Conditioning Superabrasive Grinding Tool to Prevent Thermal Edge Damage
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Solution Overview
Problem
Vitrified-bonded cBN grinding tools in gear grinding machines often cause thermal damage to the edge zone of workpieces during the initial machining phase due to 'grinding-in behavior', leading to inefficiencies and increased costs in existing methods to mitigate this issue, such as using sacrificial workpieces or reduced feed rates.
Innovation Solution
A method involving dressing and conditioning of the grinding tool with distinct kinematics, using a separate conditioning tool that differs from the machining kinematics, to achieve a desired wear condition without thermal edge zone damage, allowing for uniform machining of workpieces without the need for sacrificial pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a vitrified-bonded cBN grinding tool is used, then high material removal rates and flexibility are achieved, but thermal damage to the edge zone occurs during initial machining
Solution Approach 1:
The invention applies preliminary conditioning action to the grinding tool before actual workpiece machining. A conditioning tool with dressing-like kinematics is used to prepare the grinding tool surface, removing the initial bond layer that causes thermal damage. This preliminary action ensures that subsequent workpiece machining proceeds without edge zone thermal damage while maintaining high material removal rates throughout the tool life.
2Object-affected harmful factors
If sacrificial workpieces are used for conditioning, then thermal damage is avoided, but time and material resources are consumed
Solution Approach 1:
The invention introduces a conditioning tool as an intermediary element between the dressing tool and the workpieces. This conditioning tool, with its specific geometry and dressing-like kinematics, performs the conditioning function without requiring sacrificial workpieces. The intermediary conditioning tool enables thermal damage prevention while eliminating the time loss associated with machining and discarding sacrificial pieces.
3Object-affected harmful factors
If reduced infeed and axial feed rate are used for conditioning, then thermal damage is prevented, but machining efficiency decreases
Solution Approach 1:
The invention separates the conditioning function from the machining function by applying preliminary conditioning action with dressing-like kinematics before normal machining begins. This allows the subsequent workpiece machining to proceed at full efficiency with normal infeed and axial feed rates, while still preventing thermal damage through the preliminary preparation of the grinding tool surface.
4Manufacturing precision
If a separate conditioning tool with dressing kinematics is used, then consistent machining parameters are maintained, but device complexity increases
Solution Approach 1:
The invention integrates the conditioning function into the existing dressing device infrastructure, allowing the same device to perform both dressing and conditioning operations. The conditioning tool utilizes the dressing-like kinematics already available in the system, thereby achieving consistent machining parameters without significantly increasing overall device complexity. This multi-functional approach maintains manufacturing precision while avoiding excessive system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach prevents thermal edge zone damage during initial machining, reduces material consumption, and allows for consistent machining parameters across all workpieces, thereby improving efficiency and reducing costs by reusing the conditioning tool multiple times.
Implementation Method 1
conditioning the dressed grinding tool such that a desired wear condition of the grinding tool is produced
Data Source
AI summary
In a method of machining workpieces in a gear grinding machine with a grinding tool having vitrified-bonded abrasive grains made of a superabrasive material. The grinding tool is first dressed. Subsequently, the dressed grinding tool is conditioned such that a desired wear condition is produced. Thereafter, pre-toothed workpieces are machined using the dressed and conditioned grinding tool. Conditioning prevents undesirable grinding-in behavior of the grinding tool, which can cause thermal damage to the edge zone of the workpiece. Conditioning is performed with a conditioning kinematics, which is different from the machining kinematics and may correspond to a dressing kinematics. For conditioning, a conditioning tool is used which has a basic shape that is different from the basic shape of the workpieces.