Micosa, Walter, Ivag, Megler, Boryeong, Jung), and is the world's number one hard finisher. Technology, mainly for customers with high precision grinding requirements.
Aging society, ecology, mobility, personalization and urbanization are the hotspots of current people. These hot topics have far-reaching implications for processing technology, as new markets will emerge and old markets will die out and shift their focus.
The average national age is getting higher and higher, and people's awareness of ecological and environmental protection is also increasing. This is especially important for processing technology. An aging society will lead to an increase in the demand for medical products, which will increase the proportion of difficult-to-cut materials. In order to meet these high demands, the current processing technology must be further developed in terms of production efficiency and automation.
Processing energy efficiency
Human behavior should be in line with ecological requirements, and awareness in this area is constantly increasing, which directly and indirectly affects processing technology. The direct consequence of this is that not only must we focus on economics, but we must also consider the energy efficiency of processing. In order to meet the energy efficiency requirements of the manufacturing and manufacturing planning, various methods are used, such as optimizing the coolant supply and using new drive solutions or new tools.
In addition to these direct effects, there is a range of indirect effects as the market requires energy efficient products. This can be detected from fluid machines (eg pumps or steam turbines) as well as in automobiles. In the pump and power station manufacturing industries, a lot of manpower and resources have been spent to further improve efficiency. This increases the complexity of the surface to be machined. In order to reduce vehicle fuel consumption, automakers use high-tech engine technology. At the same time, the requirements for comfort and engine performance are also increasing.
Surface design is a key technology to accommodate these ever-increasing demands on products and parts. Increasing the surface quality will reduce friction losses, and the resulting microstructure will provide additional functionality, while improved edge areas will increase service life.
In the context of the frequent use of superhard materials and difficult-to-cut materials, grinding technology is particularly important. The “custom surface†can only be completed if the process is properly understood and the correct tool and the correct process strategy are used depending on the target geometry of the material to be machined and the surface. In this report, the challenges will be introduced and the methods used to select the right tool and the ideal process strategy will be explored. It will also show how an innovative product efficiency improvement solution can be achieved through an organic combination of tool and strategy design.
Abrasive properties
Abrasive properties will have a significant impact on application behavior, surface quality, part edge areas, and production efficiency. The wheel characteristics will be determined by the type of material being cut, the size of the material, and the density of the abrasive particles and the properties of the binder. In order to process brittle hard materials, diamond is mainly used as a cutting material. When selecting the relevant binder, it must be ensured that all the potential of the abrasive particles is utilized. In order to further improve the performance of the diamond grinding wheel, the potential of the metal binder material is enormous.
Metallic adhesives are resistant to abrasion, high temperatures and have a high thermal conductivity. "Cold" grinding is achieved when a porous structure is used at the same time. This can significantly increase the internal compressive stress. In order to be able to process a surface quality of Ra of 0.1 μm during grinding, very small abrasive particles must be used. However, reducing the size of the abrasive particles reduces the abrasive surface and the abrasive retention. This phenomenon can be overcome by tailoring the sintering parameters in a targeted manner.
Process strategy
After selecting the correct grinding wheel properties, designing the correct grinding strategy is decisive for meeting surface design requirements. Perhaps for aesthetic reasons, either to optimize fluid surfaces, or because of new applications (eg, knee implants), the proportion of free-form surfaces to be processed is also increasing. In order to economically machine freeform surfaces with high surface quality and low form tolerances, a suitable grinding strategy is required. Compared with the three-axis machining, a constant meshing condition can be obtained by placing the grinding wheel at a right angle to the feed motion plus the surface normal machining, thereby achieving higher shape accuracy and higher cutting ability.
By placing the grinding tool in the feed direction, the roughness of the part can be significantly reduced, because the cutting speed and the feed rate do not point in the same direction, and the influence of the shape of the grinding wheel will decrease. In the case of cutting with fixed cutting edges, five-axis machining has been a representative technology for a long time and is widely used in the industry. Currently, five-axis grinding is the representative of the highly respected solution, which is specifically designed for the application.
To date, the CAD/CAM program used has been designed for shaped cutting. Using this software for five-axis grinding will give you some problems. The program resolution does not meet the grinding requirements. This can cause the tool path to contain unwanted inflection points or undefined points, which can cause contour misalignment during grinding. In addition, the CAD/CAM program ignores tool wear, starting from an idealized state rather than the tool geometry that is available after trimming. Consideration of wear or actual tool shape has the potential to improve contour accuracy.
When using the best combination of suitable grinding wheel properties and grinding strategies, it is also possible to use innovative methods for surface design, such as: biomimetic microstructures.
A good example of a bionic structure is ribbed skin tissue, which mimics the shark skin structure, which reduces friction on the near wall by up to 10%. When used in fluid machines, such as pumps, steam turbines or aerospace engines, this can result in significant improvements in efficiency. The microstructures have a width of no more than 20 μm and a height of 10 μm and must be aligned in the direction of the fluid. The efficient surface-dependent surface of the free-form surface uses a free-form surface to further increase efficiency, where the fluid bends over the free-form surface. By embedding the microabrasive particles into the metal binder and using suitable sintering parameters, the desired structural dimensions can be produced in accordance with the grinding technology requirements. By using a five-axis grinding strategy, an abrasive tool capable of grinding a raised microstructure on a freeform surface can be fabricated. For this purpose, the grinding wheel geometry must match the tool track radius and the workpiece curvature.
Grinding technology development trend
Abstract For pump, steam turbine and automotive manufacturing, surface design will be a key technology in terms of energy efficiency. It is possible to use innovative methods such as biomimetic microstructures for surface design. In order to meet the energy efficiency requirements of the manufacturing and manufacturing plan, a variety of methods will be used, such as: optimized cooling...
For pump, steam turbine and automotive manufacturing, surface design will be a key technology in terms of energy efficiency. It is possible to use innovative methods such as biomimetic microstructures for surface design. In order to meet the energy efficiency requirements of the manufacturing and manufacturing planning, various methods are used, such as optimizing the coolant supply and using new drive solutions or tools.